Embedded connection toughened sandwich insulation composite wall panel and preparation method thereof

Abstract

The present invention discloses an embedded-connected toughened sandwich insulation composite wall panel and a preparation method thereof, which belongs to the technical field of prefabricated housing construction engineering. The embedded-connected toughened sandwich insulation composite wall panel comprises a substrate inner blade, an insulation board and a substrate outer blade that are sequentially connected by a connector, and a toughening layer is provided on the outer surface of the substrate inner blade and the substrate outer blade respectively; the inner side of the substrate inner blade and the substrate outer blade is provided with a full-length plate groove along the plate length direction for filling high-strength grouting material; the connector comprises a web and flanges on both sides of the web, and the web ends and the flanges are anchored in the high-strength grouting material; the web is fixedly or detachably connected to the support arm, and a positioning boss is provided on the end of the support arm. The present invention has the following effects: reliable connection of the toughening layer with the substrate inner blade and the substrate outer blade respectively is achieved, and the overall anti-deformation performance is good; the connector enhances the integrity of the wall panel; the flat mold manufacturing method is adopted, which is in line with industrial development.

Description

Technical Field

[0001] The present invention relates to the technical field of prefabricated house construction engineering, and in particular to an embedded-connected toughened sandwich insulation composite wallboard and a preparation method thereof. Background Art

[0002] Most existing walls are constructed using various types of masonry or blocks. These walls are thick, heavy, labor-intensive, slow to construct, and have poor seismic performance. At the same time, with the continuous improvement of living standards, housing construction is subject to functional requirements. In addition to traditional requirements such as safety, applicability, and durability, materials must also possess thermal insulation, fire resistance, and sound insulation properties.

[0003] To address these issues, some prefabricated wall panels have emerged in China over the years. However, the manufacturing process is complex, requiring custom production based on specific project dimensions. This prohibits pre-production and prevents true industrialization and commercialization of building products. Furthermore, these wall panels are prone to cracking during use and exhibit poor thermal insulation, sound absorption, and soundproofing.

[0004] Patent No. 202222008565.7 discloses a sandwich wall panel, which includes an insulation board and concrete boards on both sides. Metal mesh is provided inside the concrete boards. A first through hole is provided inside the insulation board, and a connector with both ends abutting the metal mesh is passed through the first through hole. The connector can accurately control the distance between the outer wire mesh and the insulation board, and the support block can limit and fix the metal mesh in all directions. However, the inner and outer blades of the sandwich wall panel are made of concrete, and the overall weight is large, which increases the difficulty of transportation and construction. The wall panel has multiple connectors and positioning parts, and the production process is complicated and maintenance is difficult.

[0005] Patent No. 201720797272.8 discloses a prefabricated prestressed insulated exterior wall panel. The exterior wall panel includes an insulating core panel, a steel mesh located on both sides of the insulating core panel, and a concrete layer cast on the steel mesh. The insulating core panel is provided with a plurality of continuous insulating core panel ribs, and the concrete layer is provided with a plurality of concrete ribs. Shear connectors connected to the steel mesh are interspersed between adjacent insulating core panel ribs. Prestressed tendons are provided in the grooves formed between adjacent insulating core panel ribs and / or in the grooves formed between adjacent concrete ribs. The wall panel uses insulating core panel ribs to reduce the amount of concrete used, reduce the deadweight of the wall panel, and improve the thermal insulation performance. However, the outer layer is made of concrete, which requires the preparation of steel mesh and prestressed tendons. The overall weight is relatively large, the insulating panel structure is complex, and it is difficult to process, which increases labor costs. Although the thermal insulation effect is improved, the thermal insulation energy-saving efficiency is low. The installation of prestressed tendons requires the installation of tensioning equipment, which has high requirements for production conditions and complex production processes. In addition, prestressing poses safety risks during on-site construction.

[0006] Patent No. 201710536108.6 discloses a lightweight composite insulation exterior wall panel, which includes an insulation core panel, FRP shear connectors, steel mesh on both sides of the insulation core panel, and a concrete layer cast on the steel mesh. The insulation core panel is provided with a full-length insulation core panel rib, and the concrete layer is provided with a plurality of concrete ribs that intersect and cooperate with the insulation core panel ribs. The outer layer of this invention uses concrete, which requires the preparation of steel mesh and prestressed tendons. The overall weight is relatively large, and the sound insulation performance is not outstanding. The structure is complex and difficult to process, which increases processing and transportation costs.

[0007] Patent No. 202210273901.2 discloses a ceramic composite wall panel with a reinforced steel truss and a surface-reinforced aluminum alloy plate facing substrate. The composite wall panel includes a decorative aluminum alloy plate, a foamed ceramic plate, a fiber cement mortar surface layer, a steel mesh, a light steel keel frame, a steel truss, a substrate concrete layer and a calcium silicate board. The present invention has a multi-layer structure and multiple components, a complicated production process, low production efficiency, and consumes a lot of manpower costs. The present invention sets a keel structure, and requires opening holes to pour foam concrete into the formwork. The on-site wet operation is large and the requirements for substrate equipment are high. Although foamed ceramic plates, light keels, and foamed concrete are used, the addition of steel trusses and other components makes the overall weight large, which increases the load and seismic force of the structure.

[0008] Patent No. 202120756780.8 discloses an ALC composite wall panel structure. Composed of an ALC protective layer, an insulation layer, a steel mesh, a finishing layer, and C-shaped slots, the ALC composite wall panel boasts high structural strength, excellent thermal insulation, easy fabrication and splicing, and excellent shrinkage resistance and waterproofing. However, the panels' surface layers are loosely connected, and peeling and shedding between them can occur under heavy loads, resulting in poor overall performance.

[0009] Patent No. 202221567913.8 discloses a combined multi-layer composite insulation exterior wall panel, which includes two layers of autoclaved sand aerated board, an insulation layer, vertical connecting rods, and a fixed plate. The connecting rod is placed in the sand aerated board, and the bolts on the connecting rod pass through the fixed plate and are fastened in the nut. The invention uses a composite structure of autoclaved sand aerated board and insulation board with good insulation performance, but the bolts and metal connectors may form thermal bridges, thereby affecting the insulation performance of the wall panel. The fixed plate ensures the durability and deformation performance of the exterior wall panel, but the fixed plate is not tightly attached to the surface of the wall panel, and the sealing is poor. Moisture and air can easily enter the wall panel, thereby affecting the performance of the wall panel. Although the vertical tie rod provides stability in the vertical direction, when the connection between the two pieces of autoclaved sand aerated board is weak, such as under the action of strong winds, the strength is insufficient. The use of fixed plates and bolts will cause stress concentration at the nodes, and the structure will weaken after long-term use.

