Prefabricated fireproof and thermal insulation sandwich wallboard and manufacturing method thereof

Abstract

This invention discloses a prefabricated fireproof and thermally insulated sandwich wall panel and its manufacturing method. The key technical points are: the prefabricated fireproof and thermally insulated sandwich wall panel includes an inner concrete leaf wall, a sandwich insulation layer, and an outer leaf wall panel, wherein the sandwich insulation layer is located between the inner concrete leaf wall and the outer leaf wall panel. This invention achieves integrated structural, thermal insulation, and decorative functions; reduces weight by more than 20% while maintaining the same energy-saving effect; improves energy-saving performance by more than 30% under the same thickness conditions; effectively reduces the thermal bridging effect of the exterior wall panel; and improves the fire resistance limit of prefabricated components under fire or high-temperature conditions.

Description

Technical Field

[0001] This invention relates to the field of thermal insulation wall panels, and particularly to a prefabricated fireproof and thermal insulation sandwich wall panel and its manufacturing method. Background Technology

[0002] Insulated wall panels are widely used in northern my country and are an important part of energy conservation.

[0003] A Chinese patent with publication number CN105863101A discloses a sandwich insulated external wall panel and its manufacturing method. This sandwich insulated external wall panel does not require independent connectors and can stably connect the first leaf plate, the second leaf plate, and the insulation layer, while having good thermal insulation performance. The key technical points are that it includes a first leaf plate, a second leaf plate, and an insulation layer disposed between the first leaf plate and the second leaf plate. The first leaf plate and the second leaf plate are respectively provided with protruding ribs and grooves that cooperate with the insulation layer on the side of the insulation layer, which strengthens the structural strength of the first leaf plate and the second leaf plate. Since the protruding ribs increase the thickness of the first leaf plate and the second leaf plate in a local area, they provide sufficient fixing area for subsequent installation of embedded hanging parts, hoisting of the entire external wall panel, and bonding and anchoring with concrete. This reduces the number of independent connectors for fixing the first leaf plate, the second leaf plate, and the insulation layer, which not only avoids thermal bridging but also ensures the integrity and sealing of the insulation layer, thus guaranteeing the thermal insulation performance.

[0004] A Chinese patent with publication number CN113431258B discloses a precast recycled concrete sandwich insulated wall panel and its manufacturing method. The precast recycled concrete sandwich insulated wall panel includes two sandwich panels and an insulation board disposed between the two sandwich panels. Locking blocks are installed on the sandwich panels, and locking grooves corresponding to the positions of the locking blocks are formed on the insulation board. The locking blocks are inserted into the locking grooves. A locking mechanism is provided within the sandwich panels. The locking mechanism includes a pushing component disposed within the sandwich panels and a locking component disposed within the locking blocks. The pushing end of the pushing component abuts against the locking component to lock the locking block within the locking groove. This application facilitates the replacement and substitution of the insulation board, thereby achieving energy-saving and environmentally friendly effects.

[0005] The aforementioned patents all have some advantages, but they also have some disadvantages, such as low fire resistance, high material density, inability to further improve thermal insulation, and inability to reduce the thermal bridging effect of the exterior wall panels. Summary of the Invention

[0006] In view of the problems mentioned in the background art, the purpose of this invention is to provide a prefabricated fireproof and heat-insulating sandwich wall panel and its manufacturing method, so as to solve the problems mentioned in the background art.

[0007] The above-mentioned technical objective of the present invention is achieved through the following technical solution:

[0008] A prefabricated fireproof and heat-insulating sandwich wall panel includes an inner concrete leaf wall, a sandwich insulation layer, and an outer leaf wall panel, wherein the sandwich insulation layer is located between the inner concrete leaf wall and the outer leaf wall panel.

[0009] Preferably, the sandwich insulation layer is made of aerogel felt or XPS board, the thickness of the sandwich insulation layer is 50-80mm, and the thickness of the concrete inner leaf wall is 100-150mm.

