Modular concrete slab house construction and method of manufacture

Abstract

This invention discloses a concrete slab-type modular housing structure, comprising: a pair of mirror-aligned top and bottom slabs, each with two rows of U-shaped ribs at its four ends; a pair of end panels, respectively disposed at opposite ends of the top / bottom slabs, each end panel having two rows of side grooves on both sides of one pair of parallel ends and two rows of inwardly arranged U-shaped ribs on the other pair of parallel ends, the U-shaped ribs on the top and bottom slabs corresponding one-to-one with the side grooves on the end panels; and a pair of side panels, respectively disposed at the other opposite ends of the top / bottom slabs, each side panel having two rows of side grooves on both sides of its four ends, the side grooves on the side panels corresponding one-to-one with the U-shaped ribs on the top and bottom slabs, and the side grooves on the side panels corresponding one-to-one with the U-shaped ribs on the pair of end panels. This invention features a simple structure, high reliability, convenient installation, and low manufacturing cost.

Description

Technical Field

[0001] This invention relates to the field of prefabricated assembled housing structures. More specifically, this invention relates to a modular concrete slab housing structure and its manufacturing method. Background Technology

[0002] Modular buildings are currently the most prefabricated building type, mainly in the form of steel structures, concrete, and wood structures. Steel structure modular buildings suffer from high steel consumption and high cost, while wood structure modular buildings suffer from low reliability of node connections and high cost. Concrete modular buildings have low material cost, good sealing performance, reliable stress distribution, simple structure, convenient construction, and low production cost, making their application prospects broader. However, existing concrete slab house structures have obvious defects, one of which is the problem of numerous installation procedures. For example, the invention patent with announcement number CN102535738B, entitled "A Fully Prefabricated House and Installation Method," discloses a structure of a fully prefabricated house. The wall panels of this house have vertical grooves on both sides, and multiple reserved sleeves for connecting the wall panels are provided in the vertical grooves. The invention connects the upper and lower wall panels by pre-reserving vertical holes for connecting steel bars and post-poured concrete in the wall panels. The vertical connection between the wall panels is achieved through vertical grooves on both sides, pre-reserved connecting steel bars, and post-poured concrete. The connection between the floor slab and the wall panels is achieved through connecting sleeves around the floor slab, horizontal connecting steel bars passing through the connecting sleeves, and post-poured ring beams. This installation method involves many procedures. Another more widespread drawback is the insufficient rigidity of the connection points. For example, the invention patent with announcement number CN103061407B, entitled "A Prefabricated Assembled House Building and its Construction Method," discloses a prefabricated assembled house building that includes a concrete base, multiple wall panels surrounding the base, connecting steel bars on the base, vertical holes at both ends of the wall panels, wall-to-wall connection structures on both sides of the wall panels for connecting the wall panels, at least one roof sloping plate above the wall panels, a wall top connection part extending along the ridge direction on the bottom surface of the roof sloping plate, the lower end face of the wall top connection part correspondingly fitting with the top face of the wall panel, a wall top connection structure between the wall top connection part and the top of the wall panel, a roof connection part extending along the ridge direction on the upper end of the roof sloping plate, and a roof connection structure between the roof connection parts of two roof sloping plates. The construction method connects the wall panels to the floor slab by vertical holes, inserting connecting bars, and pouring concrete. The vertical connection between wall panels is achieved by setting vertical dovetail grooves, horizontal clamps, connecting sleeves, vertical clamps, and pouring concrete at the wall ends. There are many assembly methods, and there is also the problem of weak rigidity of the hinged connection between the wall panels and the floor slab. Summary of the Invention

[0003] One object of the present invention is to solve at least the above-mentioned problems and to provide at least the advantages that will be described later.

[0004] Another objective of this invention is to provide a modular concrete slab housing module structure that is simple in construction, highly reliable, easy to install, and low in manufacturing cost.

[0005] To achieve these objectives and other advantages according to the present invention, a modular concrete slab housing module structure is provided, comprising: The top plate and the bottom plate are mirror images of each other, and each of the four ends of the top plate and the bottom plate is provided with two rows of U-shaped ribs; A pair of end panels are mirror images of the opposite ends of the top plate / bottom plate. Each end panel has two rows of side grooves on both sides of a pair of parallel ends and two rows of U-shaped ribs on the other pair of parallel ends. The pair of ends with the side grooves are respectively connected to the top plate and the bottom plate. The U-shaped ribs on the top plate and the bottom plate correspond one-to-one with the side grooves on the end panel. A pair of side panels are respectively disposed at the other opposite ends of the top plate / bottom plate. Each side panel has two rows of side grooves on both sides of its four ends. The side grooves on the side panels correspond one-to-one with the U-shaped ribs on the top plate and the bottom plate to connect the top plate and the bottom plate. The side grooves on the side panels correspond one-to-one with the U-shaped ribs on a pair of end panels to connect the pair of end panels. The top plate, the bottom plate, a pair of end panels, and a pair of side panels are tightly connected to form a square house structure.