[0010] Patent No. 201611103471.0 discloses an assembled, staggered, sound-insulating ALC panel composite wall. This wall is composed of two main ALC panel walls of varying thickness, connecting studs, and an internal filling of sound-insulating and fire-resistant cotton. Fiber mesh cloth and gypsum board can be installed on the outer surface to protect the main wall surface. The wall panels are structurally well-arranged, offering excellent comprehensive sound insulation, moderate thermal insulation, and superior fire resistance. However, the design of the wall panels fails to consider the inter-panel splicing structure; the internal studs of the panels vary, making positioning and assembly time-consuming and labor-intensive; and the infill layer is not tightly connected to one of the ALC panels, making delamination prone. Summary of the Invention

[0011] In view of the defects of the prior art, the present invention provides an embedded connection toughened sandwich insulation composite wall panel and a preparation method thereof. The wall panel has excellent insulation effect, light wall weight, excellent crack resistance and good insulation composite wall integrity.

[0012] To achieve the above objectives, the present invention provides a toughened sandwich thermal insulation composite wall panel with embedded connections. The specific technical solution is as follows:

[0013] A toughened sandwich insulation composite wall panel with embedded connection includes a base material inner blade plate, an insulation board and a base material outer blade plate which are connected in sequence by a connecting piece; a toughening layer is provided on the outer surface of the base material inner blade plate and the base material outer blade plate respectively; a continuous plate groove is provided on the inner side of the base material inner blade plate and the base material outer blade plate along the length direction of the plate, and the plate groove is filled with high-strength grouting material; the connecting piece includes a web and flanges located on both sides of the web, and the web end and the flange are anchored in the high-strength grouting material; support arms perpendicular to the web plane are provided at intervals on the two side surfaces of the web in the length direction, the support arms are provided in the direction close to the base material inner blade plate, the web plate is fixedly or detachably connected to the support arms, and the support arms are used to support the connecting piece on the plate groove of the base material inner blade plate; a positioning boss is provided on the end of the support arm for positioning the connection position of the connecting piece in the plate groove.

[0014] Furthermore, the web and the support arms are detachably connected in a manner that one support arm and the other support arm are fixedly connected to the web via a connecting component.

[0015] Furthermore, the connecting component is a support arm tenon or a connecting pin or a connecting column or a smooth round peg or a bolt.

[0016] Furthermore, a connecting piece lifting hole is provided on one end of the web.

[0017] Furthermore, sleeve placement openings are provided at both ends of the inner blade of the base material, one end of the sleeve placement opening passes through the plate groove, and an inner thread sleeve is provided in the sleeve placement opening. The inner thread sleeve is a cylinder with a closed bottom end and an open top end, and the top end of the inner thread sleeve opening faces the surface of the toughening layer.

[0018] Furthermore, an anchoring boss is provided on the outer side of the inner thread sleeve.

[0019] Furthermore, the length of the base material inner blade plate and the base material outer blade plate is 3.0m to 4.2m, the width is 600mm to 3m, with 300mm as the size module, and the thickness is not less than 70mm.

[0020] Furthermore, the base material inner blade plate and the base material outer blade plate are foamed ceramic plates or autoclaved aerated concrete plates; the compressive strength of the foamed ceramic plates is not less than 7 MPa, and the compressive strength of the autoclaved aerated concrete plates is not less than 2.5 MPa.

[0021] Furthermore, the toughening layer is made of one of the following materials: high-ductility concrete, reinforced fine-stone concrete, cement mortar steel mesh, and carbon fiber cloth.

[0022] Furthermore, when the material used for the toughening layer is high ductility concrete or cement mortar steel mesh, the thickness shall not be less than 15mm; when the material used for the toughening layer is reinforced fine stone concrete, the thickness shall not be less than 50mm; when the material used for the toughening layer is carbon fiber cloth, the structural adhesive shall be epoxy resin, and the carbon fiber cloth shall include longitudinal carbon fiber cloth strips and transverse carbon fiber cloth strips, the thickness of the carbon fiber cloth shall not be less than 0.15mm, and the unit area mass shall not be less than 200g / m 2 .

[0023] Furthermore, the width of the plate groove is not less than 40 mm, the depth is not less than 40 mm, and the distance between the plate groove and the side edges of the inner blade plate of the substrate and the outer blade plate of the substrate is greater than 10 mm.

[0024] Furthermore, the insulation board is made of one of polystyrene board, extruded board, graphite polystyrene, and perlite-wrapped vacuum insulation board.

[0025] Furthermore, when the insulation board is a polystyrene board, its thickness shall not be less than 90 mm; when the insulation board is an extruded board, its thickness shall not be less than 80 mm; when the insulation board is graphite polystyrene, its thickness shall not be less than 75 mm; when the insulation board is a vacuum insulation board wrapped with perlite, its thickness shall not be less than 6 mm.

[0026] Furthermore, fireproof isolation blocks are provided on both sides of the insulation board.

[0027] Furthermore, a block groove is provided on the outer side of the fireproof isolation block.

[0028] A method for preparing the aforementioned embedded connection toughened sandwich insulation composite wall panel comprises the following steps:

[0029] S1. Prefabricate the inner blade plate and the outer blade plate of the base material in the factory, accurately cut and position the inner blade plate and the outer blade plate of the base material according to the design requirements, open plate grooves on the inner blade plate and the outer blade plate of the base material, and reserve sleeve placement openings at the ends of the plate grooves of the inner blade plate of the base material;

[0030] S2. Place the inner blade of the substrate on the mold platform with the plate groove of the inner blade of the substrate facing the mold platform. Place the positioning block in the plate groove. The end face of the inner blade of the substrate is flush with the outer end face of the positioning block. The center line of the sleeve positioning groove corresponds to the center line of the sleeve placement opening. Use the limiter to fix the side mold.

