Hollow aerated concrete panel with reinforced columns and method for processing the same

Abstract

The application discloses a hollow aerated concrete slab with reinforced columns, which comprises a base slab, a closed cavity is formed in the base slab, and a plurality of reinforced columns are formed in the cavity; an organic thermal insulation layer and an organic waterproof layer are formed on the inner wall of the cavity and the outer wall of the reinforced columns; and a processing method of the hollow aerated concrete slab with reinforced columns is also provided. The application changes the structure of the autoclaved aerated concrete slab, the organic thermal insulation layer in the concrete slab is hot-melted to form a closed cavity, air convection is effectively reduced, and the sound insulation effect and the thermal insulation effect of the concrete slab are improved; the hot-melted organic matter is perfectly attached to the surface of the cavity, and the thermal insulation performance of the wallboard is further improved. The space structure reinforced column integrally formed with the base slab effectively improves the overall rigidity strength of the concrete slab, the inner and outer layers of the hollow slab are connected into one body, and the problem of rigidity weakening caused by the hollow setting is perfectly avoided.

Description

Technical Field

[0001] This invention relates to the fields of building assembly and thermal insulation technology, and more specifically to a hollow aerated concrete panel with reinforcing columns and its processing method. Background Technology

[0002] Since its introduction to China in the 1990s, autoclaved aerated concrete (AAC) has been rapidly and widely adopted domestically due to its lightweight, minimal deformation, and significant thermal insulation properties. Its excellent insulation performance allows it to meet energy-saving requirements of 50% to 65% for buildings using only this single material. However, with increasingly stringent energy-saving requirements, maximizing its insulation performance has become a crucial research direction for universities and research institutions. Utilizing an air insulation layer is one important approach. AAC is a lightweight insulation material with low density and strength. Creating a large enough spatial structure within the wall panel to form an air layer is key to achieving its energy-saving goals. However, with increased space, structural safety is compromised, failing to meet building structural safety requirements. For example, patent CN109320182A, while proposing multiple sealed cavities, achieves this by suspending molten material in a steel mesh cage. The presence of multiple sealed cavities limits their size, and excessive cavity ribs create too many "cold bridges," resulting in unsatisfactory insulation performance. Furthermore, the lack of other features in the cavity makes it difficult to maintain the overall rigidity and strength of the wall panel; the presence of too many cavities makes manufacturing very difficult and hinders industrialization.

[0003] Therefore, how to provide a material that not only has thermal insulation function and is simple to manufacture, but also can form a spatial structure, thus ensuring the structural safety of the wall panel, meeting mechanical performance requirements, and achieving better thermal insulation effect, is one of the technical problems that urgently need to be solved in this field. Summary of the Invention

[0004] In view of this, the present invention provides a hollow aerated concrete slab with reinforcing columns and a method for processing the same. The purpose is to address the aforementioned shortcomings.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0006] A hollow aerated concrete panel with reinforcing columns includes a base panel, wherein a closed cavity is formed inside the base panel, and a plurality of reinforcing columns are formed inside the cavity; and an organic heat-insulating and waterproof (seepage-proof) layer is formed on the inner wall of the cavity and the outer wall of the reinforcing columns.

[0007] Preferably, the cavity is filled with polyurethane insulation material.

[0008] Preferably, the organic thermal insulation and waterproof layer is a coating formed after the organic thermal insulation board is melted.

[0009] Preferably, the reinforcing column is integrally formed with the base plate.

[0010] Preferably, the reinforcing column is supported by steel bars or FRP bars.

[0011] Preferably, the polyurethane in the polyurethane insulation layer can be a two-component or a single-component polyurethane.

[0012] Preferably, the polyurethane can be replaced by other organic or inorganic thermal insulation materials.

[0013] Meanwhile, the present invention also provides a method for processing hollow aerated concrete panels with reinforcing columns, comprising the following steps:

[0014] 1) After the steel bars are drawn and straightened, they are welded to obtain a steel mesh;

[0015] 2) Drill through holes along the thickness direction of the organic insulation board according to the design requirements using hot melting or mechanical methods;

[0016] 3) Then place the two steel mesh pieces in parallel and weld them together at the top and bottom ends with multiple connecting pieces to form a steel mesh cage; after the steel mesh cage is treated with anti-corrosion and dried, it is ready for use.

