Prefabricated thermal insulation floor and method for producing the same

Abstract

The application discloses a prefabricated thermal insulation floor slab, which comprises a net rack, a truss and a thermal insulation slab body; the net rack is located in the thermal insulation slab body or penetrates through the side wall of the thermal insulation slab body; the foot of the truss is located in the thermal insulation slab body, and the head of the truss is exposed on the thermal insulation slab body; the thermal insulation slab body comprises thermal insulation slab body units, the number of the thermal insulation slab body units is greater than or equal to 1, different thermal insulation slab body units are sequentially arranged from bottom to top, the thermal insulation slab body unit is a non-homogeneous structure composed of a concrete slurry and foamed particles, the number of the foamed particles in the upper part of the thermal insulation slab body unit is greater than that in the lower part, and the upper surface of the thermal insulation slab unit is attached with foamed particles. The prefabricated thermal insulation floor slab has the advantages that the thermal insulation material and the concrete are not easy to be delaminated, the thermal insulation effect will not be damaged due to secondary decoration, the process of roughening is omitted and the like.

Description

A prefabricated insulated floor slab and its production method Technical Field

[0001] This invention relates to the field of prefabricated insulated floor slab technology, specifically to a prefabricated insulated floor slab and its production method. Background Technology

[0002] With the implementation of the "green building" development strategy, the country's requirements for building energy conservation are becoming increasingly stringent. Previously, only exterior walls and roofs needed insulation; now, even individual floor slabs require insulation. Therefore, each floor slab must have an insulation layer. Depending on the location of the insulation layer, there are two existing construction methods: 1) the insulation layer is above the structural layer; 2) the insulation layer is below the structural layer. However, when the insulation layer is above the structural layer, because it is generally made of relatively loose and soft materials, the surface layer is prone to uneven stress and cracking after a surface layer is applied, resulting in a poor user experience. Furthermore, the insulation layer is easily damaged by users during secondary renovations, affecting the building's energy efficiency. When the insulation layer is below the structural layer, in addition to being easily damaged and affecting energy efficiency, its adhesion to the plaster layer is limited, leading to plaster layer detachment. Therefore, existing technologies suffer from problems such as easily damaged insulation layers and unsatisfactory insulation effects. Moreover, most existing precast insulated floor slab technologies are layered structures composed of several materials, resulting in complex or weak connections between the materials. The more layers of floor slab material there are, the more difficult the production becomes, the lower the yield rate of the product, and the higher the risk of quality and durability problems. Summary of the Invention

[0003] In view of the above-mentioned shortcomings, the present invention provides a prefabricated insulated floor slab and its production method. The prefabricated insulated floor slab of the present invention has the advantages of not easily separating the insulation material from the concrete, not damaging the insulation effect due to secondary decoration, and eliminating the need for the roughening process.

[0004] To achieve the above objectives, the present invention provides a prefabricated insulated floor slab, comprising a space frame, a truss, and an insulation panel; the space frame is located within the insulation panel or penetrates the side wall of the insulation panel; the feet of the truss are located within the insulation panel, and the heads of the trusses are exposed on the insulation panel; the insulation panel comprises insulation panel units, the number of which is greater than or equal to 1, and different insulation panel units are arranged sequentially from bottom to top; each insulation panel unit is a heterogeneous structure composed of concrete slurry and foamed particles, the upper part of the insulation panel unit has a greater number of foamed particles than the lower part, and the upper surface of the insulation panel unit is coated with foamed particles.

[0005] According to one aspect of the invention, the truss is welded or bundled to the space frame.

[0006] According to one aspect of the invention, the number of trusses is multiple, and the multiple trusses are arranged in an array on the insulation panel.

[0007] According to one aspect of the present invention, the space frame is any one or a combination of two or more of the following: wire mesh, non-metallic mesh, steel bars tied together, or steel bars welded together.

[0008] According to one aspect of the present invention, the foamed particles are polystyrene particles, and the polystyrene particles are modified polystyrene particles.