[0031] S3. Place the inner thread sleeve through the sleeve placement opening and on the positioning block. Place the closed end of the inner thread sleeve in the sleeve positioning groove and install the connecting bolt on the inner thread sleeve.

[0032] S4. Apply an interface adhesive to the outer surface of the inner blade of the substrate and then add a toughening layer. The surface of the toughening layer is aligned with the opening of the inner thread sleeve and then cured. After the curing is completed, the positioning block is removed.

[0033] At the same time, in another mold platform and side mold, a toughening layer is added to the outer surface of the outer blade of the base material for curing;

[0034] S5. Turn the inner blade of the substrate that has undergone surface toughening treatment upside down and place it on the mold table, and insert the positioning boss of the connector into the plate groove;

[0035] S6. injecting high-strength grouting material into the plate groove through the pouring port formed between the adjacent support arms of the connector and the inner blade of the base material;

[0036] S7. Apply phenolic resin on the outer surface of the inner blade of the base material to form a bonding layer, install the insulation board on the inner blade of the base material, and maintain it until the high-strength grouting material is cured;

[0037] S8. Place the cured outer blade of the substrate in the formwork with the groove side of the outer blade facing upwards, inject high-strength grouting material into the groove of the outer blade of the substrate, use a turning machine to turn over the cured inner blade of the substrate, the insulation board and the connector as a whole, and place the connector upside down in the high-strength grouting material of the outer blade of the substrate;

[0038] S9. After curing and solidification, an embedded-connected toughened sandwich thermal insulation composite wall panel is formed.

[0039] Furthermore, in step S4, a toughening layer is formed on the outer surface of the inner blade plate of the substrate and the outer blade plate of the substrate, specifically: when the toughening layer is high-ductility concrete, high-ductility concrete is pressed on the surface of the inner blade plate of the substrate and the outer blade plate of the substrate as a toughening layer; when the toughening layer is reinforced fine stone concrete, the longitudinal steel bars and the transverse steel bars are first tied and fixed to the outer surface of the inner blade plate of the substrate and the outer blade plate of the substrate, and then the fine stone concrete is poured; when the toughening layer is cement mortar wire mesh, the wire mesh is first fixed to the outer surface of the inner blade plate of the substrate and the outer blade plate of the substrate, and then cement mortar is poured; when the toughening layer is carbon fiber cloth, high-strength grouting material is poured on the sleeve installation port of the inner blade plate of the substrate, phenolic resin is applied on the surface of the inner blade plate of the substrate and the outer blade plate of the substrate, longitudinal carbon fiber cloth strips and transverse carbon fiber cloth strips are pasted according to the design specifications, and phenolic resin is applied to the surface again.

[0040] Furthermore, in step S7, it also includes: applying phenolic resin on both sides of the insulation board to form an adhesive layer, and placing a fireproof isolation block outside the adhesive layer.

[0041] The present invention has the following beneficial effects:

[0042] (1) The present invention realizes the reliable connection between the toughening layer and the inner blade plate and the outer blade plate of the substrate, and has good overall anti-deformation performance, which greatly improves the bearing capacity and rigidity of the composite wallboard;

[0043] (2) The connector can achieve precise positioning, prevent slurry leakage, and has excellent shear resistance, while enhancing the integrity of the wall panel; when the web and the support arm are detachably connected, the connector can meet the use of plate grooves of different widths, and different sizes of support arms can be used according to the size of the plate groove. It is easy to install and disassemble and has a wide range of applications;

[0044] (3) The inner thread sleeve provided in the inner leaf of the wall panel facilitates the connection between the wall panel and the wall structure;

[0045] (4) The embedded connection toughened sandwich insulation composite wall panel of the present invention adopts a flat mold manufacturing method, which is in line with industrial development, realizes industrial production, has a high degree of tooling, saves construction costs and labor costs, and has good economic efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 A perspective view of a toughened sandwich insulated composite wall panel with embedded connections for toughening high ductility concrete;

[0047] Figure 2 A top view of a toughened sandwich insulation composite wall panel with embedded connections toughened for high ductility concrete;

[0048] Figure 3 for Figure 2 Cross-sectional view along the AA axis;

[0049] Figure 4 for Figure 2 Cross-sectional view along the BB direction;

[0050] Figure 5 A cross-sectional view of a toughened sandwich insulation composite wall panel toughened with reinforced fine-stone concrete and embedded connections;

[0051] Figure 6 A cross-sectional view of a toughened sandwich thermal insulation composite wall panel toughened with embedded connections using carbon fiber cloth;

[0052] Figure 7 A top view of a toughened sandwich insulation composite wall panel toughened with embedded connections using carbon fiber cloth;

[0053] Figure 8 is a three-dimensional diagram of the connecting piece;

[0054] Figure 9 It is a front view of the connecting piece;

[0055] Figure 10 A three-dimensional diagram of a connector with a groove-tenon structure for the support arm;

[0056] Figure 11 is a three-dimensional diagram of a web provided with a first splicing hole;

[0057] Figure 12 A three-dimensional diagram of a support arm with a groove-tenon structure;

[0058] Figure 13 A three-dimensional diagram of a connector with a plug-in structure for the support arm;

[0059] Figure 14 is a three-dimensional view of a web provided with a second splicing hole;

[0060] Figure 15 is a perspective view of a support arm with a connecting pin and a connecting groove;

[0061] Figure 16 is a perspective view of another support arm with a connecting pin and a connecting groove;

[0062] Figure 17 A three-dimensional diagram of a web provided with double circular splicing holes;

[0063] Figure 18 is a perspective view of a support arm with a connecting post and a slot;

[0064] Figure 19 A three-dimensional diagram of the support arm in a state where the connecting column and the card slot are connected;

[0065] Figure 20 is a three-dimensional diagram of a connector with a snap-fit ​​connection for the support arm;

[0066] Figure 21 is a three-dimensional diagram of the support arm and the snap-fit ​​component;

[0067] Figure 22 is a perspective view of a connecting member in which a support arm is connected by bolts;

[0068] Figure 23 A perspective view of a support arm connected by bolts;