[0017] 4) Place the prepared organic insulation board in the steel mesh cage and fix it; make through holes along the width of the mesh cage at the position of the connector hole for inserting and removing steel rods;

[0018] 5) The steel mesh cage prepared in step 4) is assembled and fixed on the steel rod frame by passing steel fibers through the organic insulation board and through the middle part of the connecting piece at both ends.

[0019] 6) Slurry preparation: Grind the siliceous material with water and set aside; Gypsum preparation: It can be ground together with the siliceous material or added separately; Lime powder preparation: Grind the lime powder and set aside; Add aluminum powder to water to make an aluminum powder suspension and set aside.

[0020] 7) Pouring: Pump the casting raw materials prepared in step 6) into the casting tank, add the lime powder and cement prepared in step 4) in sequence, and stir for 2 to 8 minutes. After the slurry temperature reaches 40 to 50°, add the aluminum powder suspension, stir for 20 to 100 seconds, and then pour it into the mold for preparing the autoclaved aerated concrete slab.

[0021] 8) Use a special tool to press down the organic insulation board or steel mesh cage on the upper side to prevent it from floating up and damaging the concrete slab.

[0022] 9) Place the steel rod frame obtained in step 5) into the mold that was just poured in step 7), and then cure it. The curing temperature is 30-60℃ and the curing time is 3-3.5h. After the strength of the billet reaches a certain level, pull out the rod to obtain a hollow aerated concrete slab billet with reinforcing columns.

[0023] 10) The hollow aerated concrete slab blank obtained in step 9) is transported to a cutting machine for six-sided cutting.

[0024] 11) Place the hollow aerated concrete slab blank treated in step 10) into an autoclave and vacuum it. Then add saturated steam to make the pressure inside the autoclave 1.0-1.2 MPa and the temperature 170-200℃. Cure under constant pressure for 6-8 hours. The organic insulation board melts to form a closed cavity, and the organic insulation and waterproof layer (7) is formed on the inner wall of the cavity. The hollow aerated concrete slab blank forms an aerated concrete product after hydration and other reactions.

[0025] 12) After curing and venting, open the autoclave door, pull out the final product, the hollow aerated concrete slab, and break it apart.

[0026] Preferably, the casting material in step 6) comprises the following components by weight: 60%–75% siliceous material, 12%–18% lime powder, 12%–24% cement, 5%–10% gypsum, and 0.06%–0.12% aluminum powder.

[0027] Preferably, the organic insulation board is an organic hot-melt board.

[0028] Preferably, the organic hot melt plate has multiple through holes along the thickness direction, and insertion holes adapted to the steel rod are provided on the upper and lower sides along the width direction.

[0029] Preferably, the reserved hole is provided with reinforcing bars (or reinforcing cages) to enhance the rigidity of the formed reinforced column.

[0030] Preferably, the reserved hole is provided with reinforcing bars (or reinforcing cages, FRP).

[0031] Preferably, the organic insulation board is an organic hot-melt board.

[0032] Preferably, the organic hot-melt plate is placed inside the steel mesh cage.

[0033] Preferably, or, the organic hot-melt plate extends outside the steel mesh cage.

[0034] Preferably, the steel mesh cage prepared in step 3) is subjected to anti-corrosion treatment, and the anti-corrosion agent used includes the following components: 8000-10000 kg of styrene-butadiene latex, 100-150 kg of quartz sand, 240-360 kg of cement, 80-150 kg of iron oxide red, 1.7-2.5 kg of sodium hydroxide, 2.0-2.8 kg of sodium carboxymethyl cellulose, and 5-8 kg of starch ether; the preparation method of the anti-corrosion agent is as follows: 8000-10000 kg of styrene-butadiene latex, 100-150 kg of quartz sand, 240-360 kg of cement and 80-150 kg of iron oxide red are poured into the mixing tank in sequence and stirred. Then, 1.7-2.5 kg of sodium hydroxide, 2.0-2.8 kg of sodium carboxymethyl cellulose, and 5-8 kg of starch ether are mixed together separately and stirred evenly before being poured into the mixing tank. After all the materials, including styrene-butadiene latex, quartz sand, cement, iron oxide red, sodium oxide, sodium carboxymethyl cellulose, and starch ether, are mixed evenly in the mixing tank, the mixture is poured into the anticorrosion tank. The anticorrosion agent in the anticorrosion tank is stirred for 3-5 minutes every 2-3 hours to ensure it is well mixed.