[0010] Preferably, the outer leaf wall panel includes a decorative surface layer and a base layer, wherein the base layer is made of UHPC with a strength grade of C120-C180, and the UHPC is modified by adding saturated water-absorbing resin as an internal curing agent; the thickness of the base layer is 30-50mm.

[0011] Preferably, the decorative surface layer is formulated with UHPC of C120 or below, and the color is adjusted with inorganic pigments of iron oxide series or titanium dioxide series; the thickness of the decorative surface layer is 8-12mm.

[0012] Preferably, the concrete inner leaf wall uses ceramsite concrete with a strength grade of not less than LC30 and a density grade of 1500-1900Kg / m³; the thickness of the concrete inner leaf wall is 100-150mm.

[0013] This invention also discloses a method for manufacturing a prefabricated fireproof and heat-insulating sandwich wall panel, comprising the following steps:

[0014] Step 1: Pour the UHPC decorative surface layer, with a thickness of 10mm;

[0015] Step 2: Pour the UHPC base layer and vibrate the countertop for 5-10 seconds to allow the base layer slurry to penetrate into the decorative surface layer without mixing it.

[0016] Step 3: Insert PVC pipes at the locations specified in the design for the installation of the thermal insulation tie-up components. The pipe diameter should be 3-5 times the diameter of the tie-up component. The insertion depth should not penetrate into the decorative surface layer. Place the tie-up components as required. Basalt fiber reinforced tie-up components should be used.

[0017] Step 4: After the concrete of the UHPC outer leaf wall panel has initially set but before it has fully set, pour inorganic thermal insulation slurry into the PVC pipe. The inorganic thermal insulation material is ceramsite concrete, foam concrete or aerogel coating. After it has set, pull out the PVC pipe.

[0018] Step 5: Reserve holes at the positions of the tie-in parts of the aerogel insulation material, and lay the vapor barrier layer, aerogel insulation layer, and vapor barrier layer in sequence;

[0019] Step Six: Pour the inner leaf wall with ceramsite concrete without vibration treatment;

[0020] Step 7: Remove from mold and cure until the factory age.

[0021] Preferably, the maintenance in step seven includes: spraying water five times a day when the temperature is above 5°C, and covering with insulation material and transparent film for maintenance when the temperature is below 5°C.

[0022] In summary, the present invention has the following main beneficial effects:

[0023] This invention achieves integrated functions of structure, thermal insulation and decoration; reduces weight by more than 20% while maintaining the same energy-saving effect; improves energy-saving effect by more than 30% under the same thickness conditions; effectively reduces the thermal bridging effect of exterior wall panels; and improves the fire resistance limit of prefabricated components under fire or high-temperature conditions. Attached Figure Description

[0024] Figure 1 This is one of the structural schematic diagrams of the present invention.

[0025] Figure 2 This is the second structural schematic diagram of the present invention.

[0026] Attached diagram descriptions: 1. Concrete inner leaf wall; 2. Sandwich insulation layer; 3. Outer leaf wall panel; 4. PVC pipe; 5. Base layer; 6. Vapor barrier layer; 7. Decorative surface layer; 8. Connecting components. Detailed Implementation

[0027] 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.

[0028] Example 1

[0029] refer to Figures 1 to 2 A prefabricated fireproof and heat-insulating sandwich wall panel includes an inner concrete leaf wall 1, a sandwich insulation layer 2, and an outer leaf wall panel 3, wherein the sandwich insulation layer 2 is located between the inner concrete leaf wall 1 and the outer leaf wall panel 3.

[0030] The sandwich insulation layer 2 is made of aerogel felt or XPS board, the thickness of the sandwich insulation layer 2 is 50mm, and the thickness of the concrete inner leaf wall 1 is 100mm.

[0031] The outer leaf wall panel 3 includes a decorative surface layer 7 and a base layer 5. The base layer 5 is made of C120 strength grade UHPC, and the UHPC is modified by adding saturated water-absorbing resin as an internal curing agent. The thickness of the base layer 5 is 30mm.

