A concrete frame wall panel based on polyurethane casting abdominal cavity and its manufacturing method

Abstract

The present invention discloses a concrete frame wall panel based on a polyurethane cast abdominal cavity, which is used for building exterior walls. The concrete frame wall panel consists of two base plates and an organic thermal insulation layer located between the two base plates; the upper and lower ends of the two base plates and the organic thermal insulation layer are cast to form a concrete layer plate, so that the organic thermal insulation layer is sealed in the abdominal cavity formed by the two base plates; structural columns are arranged in the two base plates, and continuous beams are arranged in the upper and lower concrete layers. The continuous beams in the upper and lower concrete layers are connected with the structural columns to form a reinforced concrete frame, which is used for casting to form a concrete frame wall panel with an abdominal cavity; the two base plates are fixedly connected by a plurality of FRP connectors. The present invention also provides a preparation method of the concrete frame wall panel. The present invention can solve the common problems of assembly efficiency and quality, not only has an excellent thermal insulation effect, but also is easy to manufacture, has a stable structure, and can have the same lifespan as the building, and is easy to assemble.

Description

Technical Field

[0001] The invention relates to the technical field of building wall panels, and more particularly to a concrete frame wall panel based on a polyurethane casting belly and a manufacturing method thereof. Background Art

[0002] With the improvement of environmental protection requirements in my country, higher requirements have been put forward for energy conservation and emission reduction in the construction field. At the same time, due to changes in the population structure, there is an increasing shortage of construction technical workers. Vigorously developing prefabricated buildings and building energy conservation is the key to solving the problem. External insulation of buildings and factory production of building components are the main methods and means. However, external insulation of buildings faces the problems of falling off, fire prevention and inability to achieve the same lifespan as the building.

[0003] Currently, most of the existing integrated insulation wall panels are made of reinforced concrete materials, but there are many problems. First, the production cost is high, the weight is heavy, and it is difficult to transport and install. Secondly, it is easy to cause uneven settlement of the foundation, causing cracks in the wall and quality risks such as water seepage. Another way is to assemble lightweight concrete strips on site, which has many construction gaps and is difficult to install. Water leakage and seepage are difficult to avoid. At the same time, the assembly efficiency of multiple wall panels is limited, which loses the true meaning of prefabricated buildings.

[0004] Therefore, how to provide a concrete frame wall panel based on polyurethane casting abdomen and its production method that can solve the common problems of assembly efficiency and quality, not only has excellent thermal insulation effect, but also is easy to manufacture, has a stable structure, and can last the same life as the building, and is easy to assemble is one of the technical problems that urgently need to be solved in this field. Summary of the invention

[0005] In view of this, the present invention provides a concrete frame wallboard based on polyurethane casting belly and a manufacturing method thereof, which is provided to solve the above-mentioned deficiencies.

[0006] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0007] A concrete frame wall panel based on a polyurethane cast belly, used for building exterior walls, the concrete frame wall panel comprises two base panels and an organic thermal insulation layer located between the two base panels; the upper and lower ends of the two base panels and the organic thermal insulation layer are cast to form concrete layer panels, so that the organic thermal insulation layer is sealed in the belly formed by the two base panels; the two base panels are provided with structural columns, and the continuous beams of the upper and lower concrete layer panels are connected to the structural columns to form a reinforced concrete frame, which is used for casting the concrete frame wall panel with a belly;

[0008] The two base plates are fixed, supported and connected by a plurality of FRP connectors.

[0009] Preferably, each of the FRP connectors extends into each of the base plates; and a support member is fixedly provided on each of the FRP connectors near the inner wall of each of the base plates for supporting the two base plates to better form the abdominal cavity.

[0010] Preferably, both the upper and lower concrete slabs are provided with a sink groove, and a sleeve connector is provided in the sink groove; one end of the sleeve connector is fixedly connected to the steel mesh cage in the concrete slab, and the other end passes through the concrete slab and is fixedly connected to the main structure of the building.

[0011] The organic thermal insulation layer is made of foamed polyurethane.

[0012] Preferably, the foamed polyurethane is poured in layers through the preset reserved holes on the base plate or the continuous beam to fill the entire abdominal cavity to form the organic thermal insulation layer.

[0013] Preferably, each of the concrete frame wall panels is recessed inwardly on one side along its height direction to form a groove, and protrudes outwardly on the other side to form a convex column matching the groove; each of the concrete frame wall panels protrudes outwardly on one side along its width direction to form a protruding L-shaped structure, and is correspondingly recessed inwardly on the other side to form a retracted L-shaped structure, so that when the upper and lower concrete frame wall panels are installed, a staggered structure is formed at the overlap, and the horizontal seam of the wall is lower on the outside and higher on the inside, thereby enhancing the waterproof effect.