[0009] According to one aspect of the invention, the insulation board is further provided with a hanging ring penetrating its upper surface.

[0010] Based on the same inventive concept, the present invention also provides a method for producing prefabricated insulated floor slabs, comprising the following steps:

[0011] Step 1: Mold installation and pre-embedding process:

[0012] After installing the mold, place the space frame and truss into the mold in sequence and connect them, and pre-embed the lifting ring points and water and electricity openings;

[0013] Step 2: First vibration:

[0014] After the concrete slurry and foamed particles are mixed evenly, they are poured into the mold; after pouring, the first vibration is carried out to obtain the first insulation board unit.

[0015] According to one aspect of the invention, a second vibration is further included, specifically:

[0016] Step 3: After mixing the concrete slurry and foamed particles evenly, pour it onto the insulation board unit; after pouring, perform a second vibration to obtain the second insulation board unit.

[0017] According to one aspect of the invention, after vibration, it is necessary to check whether the slurry has deteriorated. If so, a cement spraying machine is used to spray neat cement slurry onto the surface of the vibrated component.

[0018] According to one aspect of the invention, the first vibration time is 30-60 seconds; the second vibration time is 5-10 seconds.

[0019] The beneficial effects of this invention are:

[0020] This invention provides a precast insulated floor slab, comprising a space frame, a truss, and an insulation panel. The space frame is located within the insulation panel or penetrates the sidewall of the insulation panel. The feet of the truss are located within the insulation panel, while the heads of the trusses are exposed on the insulation panel. The insulation panel includes insulation panel units, with at least one unit, arranged sequentially from bottom to top. Each insulation panel unit is a heterogeneous structure composed of concrete slurry and foamed particles. The upper part of each insulation panel unit has a greater number of foamed particles than the lower part, and the upper surface of each insulation panel unit is coated with foamed particles. The heterogeneous structure of the insulation panel unit is achieved through vibration compaction. The foamed particles (such as modified polystyrene particles) encapsulate the cement slurry and thus bond with other components of the concrete. After the concrete hardens, although the entire structure exhibits layering, there are no clear and neat interfaces between the layers; it remains a unified whole without separation. The concrete slurry layer, which wraps around the mesh and the feet and bottom chord of the steel truss, is the main source of structural strength for the insulation board. The foamed particle layer (such as modified polystyrene particles) provides the insulation board with thermal and sound insulation properties. At the same time, the upper layer of foamed particles (such as modified polystyrene particles) forms a rough surface, which has good bonding performance with the subsequently poured concrete, eliminating the need for a roughening process. Attached Figure Description

[0021] Figure 1 is a schematic diagram of the cross-sectional structure of the thin plate of the prefabricated insulated floor slab according to an embodiment of the present invention;

[0022] Figure 2 is a schematic diagram of the cross-sectional structure of the thick plate of the prefabricated insulated floor slab according to an embodiment of the present invention;

[0023] Figure 3 is a schematic diagram of the cross-sectional structure of the secondary cast-in-place thick slab of the prefabricated insulated floor slab according to an embodiment of the present invention;

[0024] Figure 4 is a top view of the prefabricated insulated floor slab with the grid structure located inside the insulation board according to an embodiment of the present invention;

[0025] Figure 5 is a top view of the prefabricated insulated floor slab with the grid structure penetrating the side wall of the insulated panel according to an embodiment of the present invention;

[0026] Figure 6 is a schematic diagram of the structure of the extended reinforcing mesh, truss, and lifting ring obtained after the pre-embedding process described in the embodiment of the present invention;

[0027] Figure 7 shows a prefabricated insulated floor slab with a grid structure penetrating the side wall of the insulated panel body, as described in an embodiment of the present invention.

[0028] Figure 8 is a process flow diagram of the production method of the prefabricated insulated floor slab according to an embodiment of the present invention.

