A toughened sandwich thermal insulation composite wallboard and a preparation method thereof

Abstract

The application discloses a kind of toughened sandwich thermal insulation composite wallboard and preparation method thereof, belong to prefabricated house construction engineering technical field.Toughened sandwich thermal insulation composite wallboard includes a substrate inner leaf plate and substrate outer leaf plate corresponding with substrate inner leaf plate, substrate inner leaf plate and substrate outer leaf plate are between thermal insulation board, and the both ends of thermal insulation board are provided with connecting piece;Toughened layer is provided on the outer surface of substrate inner leaf plate and substrate outer leaf plate;Thermal insulation board transverse both ends are provided with protective layer respectively.The application has the following effects: realize the reliable connection of toughened layer with substrate inner leaf plate and substrate outer leaf plate respectively, and the overall deformation resistance is good;The setting of connecting piece enhances the integrity of wallboard;It is made in the mode of flat die, and it meets the industrial development.

Description

Technical Field

[0001] This invention relates to the field of prefabricated housing construction technology, and in particular to a toughened sandwich insulation composite wall panel and its preparation method. Background Technology

[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. Meanwhile, with the continuous development of living standards, building construction, due to its functional requirements, demands that its materials, in addition to traditional requirements such as safety, applicability, and durability, also possess properties such as thermal insulation, fire resistance, and sound insulation.

[0003] To address these issues, some prefabricated wall panels have emerged in China in recent years. However, their manufacturing process is quite complex, especially since they require custom production based on specific project dimensions, preventing pre-production and hindering true industrialization and commercialization of building products. Furthermore, these wall panels are prone to cracking during use and have poor thermal insulation, sound absorption, and soundproofing effects.

[0004] Patent No. 202222008565.7 discloses a sandwich wall panel, which includes an insulation board and two concrete slabs on both sides. Each concrete slab has a metal mesh inside, and the insulation board has a first through-hole through which connectors abut against the metal mesh at both ends. The connectors can precisely control the distance between the outer wire mesh and the insulation board, and the support blocks can omnidirectionally limit and fix the metal mesh. However, the sandwich wall panel is made of concrete, resulting in a large overall weight and increasing the difficulty of handling and construction. This wall panel has multiple connectors and positioning components, making the manufacturing process complex and maintenance difficult.

[0005] Patent No. 201720797272.8 discloses a precast prestressed thermal insulation exterior wall panel. This panel includes an insulation core board, a steel mesh on both sides of the core board, and a concrete layer poured over the mesh. The core board has multiple continuous insulation core board ribs, and the concrete layer has multiple concrete ribs. Shear connectors connected to the steel mesh are inserted between adjacent ribs. Prestressing tendons are placed in grooves formed between adjacent ribs or between adjacent concrete ribs. This wall panel uses insulation core board ribs to reduce concrete usage, lower the panel's weight, and improve insulation performance. However, the use of concrete for the outer layer requires the fabrication of steel mesh and prestressing tendons, resulting in a relatively large overall weight. The insulation board structure is complex, difficult to process, and increases labor costs. Although the insulation effect is improved, the energy-saving efficiency is low. Setting prestressing tendons requires tensioning equipment, which places high demands on production conditions, involves complex manufacturing processes, and poses safety hazards during on-site construction.

[0006] Patent No. 201710536108.6 discloses a lightweight composite thermal insulation exterior wall panel. This panel includes an insulation core board, FRP shear connectors, steel mesh on both sides of the insulation core board, and a concrete layer poured over the steel mesh. The insulation core board has continuous insulation core board ribs, and the concrete layer has multiple intersecting and cooperating concrete ribs. This invention uses concrete for the outer layer, requiring the fabrication of steel mesh and prestressed tendons. The overall weight is relatively large, and the sound insulation performance is not outstanding. The complex structure makes it difficult to process, increasing processing and transportation costs.

[0007] Patent No. 202210273901.2 discloses a reinforced aluminum alloy panel ceramic composite wall panel with a reinforced surface layer. This composite wall panel comprises a decorative aluminum alloy panel, a foamed ceramic panel, a fiber cement mortar surface layer, a steel mesh, a light steel keel frame, a steel truss, a base concrete layer, and a calcium silicate board. This invention has a multi-layered structure and multiple components, resulting in complex manufacturing processes, low production efficiency, and high labor costs. The invention uses a keel structure and requires openings to pour foamed concrete into the formwork, leading to extensive on-site wet work and high requirements for base material equipment. Although foamed ceramic panels, a light keel, and foamed concrete are used, the addition of the steel truss and other components increases the overall weight, increasing the structural load and seismic forces.

[0008] Patent No. 202120756780.8 discloses an ALC composite wall panel structure, which is composed of an ALC protective layer, an insulation layer, a steel mesh, a finishing layer, and C-shaped slots. It has advantages such as high structural strength, good thermal insulation performance, convenient manufacturing and splicing, and good shrinkage resistance and waterproofing. However, the connections between the various layers of this wall panel are not tight, and the layers are prone to peeling and detachment under large loads, resulting in poor overall performance.