[0032] The decorative surface layer 7 is formulated with UHPC of C120 or below, and the color is adjusted with inorganic pigments of iron oxide series or titanium dioxide series; the thickness of the decorative surface layer 7 is 12mm.

[0033] The concrete inner leaf wall 1 uses ceramsite concrete with a strength grade of not less than LC30 and a density grade of 1500Kg / m³; the thickness of the concrete inner leaf wall 1 is 100mm.

[0034] This invention also discloses a method for manufacturing a prefabricated fireproof and heat-insulating sandwich wall panel, comprising the following steps:

[0035] Step 1: Pour the UHPC decorative surface layer 7, with a thickness of 10mm;

[0036] Step 2: Pour the UHPC base layer 5 and vibrate the countertop for 5 seconds to allow the grout from the base layer 5 to penetrate into the decorative surface layer 7 without mixing it.

[0037] Step 3: Insert PVC pipe 4 at the designated location for the insulation tie member 8 as required by the design. The pipe diameter should be 3 times the diameter of the tie member 8. The insertion depth should not penetrate into the decorative surface layer 7. Place the tie member 8 as required. The tie member 8 is made of basalt fiber reinforced tie member 8.

[0038] Step 4: After the initial setting of the UHPC outer leaf wall panel 3 concrete is completed and before the final setting, pour inorganic thermal insulation slurry into the PVC pipe 4. The inorganic thermal insulation material is ceramsite concrete, foam concrete or aerogel coating. After it is formed, pull out the PVC pipe 4.

[0039] Step 5: Reserve holes at the positions of the tie members 8 corresponding to the aerogel insulation material, and lay the vapor barrier layer 6, aerogel insulation layer, and vapor barrier layer 6 in sequence;

[0040] Step 6: Pour the lightweight aggregate concrete inner leaf wall 1 without vibration treatment;

[0041] Step 7: Remove from mold and cure until the factory age.

[0042] The maintenance in step seven includes: spraying water five times a day when the temperature is above 5°C, and covering with insulation material and transparent film for maintenance when the temperature is below 5°C.

[0043] This invention integrates structural, thermal insulation, and decorative functions; reduces weight by more than 20% while maintaining the same energy-saving effect; improves energy-saving performance by more than 30% under the same thickness conditions; effectively reduces the thermal bridging effect of exterior wall panels; and improves the fire resistance limit of prefabricated components under fire or high-temperature conditions.

[0044] Example 2

[0045] refer to Figures 1 to 2A prefabricated fireproof and heat-insulating sandwich wall panel includes an inner concrete leaf wall 1, a sandwich insulation layer 2, and an outer leaf wall panel 3, wherein the sandwich insulation layer 2 is located between the inner concrete leaf wall 1 and the outer leaf wall panel 3.

[0046] The sandwich insulation layer 2 is made of aerogel felt or XPS board, the thickness of the sandwich insulation layer 2 is 80mm, and the thickness of the concrete inner leaf wall 1 is 150mm.

[0047] The outer leaf wall panel 3 includes a decorative surface layer 7 and a base layer 5. The base layer 5 is made of C180 strength grade UHPC, and the UHPC is modified by adding saturated water-absorbing resin as an internal curing agent. The thickness of the base layer 5 is 50mm.

[0048] The decorative surface layer 7 is formulated with UHPC of C120 or below, and the color is adjusted with inorganic pigments of iron oxide series or titanium dioxide series; the thickness of the decorative surface layer 7 is 12mm.

[0049] The concrete inner leaf wall 1 uses ceramsite concrete with a strength grade of not less than LC30 and a density grade of 1500-1900Kg / m³; the thickness of the concrete inner leaf wall 1 is 100-150mm.

[0050] This invention also discloses a method for manufacturing a prefabricated fireproof and heat-insulating sandwich wall panel, comprising the following steps:

[0051] Step 1: Pour the UHPC decorative surface layer 7, with a thickness of 10mm;

[0052] Step 2: Pour the UHPC base layer 5 and vibrate the countertop for 10 seconds to allow the grout from the base layer 5 to penetrate into the decorative surface layer 7 without mixing it.

