Sandwich structure composite board, production process thereof and building wall construction method

Abstract

The invention discloses a sandwich structure composite board, a production process thereof and a building wall construction method, and relates to the technical field of wall buildings, the sandwich structure composite board is used as a main body structure of a wall, and is combined with a traditional reinforced concrete frame structure to form an integral waterproof heat preservation structure. According to the prefabrication process of the sandwich structure composite board, the two layers of high-strength hydrophobic autoclaved aerated concrete boards and the middle heat preservation core material are tightly combined through an adhesive, the structure guarantees the structural strength of the wall body, and due to the fact that the middle layer adopts the modified polyurethane board and the outer layer material is hydrophobic, the heat preservation performance of the wall body is improved. Therefore, the whole wall body has excellent thermal insulation and waterproof performance. The heat preservation layer is designed in the center of the wall body, additional later heat preservation construction is avoided, and the fireproof, waterproof and anti-falling effects are achieved. In the construction process, the construction period is remarkably shortened, and the construction efficiency and quality are improved.

Description

Technical Field

[0001] This invention relates to the technical field of wall construction, specifically to a sandwich structure composite panel, its production process, and a construction method for building walls. Background Technology

[0002] Composite panel-reinforced concrete frame structure is a new type of building that combines the advantages of composite panels and reinforced concrete frames. However, ordinary composite panels have relatively low structural strength and are generally not suitable for direct use as main load-bearing walls. This is because the main walls must be able to withstand various external forces such as the weight of the building, wind pressure, and seismic forces, and the materials and structure of ordinary composite panels often cannot meet these high strength requirements.

[0003] Furthermore, rock wool boards are commonly used as exterior wall insulation material to improve the overall thermal insulation performance of buildings. However, the insulation layer, when exposed to the external environment for extended periods, is prone to cracking, water seepage, and even detachment. Exterior wall insulation construction typically requires completion of the main structural concrete pouring, which not only adds extra secondary construction steps but also makes quality control difficult due to the complexity of the construction process. This not only affects the durability of the project but also increases the cost of later maintenance and repairs.

[0004] Finally, since ordinary composite boards do not have waterproof properties, their direct application to the main wall may cause damage or performance degradation in humid environments, and may easily lead to problems such as corrosion and mold, thereby affecting the durability and service life of the structure. Summary of the Invention

[0005] The purpose of this invention is to provide a sandwich structure composite panel, its production process, and a construction method for building walls, so as to solve the problems mentioned in the background art.

[0006] A sandwich-structure composite panel includes an insulation core material, which is a modified polyurethane board. Water-repellent autoclaved aerated concrete (AAC) panels are attached to both sides of the insulation core material using an adhesive. A water-repellent agent is added to the raw materials used to prepare the water-repellent AAC panels. A steel mesh is installed inside the water-repellent AAC panels.

[0007] A manufacturing process for a sandwich structure composite panel includes at least the following steps: S10. Prepare hydrophobic autoclaved aerated concrete (AAC) panels. This step includes the following sub-steps: a. Slurry preparation: Silica tailings, desulfurized gypsum, fly ash and river sand are finely ground to prepare a uniform slurry; b. Pre-processing of reinforcing bars: The reinforcing bars are coiled into reinforcing mesh and subjected to anti-corrosion treatment. The processed reinforcing mesh is then suspended on the steel rod of the insertion and extraction rod device. c. Casting: Add lime powder, cement, water-repellent agent and air-generating agent to the slurry prepared in step a, mix and stir and pour into the mold car; place the steel rod with the steel mesh suspended in step b into the mold car that has been cast. d. Static curing and wire mesh removal: After the mold car is completed in step c, move it into the static curing chamber to allow the billet to complete the gas generation, hardening and expansion process; use the wire rod removal equipment to remove the wire rod from the mold car, leaving the steel mesh inside the billet; e. Cutting to length and autoclaving: Cut the blank obtained in step d and put the cut blank into an autoclave to allow the blank to fully complete the hydration reaction and obtain a hydrophobic autoclaved aerated concrete slab.