[0009] Patent No. 202221567913.8 discloses a combined multi-layer composite thermal insulation exterior wall panel, which includes two layers of autoclaved aerated concrete (AAC) panels, an insulation layer, vertical connecting rods, and a fixing plate. The connecting rods are placed inside the AAC panels, and the bolts on the connecting rods pass through the fixing plate and are tightened into nuts. This invention uses an AAC panel and insulation board composite structure with good thermal insulation performance; however, the bolts and metal connectors may form thermal bridges, affecting the wall panel's insulation performance. The fixing plate ensures the durability and deformation resistance of the exterior wall panel, but the fixing plate does not adhere tightly to the wall panel surface, resulting in poor sealing and allowing moisture and air to easily enter the wall panel, thus affecting its performance. Although the vertical connecting rods provide vertical stability, the strength is insufficient when the connection between the two AAC panels is weak, such as under strong winds. The use of a fixing plate and bolt configuration can cause stress concentration at the joints, leading to structural weakening over long-term use.

[0010] Patent No. 201611103471.0 discloses a prefabricated staggered-peak sound-insulating ALC panel composite wall. This prefabricated staggered-peak sound-insulating ALC panel composite wall consists of ALC panels with different thicknesses on both sides as the main wall, connecting keel, and internal filling with sound-insulating and fire-resistant cotton. A fiber mesh and gypsum board can be installed on the outer layer to protect the main wall surface. The wall panel structure is rationally arranged, possessing good overall sound insulation performance, certain thermal insulation performance, and excellent fire resistance. However, the design of this wall panel does not consider the splicing structure between the wall panels; the internal keel types are different, making positioning and assembly time-consuming and labor-intensive; and the connection between the filling layer and one of the ALC panels is not tight, making interlayer delamination prone to occur. Summary of the Invention

[0011] To address the shortcomings of existing technologies, this invention provides a toughened sandwich insulated composite wall panel and its preparation method. The wall panel has excellent thermal insulation effect, lightweight wall body, excellent crack resistance, and good overall integrity of the insulated composite wall.

[0012] To achieve the above objectives, the present invention provides a toughened sandwich insulation composite wall panel, the specific technical solution of which is as follows:

[0013] A toughened sandwich insulated composite wall panel includes an inner leaf plate of the substrate and an outer leaf plate of the substrate corresponding to the inner leaf plate. An insulation board is located between the inner leaf plate and the outer leaf plate of the substrate, and connectors are provided at both ends of the insulation board. A toughening layer is provided on the outer surface of the inner leaf plate and the outer leaf plate of the substrate. A protective layer is provided at both ends of the insulation board in the transverse direction. The connector is provided with a web and flanges located on both sides of the web. Support arms perpendicular to the web plane are provided at intervals on the inner side of the web. Positioning bosses are provided at the ends of the support arms. Mold support arms perpendicular to the web plane are provided at intervals on the outer side of the web.

[0014] Furthermore, a connecting lifting hole is provided at one end of the web plate.

[0015] Furthermore, it also includes an internal threaded sleeve, which is disposed near the flange side of the inner blade of the substrate.

[0016] Preferably, the outer side of the inner threaded sleeve is provided with an anchoring boss.

[0017] Preferably, the inner threaded sleeve is disposed on one side of the flange, and a sleeve mounting opening is provided at the end of the inner blade of the substrate.

[0018] Alternatively, the inner threaded sleeve is positioned in the space at the tip of the flange.

[0019] Furthermore, the inner blade and outer blade of the substrate are 3.0m to 4.2m in length, 600mm to 3m in width, with 300mm as the dimensional module, and the thickness is not less than 70mm.

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

[0021] Furthermore, the toughening layer is one of the following materials: high ductility concrete, reinforced fine aggregate concrete, cement mortar wire mesh, or carbon fiber cloth.

[0022] Preferably, when the toughening layer is made of high-ductility concrete or cement mortar wire mesh, its thickness is not less than 15 mm; when the toughening layer is made of reinforced fine aggregate concrete, its thickness is not less than 50 mm; when the toughening layer is made of carbon fiber cloth, the structural adhesive is epoxy resin or phenolic resin, the carbon fiber cloth includes longitudinal carbon fiber cloth strips and transverse carbon fiber cloth strips, the thickness of the carbon fiber cloth is not less than 0.15 mm, and the unit area mass is not less than 200 g / m². 2 .

[0023] Furthermore, the insulation board is a vacuum insulation board wrapped with polystyrene board, extruded polystyrene board, graphite polystyrene board, or perlite.

[0024] Preferably, when the insulation board is a polystyrene board, its thickness is not less than 90mm; when the insulation board is an extruded polystyrene board, its thickness is not less than 80mm; when the insulation board is a graphite polystyrene board, its thickness is not less than 75mm; and when the insulation board is a perlite-wrapped vacuum insulation board, its thickness should be not less than 6mm.

[0025] Furthermore, fireproof isolation blocks are installed on both sides of the insulation board.

[0026] Preferably, the outer side of the fireproof isolation block is provided with a groove.

[0027] A method for preparing the aforementioned toughened sandwich insulation composite wall panel includes the following steps:

[0028] S1. Prefabricate the inner and outer blades of the substrate in the factory and precisely cut them according to the design requirements.