[0053] Step 3: Insert PVC pipe 4 at the designated location for the insulation tie member 8 as required by the design. The pipe diameter should be 5 times the diameter of the tie member 8. The insertion depth should not penetrate into the decorative surface layer 7. Place the tie member 8 as required. The tie member 8 is made of basalt fiber reinforced tie member 8.

[0054] Step 4: After the initial setting of the UHPC outer leaf wall panel 3 concrete is completed and before the final setting, pour inorganic thermal insulation slurry into the PVC pipe 4. The inorganic thermal insulation material is ceramsite concrete, foam concrete or aerogel coating. After it is formed, pull out the PVC pipe 4.

[0055] Step 5: Reserve holes at the positions of the tie members 8 corresponding to the aerogel insulation material, and lay the vapor barrier layer 6, aerogel insulation layer, and vapor barrier layer 6 in sequence;

[0056] Step 6: Pour the lightweight aggregate concrete inner leaf wall 1 without vibration treatment;

[0057] Step 7: Remove from mold and cure until the factory age.

[0058] The maintenance in step seven includes: spraying water five times a day when the temperature is above 5°C, and covering with insulation material and transparent film for maintenance when the temperature is below 5°C.

[0059] This invention integrates structural, thermal insulation, and decorative functions; reduces weight by more than 20% while maintaining the same energy-saving effect; improves energy-saving performance by more than 30% under the same thickness conditions; effectively reduces the thermal bridging effect of exterior wall panels; and improves the fire resistance limit of prefabricated components under fire or high-temperature conditions.

[0060] Example 3

[0061] refer to Figures 1 to 2 A prefabricated fireproof and heat-insulating sandwich wall panel includes an inner concrete leaf wall 1, a sandwich insulation layer 2, and an outer leaf wall panel 3, wherein the sandwich insulation layer 2 is located between the inner concrete leaf wall 1 and the outer leaf wall panel 3.

[0062] The sandwich insulation layer 2 is made of aerogel felt or XPS board, the thickness of the sandwich insulation layer 2 is 60mm, and the thickness of the concrete inner leaf wall 1 is 130mm.

[0063] The outer leaf wall panel 3 includes a decorative surface layer 7 and a base layer 5. The base layer 5 is made of UHPC with a strength grade of C120-C180. The UHPC is modified by adding saturated water-absorbing resin as an internal curing agent. The thickness of the base layer 5 is 40mm.

[0064] The decorative surface layer 7 is formulated with UHPC of C120 or below, and the color is adjusted with inorganic pigments of iron oxide series or titanium dioxide series; the thickness of the decorative surface layer 7 is 10mm.

[0065] The concrete inner leaf wall 1 uses ceramsite concrete with a strength grade of not less than LC30 and a density grade of 1700Kg / m³; the thickness of the concrete inner leaf wall 1 is 130mm.

[0066] This invention also discloses a method for manufacturing a prefabricated fireproof and heat-insulating sandwich wall panel, comprising the following steps:

[0067] Step 1: Pour the UHPC decorative surface layer 7, with a thickness of 10mm;

[0068] Step 2: Pour the UHPC base layer 5 and vibrate the countertop for 8 seconds to allow the grout from the base layer 5 to penetrate into the decorative surface layer 7 without mixing it.

[0069] Step 3: Insert PVC pipe 4 at the designated locations for the insulation tie member 8 as required by the design. The pipe diameter should be 3-5 times the diameter of the tie member 8. The insertion depth should not penetrate into the decorative surface layer 7. Place the tie member 8 as required. The tie member 8 is made of basalt fiber reinforced tie member 8.

[0070] Step 4: After the initial setting of the UHPC outer leaf wall panel 3 concrete is completed and before the final setting, pour inorganic thermal insulation slurry into the PVC pipe 4. The inorganic thermal insulation material is ceramsite concrete, foam concrete or aerogel coating. After it is formed, pull out the PVC pipe 4.