[0029] Figure label:

[0030] 1. Space frame; 2. Truss; 3. Foamed granules; 4. Concrete slurry; 5. Lifting ring. Detailed Implementation

[0031] To make the present invention easier to understand, specific embodiments are described below to further illustrate the invention. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. 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. Unless otherwise defined, the technical terms used below have the same meaning as understood by those skilled in the art; unless otherwise specified, the raw materials and reagents involved herein can be purchased commercially or obtained by known methods.

[0032] To address the problems existing in the background technology, this application provides a prefabricated insulated floor slab, as shown in Figures 1-7, comprising a space frame 1, a truss 2, and an insulation board body; the space frame 1 is located inside the insulation board body (as shown in Figure 4) or penetrates the side wall of the insulation board body (as shown in Figures 5-7); the feet of the truss 2 are located inside the insulation board body, and the heads of the truss 2 are exposed on the insulation board body; the insulation board body includes insulation board body units, the number of which is greater than or equal to 1, and different insulation board body units are arranged sequentially from bottom to top; the insulation board body unit is a heterogeneous structure composed of concrete slurry 4 and foamed particles 3, the upper part of the insulation board body unit has a greater number of foamed particles 3 than the lower part, and the upper surface of the insulation board unit is attached with foamed particles 3.

[0033] Preferably, the truss 2 is welded or bundled to the space frame 1.

[0034] Preferably, there are multiple trusses 2 arranged in an array on the insulation panel. As shown in Figures 4-7, the trusses 2 are arranged in multiple rows, with each row including multiple trusses 2 distributed at equal intervals.

[0035] Preferably, the space frame 1 is any one or a combination of two or more of the following: steel wire mesh, non-metallic mesh (such as plastic mesh), steel bars tied together, or steel bars welded together.

[0036] Preferably, the foamed particles are polystyrene particles, and the polystyrene particles are modified polystyrene particles.

[0037] More preferably, the polystyrene particles are modified polystyrene particles.

[0038] It should be noted that the first purpose of modifying polystyrene particles is to improve the adhesion of the particle surface to cement paste, allowing the polystyrene particle surface to be coated by the cement paste, preventing it from automatically floating on the concrete surface due to its low density (in fact, the modified polystyrene particles are evenly distributed in the concrete paste due to the viscosity of the cement paste). The second purpose is to improve fire resistance. There are two main modification methods: one is to add unmodified polystyrene particles to a modifying liquid to fully coat their surface, then dry them to obtain modified polystyrene particles; the other is to add the modifying liquid and unmodified polystyrene particles together during concrete mixing to directly obtain modified polystyrene particle concrete. The modifier is a conventional reagent in this field, which will not be discussed further here.

[0039] It should be noted that the particle size of the modified polystyrene particles is preferably 3 to 5 mm.

[0040] Preferably, the insulation board is also provided with a hanging ring 5 that runs through its upper surface, as shown in Figures 4-7.

[0041] This invention also provides a method for producing prefabricated insulated floor slabs, the process flow diagram of which is shown in Figure 8, including the following steps:

[0042] Step 1: Mold installation and pre-embedding process:

[0043] After installing the mold, place the space frame and truss into the mold in sequence and connect them, and pre-embed the lifting ring points and water and electricity openings;

[0044] It should be noted that the wire-fitting mold and pre-embedding process is carried out using conventional composite floor slab production equipment; the mold-fitting and pre-embedding process is the same as that of composite floor slabs, wherein the pre-embedding process includes steel bar binding (if the space frame is steel bar bound), binding of space frame and truss, pre-embedding of lifting points, pre-embedding of water and electricity openings, etc.

[0045] Step 2: First vibration:

[0046] After the concrete slurry and foamed particles (such as modified polystyrene particles) are mixed evenly, they are poured into the mold; after pouring, the first vibration is carried out to obtain the first insulation board unit.