[0029] S2. Based on the dimensions of the inner leaf plate and the outer leaf plate of the substrate, place the side mold on the mold table to form a mold cavity. Use mold connectors to connect the edge of the side mold. Use limiters to fix the bottom of the side mold. Place pads at specific positions in the mold cavity.

[0030] S3. Add a toughening layer to the same height as the pad block;

[0031] S4. Place the outer leaf plate of the substrate on the toughened layer that has been formed in the mold cavity, and form a gap between the outer leaf plate of the substrate and the side mold.

[0032] S5. Place the connector in the gap between the outer leaf plate of the substrate and the side mold. The support arm supports the web in the gap. The mold support arm contacts the side mold to support the connector. The gap between the outer leaf plate of the substrate and the side mold and the web form a pouring port for the slurry.

[0033] S6. Inject slurry into the gap between the outer leaf plate of the substrate and the side mold through the pouring port to form a protective layer;

[0034] S7. Place an insulation board on the inner surface of the outer leaf plate of the substrate and cure the toughening layer and protective layer.

[0035] S8. Place the inner leaf plate of the substrate on the insulation board;

[0036] S9. Place an internal threaded sleeve on the flange near the inner blade side of the substrate. The internal threaded sleeve is bonded to the top of the flange or to the side of the flange.

[0037] S10. A protective layer is formed by pouring grout onto the side of the inner blade of the substrate.

[0038] S11. A toughening layer is added above the inner leaf plate of the substrate. After curing, a toughened sandwich insulation composite wall panel is formed.

[0039] Furthermore, in step S3: when the toughening layer is high-ductility concrete, pour high-ductility concrete to the same height as the spacer block; when the toughening layer is reinforced fine aggregate concrete, first tie and fix the longitudinal and transverse reinforcing bars in the mold cavity of the formwork, then pour fine aggregate concrete to the same height as the spacer block; when the toughening layer is cement mortar wire mesh, first tie and fix the wire mesh in the mold cavity of the formwork, then pour cement mortar to the same height as the spacer block; when the toughening layer is carbon fiber cloth, apply epoxy resin or phenolic resin, and attach longitudinal and transverse carbon fiber cloth strips to the mold cavity of the formwork according to the design specifications, then apply epoxy resin or phenolic resin again to the surface, with the thickness of the carbon fiber cloth being consistent with the thickness of the spacer block.

[0040] Furthermore, in step S11: when the toughening layer is high-ductility concrete, high-ductility concrete is pressed or poured onto the upper surface of the inner blade plate of the substrate to a specific thickness; when the toughening layer is reinforced fine aggregate concrete, the longitudinal and transverse reinforcing bars are first tied and fixed to the upper surface of the inner blade plate of the substrate, and fine aggregate concrete is poured to a specific thickness; when the toughening layer is cement mortar wire mesh, the wire mesh is first tied and fixed to the upper surface of the inner blade plate of the substrate, and cement mortar is poured to a specific thickness; when the toughening layer is carbon fiber cloth, epoxy resin or phenolic resin is applied, and longitudinal and transverse carbon fiber cloth strips are attached to the upper surface of the inner blade plate of the substrate according to the design specifications, and epoxy resin or phenolic resin is applied to the surface again.

[0041] Furthermore, step S7 also includes: applying phenolic resin to both sides of the insulation board to form an adhesive layer, and placing a fireproof isolation block on the outside of the adhesive layer.

[0042] Furthermore, in step S9, when the inner threaded sleeve is bonded to the side of the flange, a sleeve mounting opening is reserved at the end of the inner blade of the substrate.

[0043] The present invention has the following beneficial effects:

[0044] (1) The present invention achieves a reliable connection between the toughening layer and the inner leaf plate and the outer leaf plate of the substrate, respectively, resulting in good overall deformation resistance and greatly improving the load-bearing capacity and stiffness of the composite wall panel;

[0045] (2) The connectors have excellent shear resistance and enhance the integrity of the wall panel;

[0046] (3) The connecting sleeves set in the inner leaf plate of the substrate facilitate the connection between the toughened sandwich insulation composite wall panel and the wall structure;

[0047] (4) The toughened sandwich insulation composite wall panel adopts the flat mold manufacturing method, which is in line with industrial development, realizes industrialized production, has a high degree of tooling, saves construction costs and labor costs, and has good economic benefits. Attached Figure Description

[0048] Figure 1 A three-dimensional view of a toughened sandwich insulation composite wall panel made of high-ductility concrete.

[0049] Figure 2 Top view of a toughened sandwich insulated composite wall panel made of high-ductility concrete;

[0050] Figure 3 for Figure 2 A cross-sectional view of a toughened sandwich insulation composite wall panel with an internal threaded sleeve in the AA direction on the flange side of the connector;

[0051] Figure 4 A perspective view of the inner blade plate of the substrate with a sleeve mounting opening;

[0052] Figure 5 A cross-sectional view of a toughened sandwich insulation composite wall panel with an internal threaded sleeve at the top of the flange of the connector;

[0053] Figure 6 for Figure 2 Sectional view along the BB direction;

[0054] Figure 7 A cross-sectional view of a toughened sandwich insulated composite wall panel made of reinforced fine aggregate concrete.