[0014] Preferably, the grooves and the bosses are arranged in one or more groups; the grooves are arranged such that the cross-section thereof is concave inwardly and is one of a trapezoid, a rectangle or a circular arc; correspondingly, the bosses are also arranged such that the cross-section thereof is protruding or concave outwardly and is one of a trapezoid, a rectangle or a circular arc.

[0015] Preferably, lightweight concrete strips are embedded between the continuous beams of the upper and lower concrete slabs.

[0016] Preferably, the structural columns are arranged along the board seam direction between the lightweight concrete slabs.

[0017] Preferably, the concrete beams and columns are located between base slabs.

[0018] Preferably, the sleeve connector adopts an internal thread or external thread design, and uses bolts or nuts and connectors to connect the concrete frame wall panel to the main structure of the building.

[0019] Preferably, the continuous beam and the structural column are provided with an inorganic or organic insulation layer; wherein the inorganic or organic insulation layer of the structural column in the concrete frame wall panel with doors and windows extends to the sides of the door and window openings.

[0020] At the same time, the present invention also provides a method for manufacturing a concrete frame wall panel based on a polyurethane casting cavity, comprising the following steps:

[0021] 1) According to the design drawings, determine the size of the concrete frame wall panel based on the polyurethane casting belly, lay out the lines on the counter or site, and reserve the door and window openings if there are doors and windows;

[0022] 2) The panel layout is designed according to the confirmed concrete frame wall panel based on the polyurethane casting belly, and the size of each concrete frame wall panel is confirmed and prepared, paying attention to leaving the joint size;

[0023] 3) Use vertical or horizontal assembly to confirm the height of the concrete frame wall panel based on the polyurethane casting belly, and then set the continuous beam along the end position of the lightweight concrete strip board;

[0024] 4) According to the size of the door and window openings, leave space for the concrete structural columns and place the tied beam and column steel mesh cages or FRP mesh cages;

[0025] 5) Install the steel mesh cage on the multiple base plates prepared according to the plate arrangement drawing according to the plate arrangement requirements, and pour adhesive, structural adhesive or foamed polyurethane between two adjacent base plates;

[0026] 6) Install the continuous beam and structural column steel mesh cage in place at the end position of the concrete frame wall panel based on the polyurethane casting belly, and the structural column steel mesh cage extends into the steel mesh cage inside the continuous beam for lap connection;

[0027] 7) Install the sleeve connector, the lower half of which is connected to the steel mesh cage in the continuous beam;

[0028] 8) Flat steel is preset above and below the concrete frame wall panels with doors and windows, or cast-in-place concrete structure is used to assist in fixing doors and windows, and the ends of the flat steel extend into the base plate;

[0029] 9) Assemble and fix the formwork of the connecting beam in the concrete slab, 2-10cm below the slab surface; use thin plates to seal the formwork between the continuous beams and structural columns, and then pour concrete into the formwork; or lay the insulation layer at the bottom of the continuous beams and structural columns, at the door and window openings, and extend the insulation layer of the structural columns to the sides, and pay attention to leaving a decoration margin of 5-20mm;

[0030] 10) After vibrating the slurry, cover the surface of the concrete beams and columns with inorganic or organic insulation boards, leaving a protective layer on the outside of the insulation boards; at the door and window openings, the insulation layer covers the structural columns to the door and window openings;

[0031] 11) After the concrete has been cured for a period of time, the concrete frame wall panels are erected and the left and right panel joints are sealed with thin plates; holes are drilled at different heights on the inner side of the base panels and foamed polyurethane is injected into the gap between the two base panels to form an organic insulation layer.