[0071] Step 5: Reserve holes at the positions of the tie members 8 corresponding to the aerogel insulation material, and lay the vapor barrier layer 6, aerogel insulation layer, and vapor barrier layer 6 in sequence;

[0072] Step 6: Pour the lightweight aggregate concrete inner leaf wall 1 without vibration treatment;

[0073] Step 7: Remove from mold and cure until the factory age.

[0074] The maintenance in step seven includes: spraying water five times a day when the temperature is above 5°C, and covering with insulation material and transparent film for maintenance when the temperature is below 5°C.

[0075] This invention integrates structural, thermal insulation, and decorative functions; reduces weight by more than 20% while maintaining the same energy-saving effect; improves energy-saving performance by more than 30% under the same thickness conditions; effectively reduces the thermal bridging effect of exterior wall panels; and improves the fire resistance limit of prefabricated components under fire or high-temperature conditions.

[0076] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for manufacturing a prefabricated fireproof and heat-insulating sandwich wall panel, characterized in that: Prefabricated fireproof and thermal insulation sandwich wallboard, comprising a concrete inner leaf wall (1), a sandwich thermal insulation layer (2) and an outer leaf wallboard (3), the sandwich thermal insulation layer (2) is located between the concrete inner leaf wall (1) and the outer leaf wallboard (3); The manufacturing method comprises the following steps: Step one: pouring a UHPC decorative surface layer (7) with a thickness of 10mm; Step two: pouring a UHPC base layer (5), and vibrating the surface for 5-10s so that the base layer (5) slurry penetrates into the decorative surface layer (7) without mixing; Step three: inserting a PVC pipe (4) at the design required thermal insulation tie member (8) arrangement position, the pipe diameter is 3-5 times the diameter of the tie member (8), the insertion depth should not be deeper than the decorative surface layer (7), and the tie member (8) is placed as required, and the tie member (8) is made of basalt fiber reinforced tie member (8); Step four: after the initial setting of the UHPC outer leaf wallboard (3) and before the final setting, pouring inorganic thermal insulation slurry into the PVC pipe (4), the inorganic thermal insulation material is ceramsite concrete, foam concrete or aerogel coating, and the PVC pipe (4) is pulled out after forming; Step five: reserving holes at the positions of the aerogel thermal insulation material corresponding to the tie member (8), and sequentially laying a vapor barrier layer (6), an aerogel thermal insulation layer and a vapor barrier layer (6); Step six: pouring a ceramsite concrete inner leaf wall (1) without vibration treatment; Step seven: removing the mold and curing until the factory age.

2. The method for manufacturing a prefabricated fireproof thermal insulation sandwich wallboard according to claim 1, characterized in that: The sandwich thermal insulation layer (2) is made of aerogel felt or XPS board, the thickness of the sandwich thermal insulation layer (2) is 50-80mm, and the thickness of the concrete inner leaf wall (1) is 100-150mm.

3. The method of claim 1, wherein the method further comprises: The outer leaf wallboard (3) comprises a decorative surface layer (7) and a base layer (5), the base layer (5) is made of C120-C180 strength grade UHPC, and saturated water absorbing resin is added as an internal curing agent for modification; the thickness of the base layer (5) is 30-50mm.

4. The method of claim 3, wherein the method further comprises: The decorative surface layer (7) is prepared by using C120 and below UHPC, and the color is adjusted by using iron oxide series or titanium white powder series inorganic pigments; the thickness of the decorative surface layer (7) is 8-12mm.

5. The method of claim 1, wherein the method further comprises: The strength grade of the ceramsite concrete used in the concrete inner leaf wall (1) is not less than LC30, and the density grade is 1500-1900Kg / m; the thickness of the concrete inner leaf wall (1) is 100-150mm.

6. The method of claim 1, wherein the method further comprises: The curing of step seven comprises: when the air temperature is higher than 5℃, spraying water for curing 5 times a day, when the temperature is lower than 5℃, covering thermal insulation material and transparent film for curing.

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