[0047] It should be noted that pouring is achieved through pouring equipment, such as a concrete placing boom; the formulation of the concrete slurry determines the degree to which foamed particles (such as modified polystyrene particles) float in the concrete slurry, the workability of the concrete, and other properties. These factors should be carefully considered when setting appropriate pouring volume and vibration time.

[0048] It should be noted that during the initial vibration, the foamed particles (such as modified polystyrene particles) will float to some extent in the concrete slurry due to vibration, accumulating in the upper layer while most of the concrete slurry sinks to the lower layer. The foamed particles (such as modified polystyrene particles) encapsulate the cement slurry and thus bond with other components of the concrete. After the concrete hardens, although the entire structure exhibits layering, there are no clear, neat interfaces between the layers; it remains a unified whole. The concrete slurry layer, which encapsulates the mesh and the feet and bottom chord of the steel truss, is the primary source of structural strength for the insulation board, while the foamed particle layer (such as modified polystyrene particles) provides thermal and sound insulation properties. Simultaneously, the upper layer of foamed particles (such as modified polystyrene particles) forms a rough surface, resulting in excellent bonding with the subsequently poured concrete, eliminating the need for a roughening process.

[0049] Preferably, it also includes a second vibration, specifically:

[0050] Step 3: After mixing the concrete slurry and foamed particles evenly, pour it onto the insulation board unit; after pouring, perform a second vibration to obtain the second insulation board unit.

[0051] It should be noted that the second vibration is a secondary pouring and vibration performed according to strength requirements. It aims to strengthen the insulation board in specific areas or improve the thermal insulation performance of those areas by aggregating local concrete slurry and foamed particles (such as modified polystyrene particles). Its principle differs from the first vibration (which is uneven in the vertical direction but basically uniform on the horizontal plane). The foamed particle (such as modified polystyrene particle) concrete poured in the second phase lands on the foamed particle (such as modified polystyrene particle) layer after the first vibration. During the second vibration, because the concrete slurry is heavier than the foamed particle (such as modified polystyrene particle) layer, it tends to sink further into the foamed particle (such as modified polystyrene particle) layer while spreading on the horizontal plane. Meanwhile, the foamed particles (such as modified polystyrene particles) in the second pouring material will also float to the surface. Therefore, after the concrete hardens, the interface between the first-poured foamed particle (such as modified polystyrene particle) layer and the second-poured layer forms a concrete slurry aggregation area. These aggregated areas can be controlled by the placement of the concrete inlet during the second pour. If the concrete is poured continuously in a strip shape perpendicular to the truss, the stiffness in that direction can be enhanced, reducing deformation after the insulation board is demolded and stacked. As the concrete slurry from the second pour settles, it will push the foamed particles (such as modified polystyrene particles) on the surface of the first pour outwards, forming aggregated polystyrene particles around them. If these aggregated particles are controlled within the steel truss, the thermal bridging effect of the steel truss can be mitigated, improving the insulation performance of the insulation board.

[0052] Preferably, after vibration, it is also necessary to check whether the slurry has deteriorated. If so, a cement spraying machine is used to spray cement slurry onto the surface of the vibrated component. The purpose is to prevent the foamed particles (such as modified polystyrene particles) on the surface of the component from falling off after it has hardened.

[0053] It should be noted that the difference between cement paste and concrete paste is: concrete paste includes cement, sand, gravel, fine aggregate, and admixtures; cement paste is a paste formed by adding water to cement, and it is the main component in concrete paste that binds cement, sand, gravel, fine aggregate, and polystyrene particles together, which can be understood as "glue".

[0054] Preferably, the first vibration time is 30-60 seconds; the second vibration time is 5-10 seconds.