[0035] The present invention achieves the following technical effects compared to the prior art:

[0036] This invention creates a sealed cavity by thermally melting the organic insulation board inside a concrete slab, forming an air layer. To address the heat convection within this large air layer, polyurethane insulation material is injected into the cavity, significantly improving insulation performance. Furthermore, the hot-melt material adheres to the cavity's inner surface, increasing the surface strength of the aerated concrete and further enhancing the bond strength between the polyurethane insulation material and the wall panel, thus improving the overall performance of the wall panel. By setting pre-drilled holes in the organic insulation board, reinforcing columns can be integrally formed with the base layer during casting, creating a spatial structure that effectively improves the overall rigidity of the concrete slab, perfectly avoiding the rigidity reduction problem caused by the hollow structure. The internal polyurethane injection further enhances the overall performance of the wall panel, meeting the requirements for seismic resistance and airtightness when used as an exterior wall. Simultaneously, the presence of the hollow cavity greatly reduces the overall weight of the wall panel, making installation easier and solving the problem of difficult installation of prefabricated wall panels. Furthermore, by injecting polyurethane into the cavity, the exchange of moisture is blocked; the presence of the reinforcing column will carry the moisture accumulated on the surface of the polyurethane layer to the surface of the wall panel, thus solving the problem of exterior wall paint peeling caused by moisture content in the sandwich insulation board. Attached Figure Description

[0037] Figure 1 This is a schematic diagram of the structure of a hollow aerated concrete panel with reinforcing columns according to the present invention;

[0038] Figure 2 This is a schematic diagram of the processing framework for a hollow aerated concrete panel with reinforcing columns according to the present invention.

[0039] In the diagram: 1. Baseboard; 11. Reinforcing column; 2. Cavity; 3. Organic insulation board; 31. Insertion hole; 32. Reserved hole; 4. Connecting piece; 5. Reinforcing mesh cage; 6. Reinforcing mesh sheet; 7. Organic insulation and waterproof layer. Detailed Implementation

[0040] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0041] Example

[0042] Reference Figure 1 The diagram shows a hollow aerated concrete panel with reinforcing columns, comprising a base plate 1, wherein a closed cavity 2 is formed inside the base plate 1, and a plurality of reinforcing columns 11 are formed inside the cavity 2; an organic thermal insulation and waterproof layer 7 is formed on the inner wall of the cavity 2 and the outer wall of the reinforcing columns 11; the organic thermal insulation and waterproof layer 7 is a coating formed after the organic thermal insulation board 3 is melted; and polyurethane thermal insulation material is injected into the hollow cavity.

[0043] In this embodiment, the reinforcing column 11 is integrally formed with the base plate 1.

[0044] In this embodiment, the present invention also provides a method for processing a hollow aerated concrete panel with reinforcing columns, comprising the following steps:

[0045] 1) After the steel bars are drawn and straightened, they are welded to obtain a steel mesh 6;

[0046] 2) According to the design requirements, the organic insulation board 3 is drilled with through holes along the thickness direction using hot melting or mechanical methods;

[0047] 3) Then place the two steel mesh pieces 6 in parallel and weld them together at the top and bottom ends through multiple connecting pieces 4 to form a steel mesh cage 5; after the steel mesh cage 5 is subjected to anti-corrosion treatment and dried, it is ready for use.

[0048] 4) Place the prepared organic insulation board 3 into the steel mesh cage 5 and fix it; make through holes along the width of the steel mesh cage 5 at the position of the connector hole for inserting and removing steel rods.

[0049] 5) The steel mesh cage 5 prepared in step 4) is assembled and fixed on the steel rod frame by passing steel fibers through the organic insulation board 3 and passing the upper and lower ends through the middle part of the connecting piece 4.

[0050] 6) Slurry preparation: Grind the siliceous material with water and set aside; Gypsum preparation: It can be ground together with the siliceous material or added separately; Lime powder preparation: Grind the lime powder and set aside; Add aluminum powder to water to make an aluminum powder suspension and set aside.