[0008] S20, Apply adhesive: Take a piece of hydrophobic autoclaved aerated concrete board prepared in S10 and place it on the production line track. Apply adhesive to the upper surface of the hydrophobic autoclaved aerated concrete board using a glue spraying machine. S30, bonding insulation core material: The robotic arm picks up the insulation core material and places it on top of the S20 water-repellent autoclaved aerated concrete board sprayed with adhesive, keeping it aligned around the perimeter and bonding it. S40. Apply adhesive again: Apply adhesive to the upper surface of the insulation core material bonded by S30 using a glue spraying machine; S50, bonding hydrophobic autoclaved aerated concrete (AAC) panels: The robotic arm picks up another hydrophobic AAC panel, places it on the surface of the adhesive that has been sprayed again in S40, and ensures that the four sides are aligned and bonded. After bonding, it is conveyed to the pressure roller for pressing. S60. Drilling: After pressing, the material is conveyed to the bottom of the drilling machine for drilling. After drilling, the sandwich structure composite panel is produced.

[0009] A construction method for sandwich-structured composite panel building walls includes at least the following steps: S1. Marking lines on the panels: Mark lines on the existing walls according to the design requirements to determine the specific installation location and dimensions of the sandwich structure composite panels; S2. On-site processing of sandwich structure composite panels: The sandwich structure composite panels are partially cut on-site, and metal anchor bolts are installed at both the top and bottom ends. S3. Fixing hook bolts: Install hook bolts on the upper beam and the lower beam respectively, and weld angle iron to one end of the hook bolts that pass through the upper beam and the lower beam; S4. Panel installation: Embed the sandwich structure composite panel that has been treated on-site in S2 into the center of the wall, and ensure that there are gaps between the sandwich structure composite panel and the surrounding area. Weld the metal anchors at both ends of the sandwich structure composite panel to the angle irons that are pre-fixed on the upper and lower beams. S5. Gap filling: Fill the gaps at the bottom of the sandwich structure composite panel with polystyrene particle insulation mortar; fill the gaps at the top and left and right sides of the sandwich structure composite panel with polyurethane foam. S6. Filling gaps in the sandwich structure composite board: Hang a mesh cloth on the outer surface of the sandwich structure composite board, and use polystyrene particle thermal insulation mortar to evenly apply the joints of the sandwich structure composite board and the mesh cloth splicing to fill the gaps.

[0010] The outer surfaces of the hook bolts, angle irons, and metal anchors are all coated with Teflon.

[0011] This invention proposes a sandwich-structure composite panel, its production process, and a construction method for building walls. The beneficial effects are as follows: the sandwich-structure composite panel of this application is used as the main structure of a wall, combined with a traditional reinforced concrete frame structure to form an integrated waterproof and thermally insulated structure. The prefabrication process of the sandwich-structure composite panel involves tightly bonding two layers of high-strength, water-repellent autoclaved aerated concrete panels to an intermediate thermal insulation core material using adhesives. This structure not only ensures the structural strength of the wall, but also, due to the use of modified polyurethane panels in the intermediate layer and the water-repellent nature of the outer materials, gives the entire wall excellent thermal insulation and waterproof performance.

[0012] Furthermore, the insulation layer is designed to be located in the center of the wall, which avoids the need for additional post-construction insulation work and achieves fireproofing, waterproofing, and anti-detachment effects. During construction, the sandwich structure composite panels can be quickly assembled, significantly shortening the construction cycle and improving construction efficiency and quality.

[0013] Finally, the use of sandwich composite panels reduces reliance on traditional building materials, and due to their lightweight and high-strength characteristics, the load requirements on buildings are also reduced, thereby improving the overall performance of buildings. Attached Figure Description

[0014] Figure 1 This is a cross-sectional view of a sandwich structure composite panel; Figure 2 This is a schematic diagram of a steel mesh structure; Figure 3 This is a sectional view of a hydrophobic autoclaved aerated concrete (AAC) slab. Figure 4 This is a schematic diagram showing the connection between the sandwich structure composite panel and the wall.

[0015] In the diagram: 1. Insulation core material, 2. Adhesive, 3. Water-repellent autoclaved aerated concrete board, 4. Steel mesh, 5. Upper beam, 6. Lower beam, 7. Hook bolt, 8. Angle iron, 9. Metal anchor bolt. Detailed Implementation

[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] Please refer to the accompanying drawings. The present invention provides a technical solution: a sandwich structure composite panel, comprising an insulation core material 1, wherein the insulation core material 1 is a modified polyurethane board, and hydrophobic autoclaved aerated concrete (AAC) panels 3 are respectively installed on both sides of the insulation core material 1 by an adhesive 2, wherein a hydrophobic agent is added to the raw materials for preparing the hydrophobic AAC panels 3; and a steel mesh 4 is installed inside the hydrophobic AAC panels 3.