[0055] Figure 8Cross-sectional view of a toughened sandwich insulation composite wall panel reinforced with carbon fiber cloth.

[0056] Figure 9 Top view of a toughened sandwich insulation composite wall panel reinforced with carbon fiber cloth;

[0057] Figure 10 A three-dimensional view of the connector;

[0058] Figure 11 This is a front view of the connector;

[0059] Figure 12 A perspective view of an internal threaded sleeve with an anchoring boss;

[0060] Figure 13 This is a three-dimensional view of the combined state of the mold platform and the side mold in step S2;

[0061] Figure 14 This is a perspective view of the side mold and mold connector assembly in step S2.

[0062] Figure 15 A cross-sectional view of the toughening layer added to the mold in step S3;

[0063] Figure 16 A cross-sectional view of step S5 for preparing toughened sandwich thermal insulation composite wall panels;

[0064] Figure 17 A top view of step S5 for preparing toughened sandwich insulation composite wall panels;

[0065] Figure 18 A cross-sectional view of step S6 in the preparation of toughened sandwich thermal insulation composite wall panels;

[0066] Figure 19 A cross-sectional view of step S7 in the preparation of toughened sandwich insulation composite wall panels;

[0067] Figure 20 A cross-sectional view of step S8 in the preparation of the toughened sandwich thermal insulation composite wall panel;

[0068] Figure 21 This is a cross-sectional view of the inner threaded sleeve connected to the flange side of the connector in step S9.

[0069] Figure 22 This is a perspective view of the internal threaded sleeve on the side of the flange of the connector;

[0070] Figure 23 This is a cross-sectional view of the inner threaded sleeve being connected to the top edge of the flange of the connector in step S9.

[0071] Figure 24 This is a perspective view of the internal threaded sleeve at the top of the flange of the connector;

[0072] Figure 25 A cross-sectional view of step S11 for preparing toughened sandwich thermal insulation composite wall panels.

[0073] Explanation of reference numerals in the attached figures:

[0074] 1. Toughening layer; 2. Insulation board; 3. Protective layer; 4. Connector; 4a. Connector flange; 4b. Connector web; 4c. Connector support arm; 4c'. Connector positioning boss; 4d. Mold support arm; 4e. Connector lifting hole; 5. Inner leaf plate of substrate; 5a. Outer leaf plate of substrate; 6. Sleeve mounting port; 7. Internal threaded sleeve; 7a. Anchoring boss; 8. Mold connector; 9. Fireproof isolation block; 9a. Block groove; 10. Side mold; 11. Limiter; 12. Longitudinal reinforcement; 13. Transverse reinforcement; 14. Longitudinal carbon fiber strip; 15. Transverse carbon fiber strip; 16. Spacer block; 17. Mold table; 18. Casting port. Detailed Implementation

[0075] To make the technical problems, technical solutions and advantages of the present invention clearer, a detailed description will be given below in conjunction with the accompanying drawings and specific embodiments.

[0076] The toughened sandwich insulation composite wall panel includes an inner leaf plate 5 of the substrate and an outer leaf plate 5a of the substrate corresponding to the inner leaf plate 5. The inner leaf plate 5 and the outer leaf plate 5a of the substrate are connected by an insulation board 2. Connectors 4 are provided at both ends of the insulation board 2.

[0077] The inner leaf plate 5 and the outer leaf plate 5a of the substrate have a length of 3.0m to 4.2m, a width of 600mm to 3m, with 300mm as the dimensional module, and a thickness of not less than 70mm. Specifically, the inner leaf plate 5 and the outer leaf plate 5a of the substrate are either foamed ceramic panels or autoclaved aerated concrete panels, which have advantages such as environmental protection, energy saving, moisture resistance, and sound insulation. To ensure the strength of the toughened sandwich insulation composite wall panel, the compressive strength of the foamed ceramic panel is not less than 7MPa, and the compressive strength of the autoclaved aerated concrete panel is not less than 2.5MPa.

[0078] A toughening layer 1 is provided on the outer surface of the inner blade 5 and the outer blade 5a of the substrate. To enhance the connection between the toughening layer and the inner blade 5 and the outer blade 5a, an adhesive can be added between the layers to ensure a reliable bond between the two materials. Specifically, the toughening layer 1 is one of the following materials: high-ductility concrete, reinforced fine-aggregate concrete, cement mortar wire mesh, or carbon fiber cloth. C30 concrete is preferred for the fine-aggregate concrete, and Grade I or Grade II polymer-modified cement mortar is preferred for the cement mortar. Preferably, when the toughening layer 1 is made of high-ductility concrete or cement mortar wire mesh, its thickness is not less than 15 mm; when the toughening layer 1 is made of reinforced fine-aggregate concrete, its thickness is not less than 50 mm; when the toughening layer 1 is made of carbon fiber cloth, the structural adhesive is epoxy resin or phenolic resin, and the carbon fiber cloth includes longitudinal carbon fiber strips 14 and transverse carbon fiber strips 15, with a thickness of not less than 0.15 mm and a unit area mass of not less than 200 g / m². 2 More specifically, the layout of the carbon fiber cloth will be further explained, such as... Figure 9 As shown, the longitudinal carbon fiber strips 14 and the transverse carbon fiber strips 15 are arranged at equal intervals. The total width of the longitudinal carbon fiber strips 14 is not less than half the width of the inner leaf plate 5 and the outer leaf plate 5a of the substrate, and the total width of the transverse carbon fiber strips 15 is not less than one-quarter the length of the inner leaf plate 5 and the outer leaf plate 5a of the substrate. The toughening layer 1 improves the durability of the toughened sandwich insulation composite wall panel and greatly reduces its water absorption rate. During transportation and installation, it can effectively prevent damage to the wall surface from impacts, achieving an integrated effect of enclosure, insulation, and decoration. The toughened sandwich insulation composite wall panel of this invention has a long service life, reduces maintenance costs, and has good economic benefits. The invention meets the requirements for energy saving, heat preservation, strength and toughness, and improves the overall deformation performance. The toughening layer of the invention improves the tensile strength of the toughened sandwich insulation composite wall panel. The invention realizes the reliable connection between the toughening layer and the inner leaf plate and the outer leaf plate of the substrate, respectively. The overall deformation resistance is good, and the load-bearing capacity and stiffness of the composite wall panel are greatly improved.