[0006] Preferably, the depth of the side grooves on the end panels and the side panels is slightly greater than the extension length of the U-shaped ribs on the top plate, the bottom plate, and each end panel.

[0007] Preferably, grouting material is provided in the side grooves on the end panel and the side grooves on the side panel to fix the U-shaped ribs.

[0008] Preferably, the top plate, the bottom plate, and the two rows of U-shaped ribs on each end plate are spaced apart, and the side grooves on each end plate and each side plate are spaced apart.

[0009] Preferably, each end panel and each side panel has a side groove with a rib perpendicular to the insertion direction of the U-shaped rib.

[0010] Preferably, the end panel and / or the side panel are provided with openings for installing doors or windows.

[0011] The present invention further claims a method for manufacturing the concrete slab house module structure, comprising: Step 1: Prefabricate the top panel, bottom panel, a pair of end panels, and a pair of side panels of the appropriate size. Step 2: Assemble a pair of end panels and a pair of side panels into a U-shaped structure, and pour grout into the side grooves at the joints. After the grout is poured and formed, set it aside for later use. Step 3: Hoist the mouth-shaped structure obtained in Step 2 onto the base plate and inject grout into the side groove at the connection point; Step 4: After the grout from Step 3 has been poured and formed, hoist the top plate to the top and pour grout into the side grooves at the connection. The grout pouring and forming process completes the production.

[0012] The present invention has at least the following beneficial effects: The modular concrete slab house structure provided by the present invention adopts a double-row U-shaped reinforcement and side groove insertion structure, which simplifies the connection structure, reduces the installation difficulty, and improves the installation efficiency. At the same time, the simplification of the connection structure reduces the smallest prefabricated unit of the modular concrete slab house structure to each slab, and each slab has no reinforcement around its perimeter, which reduces the manufacturing difficulty and cost. The further reduction of the smallest prefabricated unit to each slab reduces the transportation difficulty of the modular concrete slab house structure and improves its wider applicability. The installation process of the modular concrete slab house structure provided by the present invention only involves the U-shaped reinforcement and side groove. The insertion and backfilling of grout into the side grooves ensures a tight connection between the panels. The use of double-row U-shaped ribs creates a rigid connection between the panels, resulting in better overall installation integrity. The modular concrete slab house structure provided by this invention, employing a connection structure of double-row U-shaped ribs and side grooves, significantly reduces the required length of the U-shaped ribs extending beyond each panel, further lowering manufacturing costs and complexity. Furthermore, the manufacturing method of the modular concrete slab house structure provided by this invention, where each panel is prefabricated in the factory and transported to the installation site for assembly, reduces the transportation difficulty and cost of the modular concrete slab house structure, laying the foundation for its widespread adoption.

[0013] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Attached Figure Description

[0014] Figure 1 This is a structural schematic diagram of the concrete slab house structure described in one technical solution of the present invention; Figure 2 This is a schematic diagram of the structure of the top plate or bottom plate in another technical solution of the present invention; Figure 3 This is a schematic diagram of the end panel structure in another technical solution of the present invention; Figure 4 This is a schematic diagram of the side panel structure in another technical solution of the present invention. Detailed Implementation

[0015] The present invention will now be described in further detail with reference to the accompanying drawings, so that those skilled in the art can implement it based on the description.

[0016] It should be understood that terms such as “having,” “comprising,” and “including” as used herein do not exclude the presence or addition of one or more other elements or combinations thereof.