[0032] Compared with the prior art, the present invention has achieved the following technical effects:

[0033] The present invention adopts cast-in-place concrete lock buckles designed on the upper and lower ends of the wall panels to fix each panel together, reserve insulation space for the inner and outer wall panels, and pour foamed polyurethane to make the double-layer wall panels a more solid whole; the composite wall of the present invention has the advantages of better insulation performance, stable wall structure, and not easy to deform and damage; it completely solves the problems of safety of assembled wall panel structure, integration of structure and insulation, fire prevention of wall panels and water seepage of assembled exterior walls. In addition, the present invention sets an indented L-shaped structure and a protruding L-shaped structure on both sides of the base plate. When the two composite wall panels are assembled, in addition to the assembly of the male and female notches, another cylindrical hole is formed, and bonding mortar or other bonding materials are poured into the hole; thereby making the composite wall panel connection more stable and convenient for assembly and use; and enhancing the waterproof and water-stopping effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 This is a structural schematic diagram of a concrete frame wall panel based on a polyurethane casting belly and fixedly connected by reinforced concrete according to the present invention;

[0035] Figure 2 This is a structural schematic diagram of a concrete frame wall panel based on a polyurethane casting belly using angle steel for fixed connection according to the present invention;

[0036] Figure 3 It is a left side cross-sectional view of a single lightweight concrete wall panel of a concrete frame wall panel based on a polyurethane casting belly of the present invention;

[0037] Figure 4 It is a front cross-sectional view of a single lightweight concrete wall panel of a concrete frame wall panel based on a polyurethane cast belly of the present invention;

[0038] Figure 5 A top view of a single lightweight concrete wall panel of a concrete frame wall panel based on a polyurethane cast belly according to the present invention;

[0039] In the figure: 1, base plate; 2, concrete layer plate; 21, sink; 3, organic insulation layer; 4, doors and windows; 5, FRP connector; 51, support member; 6, structural column; 7, sleeve connector; 100, indented L-shaped structure; 200, protruding L-shaped structure; 300, groove; 400, convex column. DETAILED DESCRIPTION

[0040] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0041] Example 1

[0042] Reference Figure 1-4 The concrete frame wall panel with a polyurethane-casting abdominal cavity is shown, which is used for building exterior walls. The concrete frame wall panel consists of two base panels 1 and an organic thermal insulation layer 3 located between the two base panels 1; the upper and lower ends of the two base panels 1 and the organic thermal insulation layer 3 are cast to form a concrete layer 2, so that the organic thermal insulation layer 3 is sealed in the abdominal cavity formed by the two base panels 1; structural columns 6 are arranged in the two base panels 1, and continuous beams are arranged in the upper and lower concrete layers 2. The continuous beams in the upper and lower concrete layers 2 are connected with the structural columns 6 to form a reinforced concrete frame, which is used for casting a concrete frame wall panel with an abdominal cavity; the two base panels 1 are fixedly connected by a plurality of FRP connectors 5. Each FRP connector 5 extends into each base panel 1; and a support member 51 is fixedly arranged on each FRP connector 5 near the outer wall of each base panel 1, which is used to support the two base panels 1 to better form the abdominal cavity.

[0043] As a preferred or optional embodiment of this embodiment, the organic thermal insulation layer 3 is made of foamed polyurethane.

[0044] As a preferred or optional method of this embodiment, the foamed polyurethane is poured in layers through the preset reserved holes on the base plate 1 or the continuous beam to fill the entire abdominal cavity to form an organic thermal insulation layer 3.

[0045] As a preferred or optional method of this embodiment, a sink 21 is opened in the upper and lower concrete slabs 2; and a sleeve connector 7 is arranged in the sink 21; one end of the sleeve connector 7 is fixedly connected to the steel mesh cage in the concrete slab 2, and the other end passes through the concrete slab 2 and is fixedly connected to the main structure of the building.

[0046] As a preferred or optional method of this embodiment, each concrete frame wall panel is recessed inwardly on one side along its height direction to form a groove 300, and the other side thereof protrudes outwardly to form a convex column 400 matching the groove 300; each concrete frame wall panel is protruded outwardly on one side along its width direction to form a protruding L-shaped structure 100, and the other side thereof is correspondingly recessed inwardly to form a retracted L-shaped structure 200, so that when the upper and lower concrete frame wall panels are installed, a staggered structure is formed at the overlap, and the horizontal seam of the wall is lower on the outside and higher on the inside, thereby enhancing the waterproof effect.

[0047] As a preferred or optional manner of this embodiment, the groove 300 and the boss 400 are arranged in one or more groups; the groove 300 is arranged such that the cross-section recessed inward is one of a trapezoid, a rectangle or a circular arc; correspondingly, the boss 400 is also arranged such that the cross-section protruding or recessed outward is one of a trapezoid, a rectangle or a circular arc.

[0048] As a preferred or optional mode of this embodiment, a lightweight concrete strip is embedded between the continuous beams of the upper and lower concrete slabs 2 .

[0049] As a preferred or optional manner of this embodiment, the structural columns 6 are arranged along the board seam direction between the lightweight concrete slabs.