[0079] Protective layers 3 are provided at both ends of the insulation board 2 to prevent damage to the sides of the inner leaf plate 5 and the outer leaf plate 5a of the substrate from impact or bumps. Specifically, the slurry of the protective layer 3 can be the same as that of the toughening layer 1, which is one of high-ductility concrete, fine stone concrete, or cement mortar, or it can be other concrete slurries, such as high-strength concrete slurry. When carbon fiber cloth is used as the toughening layer, high-strength concrete slurry is used to form the protective layer 3.

[0080] like Figure 10 and Figure 11As shown, the connector 4 is provided with a web 4b and flanges 4a located on both sides of the web 4b. Support arms 4c, perpendicular to the plane of the web 4b, are spaced apart on the inner side of the web 4b. Positioning bosses 4c' are provided at the ends of the support arms 4c. Mold support arms 4d, perpendicular to the plane of the web 4b, are spaced apart on the outer side of the web 4b. A connector lifting hole 4e is provided at one end of the web 4b for lifting the toughened sandwich insulation composite wall panel. During lifting, the insulation board 2 is perforated to expose the connector lifting hole 4e. After lifting, the gap in the insulation board 2 is backfilled.

[0081] It also includes an internal threaded sleeve 7, which is located on the flange 4a near the inner blade plate 5 of the substrate. The internal threaded sleeve should preferably be M20 or larger, with a length greater than 50mm to ensure anchoring strength, a wall thickness preferably not less than 5mm, and be made of Q235 carbon steel. When the thickness of the inner blade plate 5 and the toughening layer 1 meets the length requirement of the internal threaded sleeve 7, the internal threaded sleeve 7 is located in the space at the top of the flange 4a; specifically, the internal threaded sleeve 7 can be bonded to the flange 4a of the connector 4. When the thickness of the inner blade plate 5 and the toughening layer 1 does not meet the length requirement of the internal threaded sleeve 7, the internal threaded sleeve 7 is located on one side of the flange 4a, with a sleeve mounting opening 6 at the end of the inner blade plate 5 to provide installation space for the internal threaded sleeve 7. Preferably, as... Figure 12 As shown, an anchoring boss 7a is provided on the outer side of the inner threaded sleeve 7 to enhance the connection between the inner threaded sleeve 7 and the toughening layer 1 or the protective layer 3.

[0082] Insulation board 2 is a vacuum insulation board wrapped with polystyrene board, extruded polystyrene board, graphite polystyrene board, or perlite. Specifically, in order to meet the 83% energy saving standard, the thickness of insulation board 2 is further limited: when insulation board 2 is polystyrene board, its thickness is not less than 90mm; when insulation board 2 is extruded polystyrene board, its thickness is not less than 80mm; when insulation board 2 is graphite polystyrene board, its thickness is not less than 75mm; when insulation board 2 is a vacuum insulation board wrapped with perlite, its thickness should be not less than 6mm.

[0083] As a preferred embodiment, fireproof isolation blocks 9 are provided on both sides of the insulation board 2 to improve the fire resistance of the toughened sandwich insulation composite wall panel. The fireproof isolation blocks 9 are made of Class A fire-resistant materials, such as silicone plastic boards. The outer surface of the fireproof isolation blocks 9 is provided with grooves 9a, which enhances fire resistance, provides good energy-saving and environmental protection effects, and at the same time, the grooves 9a can increase the flow path length of water seepage between the boards, thus playing a better role in preventing seepage.

[0084] Figures 1 to 6 This is a cross-sectional view of a toughened sandwich insulation composite wall panel with high-ductility concrete as the toughening layer 1. Figure 7This is a cross-sectional view of a toughened sandwich insulation composite wall panel reinforced with fine aggregate concrete. The structure of the toughened sandwich insulation composite wall panel with cement mortar and wire mesh as the toughening layer is consistent with that of the toughened sandwich insulation composite wall panel reinforced with fine aggregate concrete. Figure 8 and Figure 9 This is a cross-sectional view of a toughened sandwich insulation composite wall panel with carbon fiber cloth as the toughening layer 1.