[0017] like Figures 1-4 As shown, the present invention provides a modular concrete slab housing module structure, comprising: A pair of mirror-image top plates 4 and bottom plates 3, each of the four ends of the top plate 4 and bottom plate 3 being provided with two rows of U-shaped ribs 5; A pair of end panels 1 are respectively disposed at a pair of opposite ends of the top plate 4 / bottom plate 3. Each end panel 1 has two rows of side grooves 6 on both sides of a pair of parallel ends, and two rows of U-shaped ribs 5 arranged inward on the other pair of parallel ends. The pair of ends with side grooves 6 are respectively connected to the top plate 4 and the bottom plate 3. The U-shaped ribs 5 on the top plate 4 and the bottom plate 3 correspond one-to-one with the side grooves 6 on the end panel 1. A pair of side panels 2 are respectively disposed at the other opposite ends of the top plate 4 / bottom plate 3. Each side panel 2 has two rows of side grooves 6 on both sides of its four ends. The side grooves 6 on the side panel 2 correspond one-to-one with the U-shaped ribs 5 on the top plate 4 and the bottom plate 3 to connect the top plate 4 and the bottom plate 3. The side grooves 6 on the side panel 2 correspond one-to-one with the U-shaped ribs 5 on a pair of end panels 1 to connect the pair of end panels 1. The top plate 4, bottom plate 3, a pair of end faces / 1, and a pair of side panels 2 are tightly connected to form a square house structure.

[0018] In the above technical solution, the modular concrete slab house structure includes a top slab 4, a bottom slab 3, a pair of end panels 1, and a pair of side panels 2, as shown below. Figure 2 As shown, the top plate 4 and the bottom plate 3 are mirror images of each other, with the top plate 4 being higher than the bottom plate 3. A pair of end panels 1 are mirror images of a pair of parallel ends of the top plate 4 and the bottom plate 3, and a pair of side panels 2 are mirror images of another pair of parallel ends of the top plate 4 and the bottom plate 3, forming a house structure. Each of the four ends of the top plate 4 and the bottom plate 3 is provided with two rows of U-shaped ribs 5; as shown... Figure 3 As shown, the two ends of the pair of end panels 1 facing the top plate 4 and bottom plate 3 are provided with side grooves 6 corresponding one-to-one with the U-shaped ribs 5 on the top plate and bottom plate. Therefore, the side grooves 6 are arranged in two rows, respectively located on the inner and outer sides of the end panels 1. The distance between the two rows of U-shaped ribs 5 on the top plate and bottom plate 3 is not greater than the thickness of the end panels 1. The other two ends of the pair of end panels 1 are provided with two rows of U-shaped ribs 5; Figure 4As shown, each of the four ends of the pair of side panels 2 is provided with side grooves 6. Similarly, the side grooves at each pair of ends of each side panel 2 are arranged in two rows, and correspond one-to-one with the U-shaped ribs 5 on the top plate 4 and the bottom plate 3, respectively. The side grooves at the other pair of ends of each side panel 2 are arranged in two rows, and correspond one-to-one with the U-shaped ribs 5 on a pair of end panels 1, respectively. The two rows of side grooves 6 on the side panel 2 are respectively arranged on the inner and outer sides of the side panel 2. The distance between the two rows of U-shaped ribs 5 on the top plate and the bottom plate 3 is not greater than the thickness of the side panel 2. The distance between the two rows of U-shaped ribs 5 on one end panel 1 is not greater than the thickness of the side panel 2. Preferably, the U-shaped ribs 5 on the top plate 4, the bottom plate 3 and the end panel 1 are arranged at equal intervals. The thickness of the pair of end panels 1 and the pair of side panels 2 is the same and the side grooves 6 arranged on them are arranged at equal intervals, so that the top plate 4, the bottom plate 3, the end panel 1 and the side panel 2 are all standard parts, which greatly reduces the difficulty of manufacturing modular concrete slab house structures.

[0019] In the above technical solution, the modular concrete slab house structure adopts a double-row U-shaped reinforcement 5 and a side groove 6 insertion structure for connection. After the U-shaped reinforcement 5 and the side groove 6 are inserted, grout is poured to achieve a rigid connection between the top slab 4 and the side panel 2 and the end panel 1, and a rigid connection between the bottom slab 3 and the side panel 2 and the end panel 1. Compared with the existing technology that uses reserved steel bars and reserved sleeves for connection, the top slab 4, bottom slab 3, one end panel 1 and a pair of side panels 2 in this application do not have reinforcement bars around their perimeter, which greatly reduces the manufacturing difficulty. Moreover, the double-row U-shaped reinforcement structure, compared with the single-row reserved steel bar connection structure, ensures the connection strength between the slabs. While the double-row U-shaped reinforcement structure enhances the connection strength between the slabs, it also reduces the required depth of insertion of the double-row U-shaped reinforcement 5 into the side groove 6. In other words, this application uses a double-row U-shaped reinforcement 5 and a side groove 6 for connection. The structure of groove 6 not only ensures the connection strength between the slabs, but also reduces manufacturing costs and difficulties. In the existing technology, the connection method using pre-reserved steel bars and pre-reserved sleeves requires opening holes on the side of the pre-reserved sleeves to inject grout. However, the side groove 6 of this application is opened on the side of each slab, which reduces the difficulty of grouting and construction. The connection structure of double-row U-shaped and side groove 6 only requires grouting after hoisting and insertion on site. Compared with the complex connection structure, the smallest prefabricated unit of the modular concrete slab house structure of this application is each slab, while the smallest prefabricated unit of the complex connection structure is the house body. The modular concrete slab house structure of this application has low transportation difficulty, which is more conducive to its promotion and application. Moreover, with each slab as the smallest prefabricated unit, it has a certain degree of turnover, replaceability and maintainability.