[0055] It should be noted that vibration is achieved on vibrating equipment, such as a vibrating table. Its purpose is to level and compact the concrete, achieving the desired degree of stratification. The degree of stratification can be controlled by the vibration time; the longer the vibration time, the more thorough the stratification. However, if the vibration time is too long, the cement paste on the surface of the foamed particles (such as modified polystyrene particles) may detach, and the longer the vibration time, the greater the degree of detachment. The first vibration is generally longer (30-60 seconds) to make the concrete paste layer denser and the stratification more obvious, ensuring the structural strength of the insulation board. Secondary pouring and vibration are only performed when a second pour of insulation board is required. The materials for the secondary pour are generally the same as the first, but a new concrete formula can also be used. The duration of the secondary vibration determines the position of the newly poured concrete paste within the board, and is generally shorter (5-10 seconds). Excessive time, besides causing slurry desiccation, can also cause the secondary concrete paste to sink into the first pour, thus defeating the purpose of the secondary pour.

[0056] It should be noted that insulated floor slabs can be classified into thin slabs, thick slabs, and double-cast thick slabs according to their thickness and number of pours. Thin slabs are 30-40mm thick and can be used as insulation formwork that does not require removal. Thick slabs and double-cast thick slabs are 60-90mm thick and can be used as composite insulated floor slabs. Under the same thickness and insulation layer thickness, double-cast insulation slabs have higher structural strength than single-cast ones, but their insulation performance is slightly lower.

[0057] It should be noted that the insulation boards require subsequent curing processes. During curing, it is crucial to maintain humidity levels. Measures include water spraying, covering with a film, steam curing, and carbon dioxide curing to prevent cracking and dust generation. The demolding and finished product stacking processes are the same as for conventional composite floor slabs.

[0058] The following detailed explanation is further illustrated with specific examples.

[0059] Example 1

[0060] A precast insulated floor slab, as shown in Figures 2 and 4, includes a space frame, trusses, and an insulation panel. The space frame is located within the insulation panel. The feet of the trusses are located within the insulation panel, while the heads of the trusses are exposed on the insulation panel. The insulation panel includes insulation panel units, with one unit in total. Each insulation panel unit is a heterogeneous structure composed of concrete slurry and modified polystyrene particles. The upper part of each insulation panel unit has a greater number of foamed particles than the lower part, and the upper surface of each insulation panel unit is covered with foamed particles. The trusses are welded to the space frame. Multiple trusses are arranged in an array on the insulation panel. The trusses are arranged in five rows, with each row containing multiple trusses distributed at equal intervals.

[0061] A method for producing prefabricated insulated floor slabs:

[0062] Step 1: Mold installation and pre-embedding process:

[0063] After installing the mold, place the space frame (wire mesh) and truss into the mold in sequence and connect them, and pre-embed the lifting ring points and water and electricity openings;

[0064] Step 2: First vibration:

[0065] After the concrete slurry and foamed granules are mixed evenly, they are poured into the mold; after pouring, the first vibration is carried out (50s).

[0066] After vibration, it is necessary to check whether the grout has deteriorated. If so, use a cement spraying machine to spray the cement grout onto the surface of the vibrated component.

[0067] During the curing process, it is important to ensure humidity for the insulation boards. Measures such as watering, covering with film, steam curing, and carbon dioxide curing can be taken.

[0068] The final product is a prefabricated insulated floor slab with a thickness of 60mm.

[0069] Example 2

[0070] A precast insulated floor slab, as shown in Figures 3, 5, 6, and 7, includes a space frame (made of tied steel bars), trusses, and an insulation panel. The space frame penetrates the sidewalls of the insulation panel. The feet of the trusses are located within the insulation panel, while the heads of the trusses are exposed on the insulation panel. The insulation panel includes two insulation panel units, each a heterogeneous structure composed of concrete slurry and modified polystyrene particles. The upper part of each insulation panel unit has a greater number of foamed particles than the lower part, and the upper surface of each insulation panel unit is covered with foamed particles. The trusses are welded to the space frame. Multiple trusses are arranged in an array on the insulation panel. The trusses are arranged in five rows, with each row containing multiple trusses evenly spaced.