[0050] In some embodiments, the sleeve connector 7 is designed with an inner thread or an outer thread, and uses bolts or nuts and connectors to connect the concrete frame wall panels to the main structure of the building.

[0051] In some other embodiments, both the continuous beam and the structural column 6 are provided with an inorganic or organic insulation layer; wherein the inorganic or organic insulation layer of the structural column 6 in the concrete frame wall panel with doors and windows extends to the sides of the door and window openings.

[0052] Example 2

[0053] A method for manufacturing a concrete frame wall panel based on a polyurethane casting cavity comprises the following steps:

[0054] 1) According to the design drawings, determine the size of the concrete frame wall panel based on the polyurethane casting belly, lay out the lines on the counter or site, and reserve the door and window openings if there are doors and windows;

[0055] 2) The panel layout is designed according to the confirmed concrete frame wall panel based on the polyurethane casting belly, and the size of each concrete frame wall panel is confirmed and prepared, paying attention to leaving the joint size;

[0056] 3) Use vertical or horizontal assembly to confirm the height of the concrete frame wall panel based on the polyurethane casting belly, and then set the continuous beam along the end position of the lightweight concrete strip board;

[0057] 4) According to the size of the door and window openings, leave space for the concrete structural columns and place the tied beam and column steel mesh cages or FRP mesh cages;

[0058] 5) Install steel mesh cages on multiple base plates prepared according to the plate arrangement drawing according to the plate arrangement requirements, and pour foamed polyurethane between two adjacent base plates;

[0059] 6) Install the continuous beam and structural column steel mesh cage in place at the end position of the concrete frame wall panel based on the polyurethane casting belly, and the structural column steel mesh cage extends into the steel mesh cage inside the continuous beam for lap connection;

[0060] 7) Install the sleeve connector, the lower half of which is connected to the steel mesh cage in the continuous beam;

[0061] 8) Flat steel is preset above and below the concrete frame wall panels with doors and windows, or cast-in-place concrete structure is used to assist in fixing doors and windows, and the ends of the flat steel extend into the base plate;

[0062] 9) Assemble and fix the formwork of the connecting beam in the concrete slab, 2-10cm below the slab surface; use thin plates to seal the formwork between the continuous beams and structural columns, and then pour concrete into the formwork; or lay the insulation layer at the bottom of the continuous beams and structural columns, at the door and window openings, and extend the insulation layer of the structural columns to the sides, and pay attention to leaving a decoration margin of 5-20mm;

[0063] 10) After vibrating the slurry, cover the surface of the base board with inorganic or organic insulation board at the opening, and the insulation layer covers the structural column to the side of the door and window opening; or use the reverse punching process to lay the insulation layer at the bottom of the casting mold of the continuous beam and structural column, the structural column is located at the door and window opening, and the insulation layer extends to the side.

[0064] 11) After the concrete has been cured for a period of time, the concrete frame wall panels are erected and the left and right panel joints are sealed with thin plates; holes are drilled at different heights on the inner side of the base panels and foamed polyurethane is injected into the gap between the two base panels to form an organic insulation layer.

[0065] The present invention adopts cast-in-place concrete lock buckles designed on the upper and lower ends of the wall panels to fix each panel together, reserve insulation space for the inner and outer wall panels, and pour foamed polyurethane to make the double-layer wall panels a more solid whole; the composite wall of the present invention has the advantages of better insulation performance, stable wall structure, and not easy to deform and damage; it completely solves the problems of safety of assembled wall panel structure, integration of structure and insulation, fire prevention of wall panels and water seepage of assembled exterior walls. In addition, the present invention sets an indented L-shaped structure and a protruding L-shaped structure on both sides of the base plate. When the two composite wall panels are assembled, in addition to the assembly of the male and female notches, another cylindrical hole is formed, and bonding mortar or other bonding materials are poured into the hole; thereby making the composite wall panel connection more stable and convenient for assembly and use; and enhancing the waterproof and water-stopping effect.