[0069] Figure 24 A perspective view of the support arm and the bolt and nut components;

[0070] Figure 25 It is a three-dimensional diagram of the inner thread sleeve;

[0071] Figure 26 It is a three-dimensional image of the blade inside the substrate;

[0072] Figure 27 A cross-sectional view of step S3 for preparing a toughened sandwich thermal insulation composite wall panel toughened with high ductility concrete and embedded connections;

[0073] Figure 28 A three-dimensional diagram showing an inner thread sleeve being placed in a sleeve placement opening in an inner blade of a substrate;

[0074] Figure 29 It is a three-dimensional diagram of the inner thread sleeve and the positioning block;

[0075] Figure 30 A cross-sectional view of step S4 for preparing a toughened sandwich thermal insulation composite wall panel toughened with high ductility concrete;

[0076] Figure 31 A cross-sectional view of step S5 for preparing a toughened sandwich thermal insulation composite wall panel toughened with high ductility concrete;

[0077] Figure 32 A partial top view of step S4 for preparing a toughened sandwich thermal insulation composite wall panel toughened with high ductility concrete;

[0078] Figure 33 A cross-sectional view of step S6 for preparing a toughened sandwich thermal insulation composite wall panel toughened with high ductility concrete;

[0079] Figure 34 A cross-sectional view of step S7 for preparing a toughened sandwich thermal insulation composite wall panel toughened with high ductility concrete;

[0080] Figure 35 A cross-sectional view of step S8 for preparing a toughened sandwich thermal insulation composite wall panel toughened with high ductility concrete and embedded connections.

[0081] Description of reference numerals:

[0082] 1. Toughening layer; 2. Insulation board; 3. High-strength grouting material; 4. Connector; 4a. Flange; 4b. Web; 4b'. Connector lifting hole; 4c. Support arm; 4d. Positioning boss; 4e. First splicing hole; 4f. Support arm groove; 4g. Support arm tenon; 4h. Connecting pin; 4i. Connecting groove; 4j. Second splicing hole; 4k. Double-circular splicing hole; 4m. Connecting column; 4n. Slot; 4p. Buckle; 4q. Round bolt; 4r. Round hole; 4s. Nut; 4t, bolt; 4u, threaded hole; 5, base material inner blade; 5a, base material outer blade; 6, positioning block; 6a, sleeve positioning groove; 7, plate groove; 8, bonding layer; 9, fireproof isolation block; 9a, block groove; 10, side mold; 11, limiter; 12, inner thread sleeve; 12a, anchor boss; 13, longitudinal steel bar; 14, transverse steel bar; 15, longitudinal carbon fiber cloth strip; 16, transverse carbon fiber cloth strip; 17, mold base; 18, sleeve placement port; 19, pouring port. DETAILED DESCRIPTION

[0083] In order to make the technical problems, technical solutions and advantages to be solved by the present invention clearer, a detailed description will be given below with reference to the accompanying drawings and specific embodiments.

[0084] A toughened sandwich thermal insulation composite wall panel with embedded connections includes a base material inner blade 5, an insulation board 2, and a base material outer blade 5a connected in sequence by a connector 4. The length of the base material inner blade 5 and the base material outer blade 5a is 3.0m to 4.2m, the width is 600mm to 3m, with 300mm as the dimensional modulus, and the thickness is not less than 70mm. Specifically, the base material inner blade 5 and the base material outer blade 5a are foamed ceramic boards or autoclaved aerated concrete boards, which have the advantages of environmental protection, energy saving, moisture resistance, and sound insulation. In order to ensure the service strength of the new toughened sandwich thermal insulation composite wall panel, the compressive strength of the foamed ceramic board is not less than 7MPa, and the compressive strength of the autoclaved aerated concrete board is not less than 2.5MPa.

[0085] A toughening layer 1 is provided on the outer surface of the inner blade 5 of the substrate and the outer blade 5a of the substrate, respectively. In order to strengthen the connection between the toughening layer and the inner blade 5 of the substrate and the outer blade 5a of the substrate, respectively, an adhesive can be added between the layers to ensure that the two materials form a reliable bond. Specifically, the toughening layer 1 is one of the materials of high ductility concrete, reinforced fine stone concrete, cement mortar steel mesh, and carbon fiber cloth. The fine stone concrete preferably uses C30 concrete, and the cement mortar preferably uses Class I or Class II polymer modified cement mortar. Preferably, when the material used for the toughening layer 1 is high ductility concrete or cement mortar steel mesh, the thickness is not less than 15 mm; when the material used for the toughening layer 1 is reinforced fine stone concrete, its thickness is not less than 50 mm; when the material used for the toughening layer 1 is carbon fiber cloth, the structural adhesive is epoxy resin, and the carbon fiber cloth includes longitudinal carbon fiber cloth strips 15 and transverse carbon fiber cloth strips 16. The thickness of the carbon fiber cloth is not less than 0.15 mm, and the mass per unit area is not less than 200 g / m 2 More specifically, the layout of the carbon fiber cloth is further described, such as Figure 9 As shown, the longitudinal carbon fiber cloth strips 15 and the transverse carbon fiber cloth strips 16 are arranged at equal intervals. The total width of the longitudinal carbon fiber cloth strips 15 is no less than 1 / 2 of the width of the substrate inner blade 5 and the substrate outer blade 5a, and the total width of the transverse carbon fiber cloth strips 16 is no less than 1 / 4 of the length of the substrate inner blade 5 and the substrate outer blade 5a. The toughening layer 1 improves the durability of the embedded toughened sandwich insulation composite wall panel and greatly reduces the water absorption rate of the embedded toughened sandwich insulation composite wall panel. During transportation and installation, it can effectively prevent damage to the wall surface from collisions, achieving the integrated effect of enclosure, insulation, and decoration. The embedded toughened sandwich insulation composite wall panel of the present invention has a long service life, reduces maintenance costs, and has good economic benefits. The requirements of energy conservation, heat preservation, strength and toughness are met, and the overall deformation performance is improved. The toughening layer of the present invention improves the tensile strength of the embedded toughened sandwich insulation composite wall panel. The present invention realizes the reliable connection of the toughening layer with the inner leaf plate and the outer leaf plate of the substrate respectively, and the overall anti-deformation performance is good, which greatly improves the bearing capacity and stiffness of the embedded toughened sandwich insulation composite wall panel.