[0071] A method for producing prefabricated insulated floor slabs:

[0072] Step 1: Mold installation and pre-embedding process:

[0073] After installing the mold, place the space frame and truss into the mold in sequence and connect them, and pre-embed the lifting ring points and water and electricity openings;

[0074] Step 2: First vibration:

[0075] After the concrete slurry and foamed granules are mixed evenly, they are poured into the mold; after pouring, the first vibration is carried out (7s).

[0076] After vibration, it is necessary to check whether the grout has deteriorated. If so, use a cement spraying machine to spray the cement grout onto the surface of the vibrated component.

[0077] Step 3: Second vibration:

[0078] After the concrete slurry and foamed particles are mixed evenly, they are poured onto the insulation board unit; after pouring, a second vibration is carried out.

[0079] During the curing process, it is important to ensure humidity for the insulation boards. Measures such as watering, covering with film, steam curing, and carbon dioxide curing can be taken.

[0080] After vibration, it is necessary to check whether the grout has deteriorated. If so, use a cement spraying machine to spray the cement grout onto the surface of the vibrated component.

[0081] The final product is a prefabricated insulated floor slab with a thickness of 90mm.

[0082] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A prefabricated insulated floor slab, characterized in that, The system includes a space frame, a truss, and an insulation panel. The space frame is located within the insulation panel or penetrates the side wall of the insulation panel. The feet of the truss are located within the insulation panel, and the heads of the trusses are exposed on the insulation panel. The insulation panel includes insulation panel units, the number of which is greater than or equal to one. Different insulation panel units are arranged sequentially from bottom to top. Each insulation panel unit is a heterogeneous structure composed of concrete slurry and foamed particles. The heterogeneous structure of the insulation panel unit is achieved by vibration compaction. The number of foamed particles in the upper part of the insulation panel unit is greater than that in the lower part, and foamed particles are attached to the upper surface of the insulation panel unit.

2. The prefabricated insulated floor slab according to claim 1, characterized in that, The truss is welded or bundled to the space frame.

3. The prefabricated insulated floor slab according to claim 1, characterized in that, The number of trusses is multiple, and the multiple trusses are arranged in an array on the insulation panel.

4. The prefabricated insulated floor slab according to claim 1, characterized in that, The space frame is any one or a combination of two or more of the following: steel wire mesh, non-metallic mesh, steel bars tied together, or steel bars welded together.

5. The prefabricated insulated floor slab according to claim 1, characterized in that, The foamed particles are polystyrene particles, and the polystyrene particles are modified polystyrene particles.

6. The prefabricated insulated floor slab according to claim 1, characterized in that, The insulation board is also provided with a hanging ring that runs through its upper surface.

7. A method for producing prefabricated insulated floor slabs, characterized in that, The process includes the following steps: Step 1: Mold installation and pre-embedding: After installing the mold, place the space frame and truss into the mold in sequence and connect them, and pre-embed the lifting ring points and water and electricity openings; Step 2: First vibration: After mixing the concrete slurry and foamed particles evenly, pour it into the mold; after pouring, perform the first vibration to obtain the first insulation board unit; the upper surface of the first insulation board unit is covered with foamed particles.

8. The method for producing prefabricated insulated floor slabs according to claim 7, characterized in that, It also includes a second vibration, specifically: Step 3: After the concrete slurry and foamed particles are mixed evenly, it is poured onto the insulation board unit; after the pouring is completed, a second vibration is performed to obtain a second insulation board unit; the upper surface of the second insulation board unit is covered with foamed particles.

9. The method for producing prefabricated insulated floor slabs according to claim 7 or 8, characterized in that, After vibration, it is necessary to check whether the grout has deteriorated. If so, use a cement spraying machine to spray the cement grout onto the surface of the vibrated component.

10. The method for producing prefabricated insulated floor slabs according to claim 7, characterized in that, The first vibration time is 30-60 seconds.

11. The method for producing prefabricated insulated floor slabs according to claim 8, characterized in that, The second vibration should last for 5-10 seconds.

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