[0085] The toughened sandwich insulated composite wall panel of this invention overcomes the shortcomings of the original substrate material, such as poor tensile strength and brittle fracture. It integrates the advantages of lightweight and high strength, thermal insulation, waterproofing, high temperature resistance, sound insulation, and moisture resistance. The insulation board has the same lifespan as the wall, making it energy-saving and environmentally friendly. Compared with existing wall panels, this invention requires a thinner wall while still meeting the strength requirements to achieve the same 83 energy-saving standard.

[0086] This invention achieves reliable connection between the toughening layer and the inner leaf plate and the outer leaf plate of the substrate, respectively, resulting in good overall deformation resistance and greatly improving the load-bearing capacity and stiffness of the composite wall panel. The connector has excellent shear resistance and enhances the overall integrity of the wall panel. The connecting sleeve set in the inner leaf plate of the substrate facilitates the connection between the toughened sandwich insulation composite wall panel and the wall structure.

[0087] This invention also provides a method for preparing the aforementioned toughened sandwich insulation composite wall panel, comprising the following steps:

[0088] S1. Prefabricate the inner blade 5 and outer blade 5a of the substrate in the factory, and precisely cut the inner blade 5 and outer blade 5a of the substrate according to the design requirements.

[0089] S2. Based on the dimensions of the inner leaf plate 5 and the outer leaf plate 5a of the substrate, place the side mold 10 on the mold table 17 to form a mold cavity. Use the mold connector 8 to connect the edge of the side mold 10, and use the limiter 11 to fix the bottom of the side mold 10. Figure 14 As shown. Place a pad 16 at a specific location within the mold cavity, as... Figure 13 As shown. The height of the pad 16 is determined according to the required thickness of the toughening layer. The pad 16 is used to ensure that the thickness of the toughening layer is the required thickness. The pad 16 can prevent uneven thickness of the toughening layer 1 caused by the weight of the plate during the process of preventing the outer leaf plate 5a of the substrate from being placed into the mold cavity.

[0090] S3, add toughening layer 1 to the height of pad 16, such as Figure 15As shown. Depending on the material of the toughening layer 1, the specific method of adding the toughening layer 1 is also different. Specifically: when the toughening layer 1 is high-ductility concrete, pour high-ductility concrete to the same height as the pad block 16; when the toughening layer 1 is reinforced fine stone concrete, first tie and fix the longitudinal steel bars 12 and the transverse steel bars 13 in the mold cavity of the mold platform 17, and pour fine stone concrete to the same height as the pad block 16; when the toughening layer 1 is cement mortar wire mesh, first tie and fix the wire mesh in the mold cavity of the mold platform 17, and pour cement mortar to the same height as the pad block 16; when the toughening layer 1 is carbon fiber cloth, apply epoxy resin or phenolic resin, and attach longitudinal carbon fiber cloth strips 14 and transverse carbon fiber cloth strips 15 to the mold cavity of the mold platform 17 according to the design specifications, and then apply epoxy resin or phenolic resin to the surface again. The thickness of the carbon fiber cloth is the same as the thickness of the pad block 16.

[0091] S4. Place the outer leaf plate 5a of the substrate on the toughened layer 1 that has been formed in the mold cavity, and form a gap between the outer leaf plate 5a of the substrate and the side mold 10.

[0092] S5. Place the connector 4 in the gap between the outer leaf plate 5a of the substrate and the side mold 10, such as Figure 16 As shown, support arm 4c supports web 4b in the gap, mold support arm 4d contacts side mold 10 to support connector 4, and a pouring port 18 for grout is formed between the gap between base material outer leaf plate 5a and side mold 10 and between web 4b. Figure 17 As shown.

[0093] S6. Slurry is injected into the gap between the outer leaf plate 5a of the substrate and the side mold 10 through the pouring port 18 to form a protective layer 3, such as Figure 18 As shown. Specifically, the slurry of protective layer 3 can be the same as that of toughening layer 1, and can be one of high-ductility concrete, fine aggregate concrete, or cement mortar, or other concrete slurries, such as high-strength concrete slurry. When carbon fiber cloth is used as the toughening layer, high-strength concrete slurry is used to form protective layer 3.

[0094] S7. Place the insulation board 2 on the inner surface of the outer leaf plate 5a of the substrate, and cure the toughening layer 1 and the protective layer 3; also includes: applying phenolic resin to both sides of the insulation board 2 to form an adhesive layer, and placing a fireproof isolation block 9 on the outside of the adhesive layer, such as Figure 19 As shown.

[0095] S8. Place the inner leaf plate 5 of the substrate on the insulation board 2, such as Figure 20 As shown.

[0096] S9. Place an internal threaded sleeve 7 at a position on the flange 4a near the inner blade plate 5 of the substrate. The internal threaded sleeve 7 is bonded to the top of the flange 4a. Figure 23 and Figure 24As shown. Alternatively, the inner threaded sleeve 7 is bonded to the side of the flange 4a of the connector 4, as shown. Figure 21 and Figure 22 As shown, a sleeve mounting opening 6 is reserved at the end of the inner blade 5 of the substrate to provide space for the inner threaded sleeve 7 to be placed on the side of the flange 4a. The side wall of the inner threaded sleeve 7 is in contact with the sleeve mounting opening 6. Connecting bolts (not shown in the figure) are installed on the inner threaded sleeve 7 to prevent material from entering the inner threaded sleeve 7 when the toughening layer 1 is added.