[0086] The inner and outer blades 5a of the substrate are provided with a continuous groove 7 along their length. The groove 7 is filled with high-strength grouting material 3. The connector 4 comprises a web 4b and flanges 4a on either side of the web 4b. The ends of the web 4b and the flanges 4a are anchored in the high-strength grouting material 3. Specifically, the groove 7 is at least 40 mm wide and 40 mm deep, providing sufficient space for the ends of the web 4b and flanges 4a of the connector 4, ensuring the anchoring strength of the high-strength grouting material 3 to the connector 4. The groove 7 is located at a distance of more than 10 mm from the side edges of the inner and outer blades 5a.

[0087] Specifically, the structure of the connecting member 4 is as follows: support arms 4c perpendicular to the plane of the web 4b are arranged at intervals in the length direction of the two side surfaces of the web 4b, the support arms 4c are arranged in the direction close to the inner blade 5 of the substrate, the web 4b is fixedly or detachably connected to the support arms 4c, and the support arms 4c are used to support the connecting member 4 on the plate groove 7 of the inner blade 5 of the substrate; a positioning boss 4d is provided on the end of the support arm 4c for positioning the connection position of the connecting member 4 in the plate groove 7.

[0088] The connector 4 of the present invention achieves precise positioning, prevents grout leakage, and exhibits superior shear resistance. The flange 4a at the end of the web 4b of the connector 4 strengthens the tightness of the connection between the connector 4 and the high-strength grouting material 3, enhancing the integrity of the embedded, toughened, and thermally insulated sandwich composite wallboard. With the web 4b and support arm 4c detachably connected, the connector 4 can accommodate panel slots 7 of varying widths. Support arms 4c of varying sizes can be used depending on the size of the panel slot 7, making installation and disassembly easy and widely applicable.

[0089] As a preferred embodiment, the web 4b and support arm 4c are detachably connected by a connecting member, wherein one support arm 4c is fixedly connected to the web 4b via a connecting member. The connecting member may be a support arm tenon 4g, a connecting pin 4h, a connecting column 4m, a plain round peg 4q, or a bolt 4t.

[0090] Specifically, the embodiment of the present invention provides five solutions for detachably connecting the web 4b and the support arm 4c. Other detachable connection solutions are also within the protection scope of the present invention.

[0091] The first solution of the detachable connection between the web 4b and the support arm 4c is: Figures 10 to 12 As shown, one side end of one support arm 4c is provided with a support arm tenon 4g, and one side end of the other support arm 4c is provided with a support arm groove 4f corresponding to the support arm tenon 4g. A first splicing hole 4e is provided on the web 4b for passing the support arm 4c. After the support arm 4c with the support arm tenon 4g passes through the first splicing hole 4e, it is connected to the slot of the other support arm 4c with the support arm groove 4f.

[0092] The second solution of the detachable connection between the web 4b and the support arm 4c is as follows: Figures 13 to 15As shown, a connecting pin 4h is provided on the end face of one support arm 4c opposite to the positioning boss 4d, and a connecting groove 4i is provided on the end face of the other support arm 4c opposite to the positioning boss 4d. A second splicing hole 4j having the same cross-sectional dimensions as the connecting pin 4h is provided on the web 4b for passing through the connecting pin 4h. After the connecting pin 4h of one support arm 4c passes through the second splicing hole 4j, it is connected to the slot of the connecting groove 4i of the other support arm 4c. Alternatively, the connecting pin 4h and the connecting groove 4i can also be provided on the same end face of the positioning boss 4d, as shown in FIG. Figure 16 shown.

[0093] The third solution of the detachable connection between the web 4b and the support arm 4c is as follows: Figures 17 to 19 As shown, one side end of one support arm 4c is provided with two connecting columns 4m, and one side end of the other support arm 4c is provided with two card slots 4n corresponding to the connecting columns 4m, and two double-circle splicing holes 4k with the same cross-sectional size as the connecting columns 4m are provided on the web 4b for passing through the connecting columns 4m. After the connecting column 4m of one support arm 4c passes through the double-circle splicing hole 4k, it is connected to the slot of the card slot 4n of the other support arm 4c.

[0094] The fourth solution for the detachable connection between the web 4b and the support arm 4c is as follows: two double-circular splicing holes 4k are provided on the web 4b, and a connecting rib is provided at the end of the support arm 4c. The connecting rib has two circular holes 4r of the same size as the double-circular splicing holes 4k. After the light cylindrical nail 4q passes through the circular hole 4r of the connecting rib on one of the support arms, the double-circular splicing hole 4k and the circular hole 4r of the connecting rib on the other support arm in sequence, the light cylindrical nail 4q is fixed with the buckle 4p to realize the buckle connection between the web 4b and the support arm 4c. Figure 20 and Figure 21 shown.

[0095] A fifth solution for the detachable connection between the web 4b and the support arm 4c is as follows: two double-circular splicing holes 4k are provided on the web 4b, and a connecting rib is provided at the end of the support arm 4c. The connecting rib has two threaded holes 4u of the same size as the double-circular splicing holes 4k. After the bolt 4t passes through the threaded hole 4u of the connecting rib on one of the support arms 4c, the double-circular splicing hole 4k, and the threaded hole 4u of the connecting rib on the other support arm 4c in sequence, the bolt 4t is fixed with a nut 4s to realize the bolt connection between the web 4b and the support arm 4c. Figures 22 to 24 shown.

[0096] As a preferred embodiment, a connecting piece hoisting hole 4b' is provided on one end of the web 4b for hoisting the toughened sandwich insulation composite wall panel with embedded connection. Before hoisting, the insulation board 2 is hollowed out to expose the connecting piece hoisting hole 4b'. After hoisting, the gap of the insulation board 2 can be backfilled.

[0097] Furthermore, sleeve placement openings 18 are provided at both ends of the inner blade 5 of the substrate. Figure 26 As shown, it is used to install the inner thread sleeve 12. One end of the sleeve placement port 18 passes through the plate groove 7, and the inner thread sleeve 12 is provided in the sleeve placement port 18. The inner thread sleeve 12 is a cylinder with a closed bottom end and an open top end, as shown in FIG. Figure 25 As shown, the open top of the inner thread sleeve 12 faces the surface of the toughening layer 1.