[0051] 7) Pouring: Pump the casting raw materials prepared in step 6) into the casting tank, add the lime powder and cement prepared in step 4) in sequence, and stir for 2 to 8 minutes. After the slurry temperature reaches 40 to 50°, add the aluminum powder suspension, stir for 20 to 100 seconds, and then pour it into the mold for preparing the autoclaved aerated concrete slab.

[0052] 8) Use a special tool to press down the organic insulation board 3 or the steel mesh cage 5 on the upper side of the organic insulation board 3 to prevent it from floating up and damaging the concrete slab body.

[0053] 9) Place the steel rod frame obtained in step 5) into the mold that was just poured in step 7), and then cure it. The curing temperature is 30-60℃ and the curing time is 3-3.5h. After the strength of the billet reaches a certain level, pull out the rod to obtain a hollow aerated concrete slab billet with reinforcing columns.

[0054] 10) The hollow aerated concrete slab blank obtained in step 9) is transported to a cutting machine for six-sided cutting.

[0055] 11) Place the hollow aerated concrete slab blank treated in step 10) into an autoclave and evacuate it. Then add saturated steam to make the pressure inside the autoclave 1.0-1.2 MPa and the temperature 170-200℃. Cure under constant pressure for 6-8 hours. The organic insulation board 3 melts to form a closed cavity 2. The organic insulation and waterproof layer 7 is formed on the inner wall of the cavity. The hollow aerated concrete slab blank is formed into an aerated concrete product after hydration and other reactions.

[0056] 12) After curing and venting, open the autoclave door, pull out the final product, the hollow aerated concrete slab, and break it apart.

[0057] In this embodiment, the prefabricated organic insulation board 3 in step 3) has 6 through reserved holes 32 on the front and back sides, and insertion holes 31 on the top and bottom sides that are compatible with the steel rod.

[0058] In this embodiment, the organic insulation board 3 is an organic hot melt board.

[0059] In this embodiment, a steel bar is provided in the reserved hole 32 to enhance the rigidity of the formed reinforcing column 11.

[0060] In some embodiments, the reserved hole 32 can be cylindrical or any other geometric prism, and the reinforcing bar inside the hole can also be FRP made of glass fiber, basalt wire or carbon fiber and resin, which can replace the reinforcing bar.

[0061] In some embodiments, the organic hot-melt plate is located inside the steel mesh cage 5, or it can protrude from the mesh cage to increase the proportion of the cavity.

[0062] In other embodiments, the polyurethane insulation material can be either two-component or one-component.

[0063] In other embodiments, polyurethane insulation material can also be replaced by other organic or inorganic insulation materials.

[0064] This invention creates a sealed cavity by thermally melting the organic insulation board inside a concrete slab, forming an air layer. To address the heat convection within this large air layer, polyurethane insulation material is injected into the cavity, significantly improving insulation performance. Furthermore, the hot-melt material adheres to the cavity's inner surface, increasing the surface strength of the aerated concrete and further enhancing the bond strength between the polyurethane insulation material and the wall panel, thus improving the overall performance of the wall panel. By setting pre-drilled holes in the organic insulation board, reinforcing columns can be integrally formed with the base layer during casting, creating a spatial structure that effectively improves the overall rigidity of the concrete slab, perfectly avoiding the rigidity reduction problem caused by the hollow structure. The internal polyurethane injection further enhances the overall performance of the wall panel, meeting the requirements for seismic resistance and airtightness when used as an exterior wall. Simultaneously, the presence of the hollow cavity greatly reduces the overall weight of the wall panel, making installation easier and solving the problem of difficult installation of prefabricated wall panels. Furthermore, by injecting polyurethane into the cavity, the exchange of moisture is blocked; the presence of the reinforcing column will carry the moisture accumulated on the surface of the polyurethane layer to the surface of the wall panel, thus solving the problem of exterior wall paint peeling caused by moisture content in the sandwich insulation board.

[0065] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A hollow aerated concrete slab with reinforcing columns, comprising a base slab (1), characterized in that, The base plate (1) forms a closed cavity (2) inside, and multiple reinforcing columns (11) are formed inside the cavity (2); an organic thermal insulation and waterproof layer (7) is formed on the inner wall of the cavity (2) and the outer wall of the reinforcing column (11); polyurethane thermal insulation material is injected into the cavity (2), wherein the organic thermal insulation and waterproof layer (7) is a coating formed after the organic thermal insulation board (3) is melted, the organic thermal insulation board (3) has multiple through holes (32) along the thickness direction, the through holes (32) form reinforcing columns (11) integrally formed with the base plate (1) during casting, and steel bars or FRP bars are set in the through holes (32) to improve the rigidity of the formed reinforcing column (11); wherein the thermal insulation board (3) is an organic hot melt board.