[0020] like Figure 3 and Figure 4As shown, in one of the technical solutions, the depth of the side groove 6 on the end panel 1 and the side panel 2 is slightly greater than the extension length of the U-shaped rib 5 on the top plate 4, the bottom plate 3 and the end panel 1, so that the U-shaped plate 5 of the top plate 4, the bottom plate 3 and the end panel 1 can be inserted into the corresponding side groove 6 on the end panel 1 and the side panel 2, and at the same time, the connection strength between the U-shaped rib 5 and the side groove 5 is enhanced by grouting material.

[0021] like Figure 3 and Figure 4 As shown, in one of the technical solutions, grouting material is provided in the side groove 6 on the end panel 1 and the side groove 6 on the side panel to fix the U-shaped rib 5. After the U-shaped rib 5 is inserted into the corresponding side groove 6, the grouting material is filled from the side of the side groove 6, which reduces the installation difficulty and improves the installation efficiency.

[0022] like Figures 1-4 As shown, in one technical solution, two rows of U-shaped ribs 5 on the top plate 4, bottom plate 3, and each end panel 1 are spaced apart, and side grooves 6 on each end panel 1 and side panel 2 are spaced apart. That is, adjacent U-shaped ribs 5 are located at opposite corners of their respective planes, and adjacent side grooves 6 are located at opposite corners of their respective planes. While ensuring the connection strength between the plates, the arrangement density of U-shaped ribs 5 and side grooves 6 is reduced, thus reducing the manufacturing cost. The arrangement density of U-shaped ribs 5 and side grooves 6 is set according to the connection strength requirements between the plates. The portions of the two rows of U-shaped ribs 5 on the top plate 4, bottom plate 3, and each end panel 1 located inside the top plate 4, bottom plate 3, and end panel 1 are connected by steel bars to form a continuous series of multiple U-shaped structures.

[0023] In one of the technical solutions, each end panel 1 and side panel 2 has a side groove 6 with a rib perpendicular to the insertion direction of the U-shaped rib 5 to improve the connection strength between the panels.

[0024] In one of the technical solutions, the end panel and / or side panel are provided with openings for installing doors or windows. The end panel 1 or side panel 2 is provided with openings, the shape of which is adapted to its purpose. For example, if the end panel 1 or side panel 1 is provided with an opening for installing a window, then the end panel 1 is provided with an opening adapted to the window. If the end panel 1 or side panel 1 is provided with an opening for installing a door, then the end panel 1 is provided with an opening adapted to the door.

[0025] The present invention further claims a method for manufacturing the concrete slab house module structure, comprising: Step 1: Prefabricate the top plate 4, bottom plate 3, a pair of end panels 1 and a pair of side panels 2 with the appropriate dimensions; Step 2: Assemble a pair of end panels 1 and a pair of side panels 2 into a mouth-shaped structure, and inject grout into the side grooves 6 at the connection point. After the grout is injected and formed, it is ready for use. Step 3: Hoist the mouth-shaped structure obtained in Step 2 onto the base plate 3, and inject grout into the side groove 6 at the connection point; Step 4: After the grout from Step 3 has been poured and formed, hoist the top plate 4 to the top and pour grout into the side groove 6 at the connection point. The grout pouring and forming process completes the manufacturing process.

[0026] In the above technical solution, the method for manufacturing the modular concrete slab house structure first involves manufacturing each slab, namely the top slab 4, the bottom slab 3, a pair of end panels 1, and a pair of side panels 2. The smallest prefabricated unit of the modular concrete slab house structure is each slab, which is also the unit with the lowest processing difficulty in the modular concrete slab house structure. The transportation difficulty and transportation cost of each slab are low. After the slabs are transported to the installation site, the on-site installation work includes assembling the pair of end panels 1 and the pair of side panels 2 into a U-shaped structure, and injecting grout into the side grooves 6 at the connection. After the grout is formed, it is ready for use. The resulting U-shaped structure is hoisted onto the bottom slab 3, and grout is injected into the side grooves 6 at the connection. Finally, the top slab 4 is hoisted to the top, and grout is injected into the side grooves 6 at the connection. The manufacturing is completed after the grout is formed. All the installation work only involves the insertion of the U-shaped ribs 5 and the side grooves 6 and the grouting of the side grooves. The installation is simple and efficient.