[0098] As a preferred embodiment, an anchoring boss 12a is provided on the outer side of the inner thread sleeve 12. The inner thread sleeve 12 is placed in the sleeve placement opening 18, and a toughening layer slurry or a high-strength grouting material is added to form an anchor connection of the inner thread sleeve 12. When the toughening layer is one of high-ductility concrete, reinforced fine stone concrete, and cement mortar steel mesh, the inner thread sleeve 12 is surrounded by the same slurry as the toughening layer 1 to achieve the fixation of the inner thread sleeve 12; when the toughening layer 1 is carbon fiber cloth, the inner thread sleeve 12 is surrounded by a high-strength grouting material.

[0099] Insulation board 2 is made of one of polystyrene, extruded board, graphite polystyrene, or perlite-coated vacuum insulation board. Specifically, to meet the 83% energy efficiency standard, the thickness of insulation board 2 is further limited: when polystyrene is used, its thickness must be no less than 90 mm; when extruded board is used, its thickness must be no less than 80 mm; when graphite polystyrene is used, its thickness must be no less than 75 mm; and when perlite-coated vacuum insulation board is used, its thickness must be no less than 6 mm.

[0100] As a preferred solution, fireproof insulation blocks 9 are installed on both sides of the insulation board 2 to enhance the fire resistance of the new toughened sandwich insulation composite wallboard. Fireproof insulation blocks 9 are made of Class A fireproof material, such as silicone plastic board. Block grooves 9a are provided on the outer sides of the fireproof insulation blocks 9, enhancing fire resistance and achieving excellent energy conservation and environmental protection. Furthermore, the block grooves 9a increase the flow path length of water seepage through the joints between the panels, providing effective anti-seepage performance.

[0101] After testing, the cracking load of the untoughened sandwich insulation composite wall panel (2400mm long, 600mm wide, 80mm thick inner and outer blades, made of foam ceramic board, 50mm sandwich insulation layer) is 6.815kN, and the ultimate load is 42.639kN; the sandwich insulation composite wall panel toughened with single-sided carbon fiber cloth (total carbon fiber width 300mm, length 2400mm, and end transverse carbon fiber cloth toughening is provided according to the specification) has a cracking load of 7.712kN and an ultimate load of 47.504kN. For the sandwich insulation composite wall panel toughened with double-sided carbon fiber cloth, the cracking load of the carbon fiber toughened sandwich insulation composite wall panel is 7.927kN and the ultimate load is 50.757kN.

[0102] The embedded, toughened sandwich insulated composite wall panels of this invention overcome the shortcomings of the original base material, such as poor tensile strength and brittle failure. They combine lightweight, high-strength, thermal insulation, waterproofing, high-temperature resistance, sound insulation, and moisture resistance. The insulation panels have the same lifespan as the wall, ensuring energy conservation and environmental protection. Compared to existing wall panels, while meeting the same 83 energy-saving standards, the wall panels of this invention are thinner and meet strength requirements.

[0103] The embodiment of the present invention also provides a method for preparing the aforementioned embedded connection toughened sandwich insulation composite wall panel, comprising the following steps:

[0104] S1. Prefabricate the inner blade plate 5 and the outer blade plate 5a of the substrate in the factory, accurately cut and position the inner blade plate 5 and the outer blade plate 5a of the substrate according to the design requirements, open the plate groove 7 on the inner blade plate 5 and the outer blade plate 5a of the substrate, and reserve the sleeve placement opening 18 at the end of the plate groove 7 of the inner blade plate 5 of the substrate. Figure 26 shown.

[0105] S2. Place the inner blade plate 5 of the substrate on the mold platform 17, with the plate groove of the inner blade plate 5 facing the mold platform 17, place the positioning block 6 in the plate groove 7, the end face of the inner blade plate 5 of the substrate is flush with the outer end face of the positioning block 6, the center line of the sleeve positioning groove 6a corresponds to the center line of the sleeve placement port 18, and use the limiter 11 to fix the side mold 10.

[0106] Specifically, the positioning block 6 is in the shape of a rectangular parallelepiped, and the width of the positioning block matches the plate slot 7. A sleeve positioning slot 6a is provided in the width centerline direction of the positioning block 6, as shown in FIG. Figure 29 As shown, when in use, the outer end surface of the positioning block is flush with the end surface of the inner blade of the substrate, and the center line of the sleeve positioning groove 6 a corresponds to the center line of the sleeve placement opening 18 .

[0107] S3. Place the inner thread sleeve 12 through the sleeve placement opening 18 and on the positioning block 6. Place the closed end of the inner thread sleeve 12 in the sleeve positioning groove 6a. Install the connecting bolt on the inner thread sleeve 12.

[0108] S4, after applying the interface adhesive on the outer surface of the inner blade 5 of the substrate, add the toughening layer 1, align the surface of the toughening layer 1 with the opening of the inner wire sleeve 12, and perform maintenance, such as Figure 30 As shown, after the curing is completed, the positioning block 6 is removed; at the same time, in another mold platform 17 and the side mold 10, a toughening layer 1 is added to the outer surface of the outer blade 5a of the base material for curing.

[0109] Furthermore, a toughening layer 1 is formed on the outer surface of the inner blade 5 of the substrate and the outer blade 5a of the substrate, specifically: when the toughening layer 1 is high-ductility concrete, high-ductility concrete is pressed on the surface of the inner blade 5 of the substrate and the outer blade 5a of the substrate as the toughening layer 1; when the toughening layer 1 is reinforced fine stone concrete, the longitudinal steel bars 13 and the transverse steel bars 14 are first tied and fixed to the outer surface of the inner blade 5 of the substrate and the outer blade 5a of the substrate, and then the fine stone concrete is poured; when the toughening layer 1 is cement mortar wire mesh, the wire mesh is first fixed to the outer surface of the inner blade 5 of the substrate and the outer blade 5a of the substrate, and then cement mortar is poured; when the toughening layer 1 is carbon fiber cloth, high-strength grouting material 3 is poured on the sleeve installation port 18 of the inner blade 5 of the substrate, phenolic resin is applied on the surface of the inner blade 5 of the substrate and the outer blade 5a of the substrate, longitudinal carbon fiber cloth strips 15 and transverse carbon fiber cloth strips 16 are pasted according to the design specifications, and phenolic resin is applied to the surface again.