2. A method for processing a hollow aerated concrete slab with reinforcing columns as described in claim 1, characterized in that, Includes the following steps: 1) After the steel bars are drawn and straightened, they are welded to obtain a steel mesh (6); 2) The organic insulation board (3) is opened with through holes along the thickness direction by hot melting or mechanical method according to the design requirements; the organic insulation board (3) has multiple through reserved holes (32) on the front and back sides, and steel bars are set in the reserved holes (32) to improve the rigidity of the formed reinforcing column (11); 3) Then place the two steel mesh pieces (6) in parallel and weld them together at the top and bottom ends through multiple connecting pieces (4) to form a steel mesh cage (5); after the steel mesh cage (5) is subjected to anti-corrosion treatment and dried, it is ready for use. 4) Place the prepared organic insulation board (3) in the steel mesh cage (5) and fix it; make a through hole along the width direction of the steel mesh cage (5) at the position of the connector hole for inserting and pulling the steel rod; the organic insulation board (3) has insertion holes (31) on the upper and lower sides that are compatible with the steel rod. 5) The steel mesh cage (5) prepared in step 4) is made by passing steel fibers through the organic insulation board (3) and passing its upper and lower ends through the middle part of the connecting piece (4) and fixing it, thereby assembling and fixing the steel mesh cage (5) on the steel rod frame. 6) Slurry preparation: Grind the siliceous material with water and set aside; Gypsum preparation: It can be ground together with the siliceous material or added separately; Lime powder preparation: Grind the lime powder and set aside; Add aluminum powder to water to make an aluminum powder suspension and set aside. 7) Pouring: Pump the casting raw materials prepared in step 6) into the casting tank, add the lime powder and cement prepared in step 4) in sequence, and stir for 2 to 8 minutes. After the slurry temperature reaches 40 to 50°, add the aluminum powder suspension, stir for 20 to 100 seconds, and then pour it into the mold for preparing the autoclaved aerated concrete slab. 8) Use a special tool to press down the organic insulation board (3) or the steel mesh cage (5) on the upper side of the organic insulation board (3) to prevent it from floating up and damaging the concrete slab body. 9) Place the steel rod frame obtained in step 5) into the mold that was just poured in step 7), and then cure it. The curing temperature is 30-60℃ and the curing time is 3-3.5h. After the strength of the billet reaches a certain level, pull out the rod to obtain a hollow aerated concrete slab billet with reinforcing columns. 10) The hollow aerated concrete slab blank obtained in step 9) is transported to a cutting machine for six-sided cutting. 11) The hollow aerated concrete slab blank processed in step 10) is placed in an autoclave and vacuumed. Then saturated steam is added to make the pressure inside the autoclave 1.0-1.2 MPa and the temperature 170-200℃. It is then cured under constant pressure for 6-8 hours. The organic insulation board (3) melts to form a closed cavity (2). The organic insulation and waterproof layer (7) is formed on the inner wall of the cavity. The organic insulation and waterproof layer (7) is a coating formed after the organic insulation board (3) melts. Polyurethane insulation material is injected into the cavity. The hollow aerated concrete slab blank is hydrated to form an aerated concrete product. 12) After curing and venting, open the autoclave door, pull out the final product, the hollow aerated concrete slab, and break it apart.

3. The processing method of a hollow aerated concrete slab with reinforcing columns according to claim 2, characterized in that, The casting material in step 6) includes the following components by weight: 50%–75% siliceous material, 12%–18% lime powder, 12%–24% cement, 2%–10% gypsum, and 0.06%–0.12% aluminum powder (paste).

4. The processing method of a hollow aerated concrete slab with reinforcing columns according to claim 3, characterized in that, The organic insulation board (3) is located inside the steel mesh cage (5).

5. A method for processing a hollow aerated concrete slab with reinforcing columns according to claim 3, characterized in that, The organic insulation board (3) extends through the connecting piece (4) to the outside of the steel mesh cage (5).

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