[0027] As described above, according to the present invention, the modular concrete slab house structure provided by the present invention adopts a double-row U-shaped reinforcement and side groove insertion structure, which simplifies the connection structure, reduces installation difficulty, and improves installation efficiency. Simultaneously, the simplification of the connection structure reduces the smallest prefabricated unit of the modular concrete slab house structure to individual slabs, and each slab has no reinforcement around its perimeter, reducing manufacturing difficulty and cost. Further reducing the smallest prefabricated unit to individual slabs reduces the transportation difficulty of the modular concrete slab house structure and improves its wider applicability. The installation process of the modular concrete slab house structure provided by the present invention only involves the U-shaped reinforcement and side grooves... The insertion and backfilling of grout into the side grooves ensure a tight connection between the panels. The use of double-row U-shaped ribs provides a rigid connection between the panels, resulting in better overall installation integrity. The modular concrete slab house structure provided by this invention, employing a connection structure with double-row U-shaped ribs and side grooves, significantly reduces the required length of the U-shaped ribs extending beyond each panel, further lowering manufacturing costs and complexity. Furthermore, the manufacturing method of the modular concrete slab house structure provided by this invention, where each panel is prefabricated in the factory and transported to the installation site for assembly, reduces the transportation difficulty and cost of the modular concrete slab house structure, laying the foundation for its widespread adoption.

[0028] The number of devices and processing scale described herein are for the purpose of simplifying the description of the invention. Applications, modifications, and variations of the modular concrete slab house structure of this invention will be readily apparent to those skilled in the art.

[0029] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and illustrations shown and described herein.

Claims

1. Modular concrete slab house structure, characterized by, include: The top plate and the bottom plate are mirror images of each other, and each of the four ends of the top plate and the bottom plate is provided with two rows of U-shaped ribs; A pair of end panels are mirror images of the opposite ends of the top plate / bottom plate. Each end panel has two rows of side grooves on both sides of a pair of parallel ends and two rows of U-shaped ribs on the other pair of parallel ends. The pair of ends with the side grooves are respectively connected to the top plate and the bottom plate. The U-shaped ribs on the top plate and the bottom plate correspond one-to-one with the side grooves on the end panel. A pair of side panels are respectively disposed at the other opposite ends of the top plate / bottom plate. Each side panel has two rows of side grooves on both sides of its four ends. The side grooves on the side panels correspond one-to-one with the U-shaped ribs on the top plate and the bottom plate to connect the top plate and the bottom plate. The side grooves on the side panels correspond one-to-one with the U-shaped ribs on a pair of end panels to connect the pair of end panels. The top plate, the bottom plate, a pair of end panels, and a pair of side panels are tightly connected to form a square house structure.

2. A modular concrete panel house structure as claimed in claim 1, wherein, The depth of the side grooves on the end panel and the side panel is slightly greater than the protruding length of the U-shaped ribs on the top plate, the bottom plate, and each end panel.

3. The modular concrete panelized house structure of claim 1, wherein, Grouting material is provided in the side grooves on the end panel and the side grooves on the side panel to fix the U-shaped ribs.

4. The modular concrete slab house structure as described in claim 1, characterized in that, The top plate, the bottom plate, and the two rows of U-shaped ribs on each end plate are spaced apart, and the side grooves on each end plate and each side plate are spaced apart.

5. The modular concrete slab house structure as described in claim 1, characterized in that, Each end panel and each side panel has a side groove with a rib perpendicular to the insertion direction of the U-shaped rib.

6. The modular concrete slab house structure as described in claim 1, characterized in that, The end panel and / or the side panel are provided with openings for installing doors or windows.

7. The method for manufacturing a concrete slab-type modular housing structure as described in any one of claims 1 to 6, characterized in that, include: Step 1: Prefabricate the top plate, the bottom plate, a pair of end panels, and a pair of side panels, each with a suitable size. Step 2: Assemble a pair of end panels and a pair of side panels into a U-shaped structure, and pour grout into the side grooves at the joints. After the grout is poured and formed, set it aside for later use. Step 3: Hoist the mouth-shaped structure obtained in Step 2 onto the base plate, and inject grout into the side groove at the connection point; Step 4: After the grout from Step 3 has been poured and formed, the top plate is hoisted to the top and grout is poured into the side groove at the connection point. The grout pouring and forming process completes the manufacturing process.

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