[0110] S5, turn the inner blade 5 of the substrate after surface toughening treatment upside down and place it on the mold platform 17, and insert the positioning boss 4d of the connecting piece 4 into the plate groove 7, as shown in FIG. Figure 31 shown.

[0111] S6, inject high-strength grouting material 3 into the plate groove 7 through the pouring port 19 formed between the adjacent support arms 4c of the connecting member 4 and the inner blade 5 of the base material. The position of the pouring port is as follows: Figure 32 As shown, after adding high-strength grouting material 3, Figure 33 As shown, the high-strength grouting material 3 realizes the anchor connection and fixation of the connecting piece 4.

[0112] S7. Apply phenolic resin on the outer surface of the inner blade plate 5 of the base material to form a bonding layer 8, install the insulation board 2 on the inner blade plate 5 of the base material, and maintain it until the high-strength grouting material 3 is cured.

[0113] Furthermore, in step S7, it further includes: applying phenolic resin on both sides of the insulation board 2 to form a bonding layer 8, and placing a fireproof isolation block 9 outside the bonding layer 8, such as Figure 34 shown.

[0114] S8, place the cured outer blade 5a of the substrate in the mold platform 17, with the plate groove 7 of the outer blade 5a facing upward, inject high-strength grouting material 3 into the plate groove 7 of the outer blade 5a of the substrate, and use a turning machine to turn over the solidified inner blade 5 of the substrate, the insulation board 2 and the connecting piece 4 as a whole. Figure 35 As shown, the connecting piece 4 is placed upside down in the high-strength grouting material 3 of the outer blade 5a of the base material.

[0115] S9. After curing and solidification, an embedded-connected toughened sandwich thermal insulation composite wall panel is formed.

[0116] The embedded connection toughened sandwich insulation composite wall panel of the present invention adopts a flat mold production method, which is in line with industrial development, realizes industrial production, and has a high degree of tooling. The inner thread sleeve arranged in the inner leaf plate of the wall panel facilitates the connection between the wall panel and the overall structure, saves construction costs and labor costs, and has good economy.

[0117] The above is a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications should also be regarded as within the scope of protection of the present invention.

Claims

1. An embedded and connected toughened sandwich thermal insulation composite wall panel, comprising a base material inner blade (5), an insulation board (2) and a base material outer blade (5a) connected in sequence by a connector (4), characterized in that: A toughening layer (1) is provided on the outer surface of the base material inner blade (5) and the base material outer blade (5a); The inner sides of the base material inner blade plate (5) and the base material outer blade plate (5a) are provided with a continuous plate groove (7) along the plate length direction, and the plate groove (7) is filled with high-strength grouting material (3); The connecting member (4) comprises a web (4b) and flanges (4a) located on both sides of the web (4b), and the ends of the web (4b) and the flanges (4a) are anchored in the high-strength grouting material (3); Support arms (4c) perpendicular to the plane of the web (4b) are arranged at intervals on both sides of the web (4b) in the longitudinal direction. The support arms (4c) are arranged in a direction close to the inner blade (5) of the base material. The web (4b) and the support arms (4c) are fixedly or detachably connected. The support arms (4c) are used to support the connecting member (4) on the plate groove (7) of the inner blade (5) of the base material. A positioning boss (4d) is provided on the end of the support arm (4c) for positioning the connection position of the connecting member (4) in the plate groove (7).

2. The embedded connection toughened sandwich thermal insulation composite wall panel according to claim 1, characterized in that: The web (4b) and the support arm (4c) are detachably connected in the following manner: one support arm (4c) and the other support arm (4c) are fixedly connected to the web (4b) via a connecting component.

3. The embedded connection toughened sandwich thermal insulation composite wall panel according to claim 2, characterized in that: The connecting component is a supporting arm tenon (4g) or a connecting column (4m) or a smooth round peg (4q) or a bolt (4t).

4. The embedded connection toughened sandwich thermal insulation composite wall panel according to claim 1, characterized in that: A connecting piece hoisting hole (4b') is provided on one end of the web (4b).

5. The embedded connection toughened sandwich thermal insulation composite wall panel according to claim 1, characterized in that: Sleeve placement openings (18) are provided at both ends of the inner blade plate (5) of the base material. One end of the sleeve placement opening (18) passes through the plate groove (7). An inner thread sleeve (12) is provided in the sleeve placement opening (18). The inner thread sleeve (12) is a cylindrical body with a closed bottom end and an open top end. The open top end of the inner thread sleeve (12) faces the surface of the toughening layer (1).

6. The embedded connection toughened sandwich thermal insulation composite wall panel according to claim 5, characterized in that: An anchoring boss (12a) is provided on the outer side of the inner thread sleeve (12).

7. The embedded connection toughened sandwich thermal insulation composite wall panel according to claim 1, characterized in that: The length of the base material inner blade (5) and the base material outer blade (5a) is 3.0m to 4.2m, the width is 600mm to 3m, with 300mm as the size module, and the thickness is not less than 70mm.

8. The embedded connection toughened sandwich thermal insulation composite wall panel according to claim 1, characterized in that: The base material inner blade plate (5) and the base material outer blade plate (5a) are foamed ceramic plates or autoclaved aerated concrete plates; The compressive strength of foamed ceramic panels shall not be less than 7MPa, and the compressive strength of autoclaved aerated concrete panels shall not be less than 2.5MPa.

9. The embedded connection toughened sandwich thermal insulation composite wall panel according to claim 1, characterized in that: The toughening layer (1) is made of one of the following materials: high-ductility concrete, reinforced fine stone concrete, cement mortar steel wire mesh, and carbon fiber cloth.