[0066] The above description is only a preferred embodiment of the present invention and does not limit the technical scope of the present invention. Therefore, any slight modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A method for manufacturing a concrete frame wall panel based on a polyurethane casting cavity, wherein the concrete frame wall panel is used for a building exterior wall, characterized in that: A concrete frame wall panel comprises two base panels (1) and an organic thermal insulation layer (3) located between the two base panels (1); upper and lower ends of the two base panels (1) and the organic thermal insulation layer (3) are cast to form concrete layer panels (2), thereby sealing the organic thermal insulation layer (3) in a cavity formed by the two base panels (1); structural columns (6) are arranged in the two base panels (1), and continuous beams are arranged in the upper and lower concrete layer panels (2); a reinforced concrete frame is formed by connecting the upper and lower continuous beams with the structural columns (6) for casting the concrete frame wall panel with a cavity; the two base panels (1) are fixed, supported and connected by a plurality of FRP connectors (5). The FRP connector (5) is connected to each base plate (1); each FRP connector (5) is fixedly provided with a support member (51) near the outer wall of each base plate (1) on each FRP connector (5) for supporting the two base plates (1) to better form the abdominal cavity; a sink (21) is provided on the inner side of the upper and lower concrete slabs (2); a sleeve connector (7) is provided in the sink (21); one end of the sleeve connector (7) is fixedly connected to the steel mesh cage in the concrete slab (2), and the other end passes through the concrete slab (2) and is fixedly connected to the main structure of the building; a lightweight concrete strip is embedded between the continuous beams of the upper and lower concrete slabs (2); The method for making the concrete frame wall panel comprises the following steps: 1) According to the design drawings, determine the size of the concrete frame wall panel based on the polyurethane casting belly, lay out the lines on the counter or site, and reserve the door and window openings if there are doors and windows; 2) The panel layout is designed according to the confirmed concrete frame wall panel based on the polyurethane casting belly, and the size of each concrete frame wall panel is confirmed and prepared, paying attention to the size of the joints; 3) Use vertical or horizontal assembly to confirm the height of the concrete frame wall panel based on the polyurethane casting belly, and then set the continuous beam along the end of the lightweight concrete strip; 4) According to the size of the door and window openings, leave space for the concrete structural columns and place the tied beam and column steel mesh cages; 5) Install the steel mesh cages on the multiple base plates prepared according to the plate arrangement drawing according to the plate arrangement requirements, and apply bonding mortar or structural adhesive or use foamed polyurethane between two adjacent base plates; 6) Install the continuous beam and structural column steel mesh cage in place at the end position of the concrete frame wall panel based on the polyurethane casting belly, and the structural column steel mesh cage extends into the steel mesh cage inside the continuous beam for lap connection; 7) Install the sleeve connector, the lower half of which is connected to the steel mesh cage in the continuous beam; 8) Flat steel is preset above and below the concrete frame wall panels with doors and windows, or cast-in-place concrete structure is used to assist in fixing doors and windows, and the ends of the flat steel extend into the base plate; 9) Assemble and fix the formwork of the concrete connecting beam, 2-10cm lower than the lightweight board surface; use thin plates to seal the base plates between the continuous beam and the structural column, and then pour the concrete into the mold; leave a protective layer on the outside of the insulation layer; at the door and window openings, the insulation layer of the structural column extends to the side, and pay attention to leaving a decoration margin of 5-20mm; 10) After vibrating the slurry, cover the concrete surface with an inorganic or organic insulation board, leaving a protective layer on the outside of the insulation board; or use the reverse process to lay the insulation layer on the bottom of the continuous beam and structural column casting mold, with the bottom of the insulation board as a protective layer; at the door and window openings, the insulation layer covers the structural column to the door and window frames; 11) After the concrete has been cured for a period of time, the concrete frame wall panels are erected and the holes on both sides of the wall panels are sealed with thin plates; holes are drilled at different heights on the inner side of the base panels and foamed polyurethane is injected into the gap between the two base panels to form an organic insulation layer.

2. The method for manufacturing a concrete frame wall panel based on polyurethane casting belly according to claim 1, characterized in that: Each concrete frame wall panel has one side along its height direction that is recessed inwardly to form a groove (300), and the other side protrudes outwardly to form a convex column (400) that matches the groove (300); each concrete frame wall panel has one side along its width direction that is protruding outwardly to form a protruding L-shaped structure (100), and the other side is correspondingly recessed inwardly to form a retracted L-shaped structure (200), so that when the upper and lower concrete frame wall panels are installed, a staggered structure is formed at the overlap, and the horizontal seam of the wall is lower on the outside and higher on the inside, thereby enhancing the waterproof effect.

3. The method for manufacturing a concrete frame wall panel based on polyurethane casting belly according to claim 2, characterized in that: The grooves (300) and the convex columns (400) are arranged in one or more groups; the grooves (300) are arranged such that the cross-section concave inwards is one of a trapezoid, a rectangle or a circular arc; correspondingly, the convex columns (400) are also arranged such that the cross-section protruding outwards is one of a trapezoid, a rectangle or a circular arc.

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