[0097] S10. A protective layer 3 is formed by pouring grout into the side of the inner leaf plate 5 of the substrate. Specifically, the grout of the protective layer 3 can be the same as the grout of the toughening layer 1, which is one of high ductility concrete, fine stone concrete, or cement mortar, or it can be other concrete grout, such as high-strength concrete grout. When carbon fiber cloth is used as the toughening layer, high-strength concrete grout is used to form the protective layer 3.

[0098] S11. A toughening layer 1 is added above the inner leaf plate 5 of the substrate. After curing, a toughened sandwich insulation composite wall panel is formed, such as... Figure 25 As shown. Furthermore, depending on the material of the toughening layer 1, the specific method of adding the toughening layer is also different. Specifically: when the toughening layer 1 is high-ductility concrete, high-ductility concrete is pressed or poured onto the upper surface of the inner blade 5 of the substrate to a specific thickness; when the toughening layer 1 is reinforced fine stone concrete, the longitudinal steel bars 12 and the transverse steel bars 13 are first tied and fixed to the upper surface of the inner blade 5 of the substrate, and fine stone concrete is poured to a specific thickness; when the toughening layer 1 is cement mortar wire mesh, the wire mesh is first tied and fixed to the upper surface of the inner blade 5 of the substrate, and cement mortar is poured to a specific thickness; when the toughening layer 1 is carbon fiber cloth, epoxy resin or phenolic resin is applied, and longitudinal carbon fiber cloth strips 14 and transverse carbon fiber cloth strips 15 are attached to the upper surface of the inner blade 5 of the substrate according to the design specifications, and epoxy resin or phenolic resin is applied to the surface again.

[0099] The toughened sandwich insulated composite wall panel of this invention adopts a flat mold manufacturing method, which conforms to industrial development, realizes industrialized production, and has a high degree of tooling. At the same time, the setting of the internal threaded sleeve facilitates the connection between the toughened sandwich insulated composite wall panel and the wall structure, saving construction and labor costs, and has good economic benefits.

[0100] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A toughened sandwich insulation composite wall panel, characterized in that, It includes an inner blade plate (5) of the substrate and an outer blade plate (5a) of the substrate corresponding to the inner blade plate (5). There is an insulation board (2) between the inner blade plate (5) and the outer blade plate (5a). Connectors (4) are provided at both ends of the insulation board (2). It also includes an inner threaded sleeve (7). The inner threaded sleeve (7) is provided on the flange (4a) near the inner blade plate (5). An anchoring boss (7a) is provided on the outer side of the inner threaded sleeve (7). The inner threaded sleeve (7) is provided on one side of the flange (4a). A sleeve placement port (6) is provided at the end of the inner blade plate (5). Alternatively, the inner threaded sleeve (7) is provided in the space at the top of the flange (4a). A toughening layer (1) is provided on the outer surface of the inner blade (5) and the outer blade (5a) of the substrate; The insulation board (2) has protective layers (3) at both ends of its horizontal direction; The connector (4) is provided with a web (4b) and flanges (4a) on both sides of the web (4b). Support arms (4c) perpendicular to the plane of the web (4b) are provided at intervals on the inner side of the web (4b). Positioning bosses (4c') are provided at the ends of the support arms (4c). Mold support arms (4d) perpendicular to the plane of the web (4b) are provided at intervals on the outer side of the web (4b).

2. The toughened sandwich insulation composite wall panel according to claim 1, characterized in that, A connector hoisting hole (4e) is provided at one end of the web (4b).

3. The toughened sandwich insulation composite wall panel according to claim 1, characterized in that, The inner leaf plate (5) and the outer leaf plate (5a) of the substrate are 3.0m to 4.2m in length, 600mm to 3m in width, with 300mm as the dimensional module, and the thickness is not less than 70mm.

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

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

6. The toughened sandwich insulation composite wall panel according to claim 5, characterized in that, When the toughening layer (1) is made of high-ductility concrete or cement mortar wire mesh, the thickness shall not be less than 15 mm. When the toughening layer (1) is made of reinforced fine stone concrete, its thickness shall not be less than 50 mm. When the toughening layer (1) is made of carbon fiber cloth, the structural adhesive is epoxy resin or phenolic resin. The carbon fiber cloth includes longitudinal carbon fiber cloth strips (14) and transverse carbon fiber cloth strips (15). The thickness of the carbon fiber cloth is not less than 0.15 mm, and the unit area mass is not less than 200 g / m². 2 .

7. The toughened sandwich insulation composite wall panel according to claim 1, characterized in that, The insulation board (2) is a vacuum insulation board wrapped with polystyrene board, extruded board, graphite polystyrene board or perlite.