10. The embedded connection toughened sandwich thermal insulation composite wall panel according to claim 9, characterized in that: When the material used for the toughening layer (1) is high ductility concrete or cement mortar steel mesh, the thickness shall not be less than 15 mm; When the material used for the toughening layer (1) is reinforced fine stone concrete, its thickness shall not be less than 50 mm; When the material used for the toughening layer (1) is carbon fiber cloth, the structural adhesive is epoxy resin, the carbon fiber cloth includes longitudinal carbon fiber cloth strips (15) and transverse carbon fiber cloth strips (16), the thickness of the carbon fiber cloth is not less than 0.15mm, and the unit area mass is not less than 200g / m 2 .

11. The embedded connection toughened sandwich thermal insulation composite wall panel according to claim 1, characterized in that: The width of the plate groove (7) is not less than 40 mm, and the depth is not less than 40 mm. The distance between the plate groove (7) and the side edges of the substrate inner blade (5) and the substrate outer blade (5a) is greater than 10 mm.

12. The embedded connection toughened thermal insulation composite wallboard according to claim 1, characterized in that: The insulation board (2) is a polystyrene board; or the insulation board (2) is an extruded board; or the insulation board (2) is graphite polystyrene; or the insulation board (2) is a vacuum insulation board wrapped with perlite.

13. The embedded connection toughened sandwich thermal insulation composite wall panel according to claim 12, characterized in that: When the insulation board (2) is a polystyrene board, its thickness is not less than 90 mm; When the insulation board (2) is an extruded board, its thickness is not less than 80 mm; When the insulation board (2) is graphite polystyrene, its thickness is not less than 75 mm; When the insulation board (2) is a perlite-wrapped vacuum insulation board, its thickness should be no less than 6 mm.

14. The embedded connection toughened sandwich thermal insulation composite wall panel according to claim 1, characterized in that: Fireproof isolation blocks (9) are provided on both sides of the thermal insulation board (2).

15. The embedded connection toughened thermal insulation composite wall panel according to claim 14, characterized in that: The outer side surface of the fireproof isolation block (9) is provided with a block groove (9a).

16. A method for preparing the embedded-connected toughened sandwich thermal insulation composite wallboard according to any one of claims 1 to 15, characterized in that: The following steps are involved: S1. Prefabricate the base material inner blade plate (5) and the base material outer blade plate (5a) in a factory, perform precise cutting and positioning processing on the base material inner blade plate (5) and the base material outer blade plate (5a) according to design requirements, open plate grooves (7) on the base material inner blade plate (5) and the base material outer blade plate (5a), and reserve sleeve placement openings (18) at the ends of the plate grooves (7) of the base material inner blade plate (5); S2. Place the inner blade plate (5) of the substrate on the die table (17), with the plate groove of the inner blade plate (5) facing the die table (17), place the positioning block (6) in the plate groove (7), the end face of the inner blade plate (5) of the substrate is flush with the outer end face of the positioning block (6), the center line of the sleeve positioning groove (6a) corresponds to the center line of the sleeve placement opening (18), and use the limiter (11) to fix the side mold (10); S3, placing the inner thread sleeve (12) through the sleeve placement opening (18) on the positioning block (6), placing the closed end of the inner thread sleeve (12) in the sleeve positioning groove (6a), and installing the connecting bolt on the inner thread sleeve (12); S4, applying an interface adhesive to the outer surface of the inner blade (5) of the substrate, and then adding a toughening layer (1), aligning the surface of the toughening layer (1) with the opening of the inner thread sleeve (12) flatly, and performing curing. After the curing is completed, the positioning block (6) is removed; At the same time, in another mold platform (17) and a side mold (10), a toughening layer (1) is added to the outer surface of the outer blade (5a) of the base material and cured; S5, turning the inner blade (5) of the substrate that has undergone surface toughening treatment upside down and placing it on the mold platform (17), and inserting the positioning boss (4d) of the connecting member (4) into the plate groove (7); S6, injecting high-strength grouting material (3) into the plate groove (7) through the pouring port (19) formed between the adjacent support arms (4c) of the connecting member (4) and the inner blade (5) of the base material; S7, applying phenolic resin on the outer surface of the inner blade plate (5) of the base material to form a bonding layer (8), installing the insulation board (2) on the inner blade plate (5) of the base material, and curing until the high-strength grouting material (3) is solidified; S8, placing the cured substrate outer blade (5a) in the mold platform (17), with the plate groove (7) of the substrate outer blade (5a) facing upward, injecting high-strength grouting material (3) into the plate groove (7) of the substrate outer blade (5a), using a turning machine to reverse the solidified substrate inner blade (5), the insulation board (2) and the connecting piece (4) as a whole, and placing the connecting piece (4) upside down in the high-strength grouting material (3) of the substrate outer blade (5a); S9. After curing and solidification, an embedded-connected toughened sandwich thermal insulation composite wall panel is formed.

17. The method for preparing the embedded connection toughened sandwich thermal insulation composite wallboard according to claim 16, characterized in that: In step S4, a toughening layer (1) is formed on the outer surface of the substrate inner blade (5) and the substrate outer blade (5a), specifically: When the toughening layer (1) is high-ductility concrete, the high-ductility concrete is pressed onto the surface of the inner blade (5) and the outer blade (5a) of the substrate as the toughening layer (1); When the toughening layer (1) is reinforced fine stone concrete, firstly, the longitudinal steel bars (13) and the transverse steel bars (14) are tied and fixed to the outer surfaces of the base material inner blade (5) and the base material outer blade (5a), and then the fine stone concrete is poured; When the toughening layer (1) is a cement mortar steel mesh, the steel mesh is first fixed to the outer surface of the base material inner blade (5) and the base material outer blade (5a), and then the cement mortar is poured; When the toughening layer (1) is made of carbon fiber cloth, a high-strength grouting material (3) is poured on the sleeve placement opening (18) of the inner blade (5) of the base material, phenolic resin is applied to the surface of the inner blade (5) and the outer blade (5a) of the base material, longitudinal carbon fiber cloth strips (15) and transverse carbon fiber cloth strips (16) are attached according to design specifications, and phenolic resin is applied to the surface again.

18. The method for preparing the embedded connection toughened sandwich thermal insulation composite wallboard according to claim 16, characterized in that: In step S7, the method further includes: applying phenolic resin on both sides of the insulation board (2) to form an adhesive layer (8), and placing a fireproof isolation block (9) outside the adhesive layer (8).

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