8. The toughened sandwich insulation composite wall panel according to claim 7, characterized in that, When the insulation board (2) is a polystyrene board, its thickness shall not be less than 90 mm; When the insulation board (2) is an extruded polystyrene board, its thickness shall not be less than 80 mm; When the insulation board (2) is a graphite polystyrene board, its thickness shall not be less than 75 mm; When the insulation board (2) is a vacuum insulation board wrapped with perlite, its thickness should not be less than 6mm.

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

10. The toughened sandwich insulation composite wall panel according to claim 9, characterized in that, The outer side of the fireproof isolation block (9) is provided with a block groove (9a).

11. A method for preparing a toughened sandwich thermal insulation composite wall panel according to any one of claims 1-10, characterized in that, Includes the following steps: S1. Prefabricate the inner leaf plate (5) and outer leaf plate (5a) of the substrate in the factory, and precisely cut the inner leaf plate (5) and outer leaf plate (5a) of the substrate according to the design requirements. S2. Based on the dimensions of the inner leaf plate (5) and the outer leaf plate (5a) of the substrate, place the side mold (10) on the mold table (17) to form a mold cavity. Use the mold connector (8) to connect the edge of the side mold (10). Use the limiter (11) to fix the bottom of the side mold (10). Place the pad (16) at a specific position in the mold cavity. S3. Add toughening layer (1) to the same height as pad (16); S4. Place the outer leaf plate (5a) of the substrate on the toughened layer (1) that has been formed in the mold cavity, and form a gap between the outer leaf plate (5a) of the substrate and the side mold (10); S5. Place the connector (4) in the gap between the outer leaf plate (5a) of the substrate and the side mold (10). The support arm (4c) supports the web plate (4b) in the gap. The mold support arm (4d) contacts the side mold (10) to support the connector (4). A pouring port (18) for pouring slurry is formed between the gap between the outer leaf plate (5a) of the substrate and the side mold (10) and the web plate (4b). S6. Slurry is injected into the gap between the outer leaf plate (5a) of the substrate and the side mold (10) through the pouring port (18) to form a protective layer (3). S7. Place the insulation board (2) on the inner surface of the outer leaf plate (5a) of the substrate and cure the toughening layer (1) and the protective layer (3) to be cured. S8. Place the inner leaf plate (5) of the substrate on the insulation board (2); S9. Place an inner threaded sleeve (7) on the flange (4a) near the inner blade plate (5) of the substrate. The inner threaded sleeve (7) is bonded to the top of the flange (4a) or to the side of the flange (4a). S10. Pour grout into the side of the inner leaf plate (5) of the substrate to form a protective layer (3). S11. Add a toughening layer (1) above the inner leaf plate (5) of the substrate, and after curing, form a toughened sandwich insulation composite wall panel.

12. The method for preparing the toughened sandwich thermal insulation composite wall panel according to claim 11, characterized in that, In step S3 When the toughening layer (1) is high ductility concrete, pour high ductility concrete up to the same height as the pad block (16); When the toughening layer (1) is reinforced fine stone concrete, first tie and fix the longitudinal steel bars (12) and transverse steel bars (13) in the mold cavity of the mold platform (17), and pour fine stone concrete up to the height of the pad block (16); When the toughening layer (1) is cement mortar wire mesh, first tie and fix the wire mesh in the mold cavity of the mold table (17), and pour cement mortar up to the height of the pad block (16); When the toughening layer (1) is carbon fiber cloth, apply epoxy resin or phenolic resin, and attach longitudinal carbon fiber cloth strips (14) and transverse carbon fiber cloth strips (15) to the mold cavity of the mold platform (17) according to the design specifications. Apply epoxy resin or phenolic resin to the surface again. The thickness of the carbon fiber cloth is consistent with the thickness of the pad (16).

13. The method for preparing the toughened sandwich thermal insulation composite wall panel according to claim 11, characterized in that, In step S11, When the toughening layer (1) is high ductility concrete, high ductility concrete is pressed or poured onto the upper surface of the inner leaf plate (5) of the substrate to a specific thickness. When the toughening layer (1) is reinforced fine stone concrete, the longitudinal steel bars (12) and transverse steel bars (13) are first tied and fixed to the upper surface of the inner leaf plate (5) of the substrate, and fine stone concrete is poured to a specific thickness. When the toughening layer (1) is a cement mortar wire mesh, first tie and fix the wire mesh to the upper surface of the inner leaf plate (5) of the substrate, and pour cement mortar to a specific thickness. When the toughening layer (1) is carbon fiber cloth, apply epoxy resin or phenolic resin, and attach longitudinal carbon fiber cloth strips (14) and transverse carbon fiber cloth strips (15) to the upper surface of the inner leaf plate (5) of the substrate according to the design specifications, and apply epoxy resin or phenolic resin to the surface again.

14. The method for preparing the toughened sandwich thermal insulation composite wall panel according to claim 11, characterized in that, In step S7, the following steps are also included: applying phenolic resin to both sides of the insulation board (2) to form an adhesive layer, and placing a fireproof isolation block (9) on the outside of the adhesive layer.

15. The method for preparing the toughened sandwich thermal insulation composite wall panel according to claim 11, characterized in that, In step S9, when the inner thread sleeve (7) is bonded to the side of the flange (4a), a sleeve mounting opening (6) is reserved at the end of the inner blade plate (5) of the substrate.

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