[0018] A manufacturing process for a sandwich structure composite panel includes at least the following steps: S10. Prepare hydrophobic autoclaved aerated concrete slab 3. This step includes the following sub-steps: a. Slurry preparation: In the raw material preparation process, we use a mill to finely grind raw materials such as silica tailings, desulfurized gypsum, fly ash, and river sand to ensure that the particle size meets the process parameter requirements, thereby preparing a uniform slurry.

[0019] b. Pre-processing of reinforcing bars: In the pre-processing stage of reinforcing bars, we perform a series of processes on the coiled reinforcing bars, including rust removal, straightening, cutting, and welding, to process them into reinforcing mesh 4 that meets production requirements. Subsequently, in the anti-corrosion treatment stage of reinforcing mesh 4, the processed reinforcing mesh 4 is suspended on a plugging and pulling device to perform the corresponding anti-corrosion treatment procedure, thereby enhancing the durability of reinforcing mesh 4.

[0020] c. Casting: The lime blocks are crushed and further ground into lime powder, which is then stored in lime powder silos. Cement is poured into designated cement silos, and additives such as water-repellent agents and air-generating agents are accurately added to the feeders to prepare for subsequent use. According to the proportions specified in the process design, the slurry prepared in step a is mixed with lime powder, cement, water-repellent agents, and air-generating agents until a slurry meeting the required temperature and consistency standards is formed. Subsequently, the prepared slurry is poured into the mold cart using a casting mixer, ensuring uniform distribution. Finally, the steel rods with suspended mesh are accurately inserted into the cast mold cart using a rod-pulling device to ensure a tight bond between the steel mesh 4 and the slurry.

[0021] d. Static Curing and Removal of Steel Mesh: After completing step c, the mold carriage is moved into the static curing chamber for static curing. During this process, the billet undergoes gas generation, hardening, and expansion until it meets the process requirements. Subsequently, when the billet reaches the predetermined process standards, the steel rods are removed from the mold carriage using a rod-pulling device, while the steel mesh 4 remains inside the billet, thus forming the hydrophobic autoclaved aerated concrete slab 3.

[0022] e. Cutting to Length and Autoclaving: The blanks obtained in step d are cut. Before cutting, the blanks must be checked to ensure they meet the cutting requirements and that their dimensions and quality conform to standards. The blanks are precisely cut to the dimensions required by the customer using cutting equipment. Then, the cut blanks are placed in an autoclave for high-temperature, high-pressure autoclaving for 12 hours to ensure the complete hydration reaction, thus obtaining the desired hydrophobic autoclaved aerated concrete (AAC) slab 3. After autoclaving, the mold cart is removed from the autoclave for splitting and packaging. Splitting and packaging equipment ensures the slabs are safely and effectively packaged for easy transportation, resulting in the hydrophobic AAC slab 3.

[0023] S20, Apply adhesive 2: Take a piece of hydrophobic autoclaved aerated concrete board 3 prepared in S10 and place it on the production line track. Apply adhesive 2 to the upper surface of the hydrophobic autoclaved aerated concrete board 3 using a glue spraying machine. S30, Applying Insulation Core Material 1: The robotic arm picks up the insulation core material 1 and places it on top of the water-repellent autoclaved aerated concrete board 3 sprayed with adhesive 2 in S20, keeping it aligned around the perimeter and applying it. S40, Apply adhesive 2 again: Apply adhesive 2 to the upper surface of the insulation core material 1 bonded in S30 using a glue spraying machine; S50, bonding hydrophobic autoclaved aerated concrete board 3: The robotic arm grabs another hydrophobic autoclaved aerated concrete board 3, places it on the surface of the adhesive 2 that has been sprayed again in S40, and ensures that the four sides are aligned and bonded. After bonding, it is conveyed to the pressure roller for pressing. S60. Drilling: After pressing, the material is conveyed to the bottom of the drilling machine for drilling, so that metal anchor bolts 9 can be installed later. After drilling is completed, the sandwich structure composite panel is produced.

[0024] A construction method for sandwich-structured composite panel building walls includes at least the following steps: S1. Marking lines on the panels: Mark lines on the existing walls according to the design requirements to determine the specific installation location and dimensions of the sandwich structure composite panels; S2. On-site processing of sandwich structure composite panels: According to the actual situation, the sandwich structure composite panels are partially cut on-site, and metal anchor bolts 9 are installed at the upper and lower ends respectively. S3. Fixing hook bolts 7: Hook bolts 7 are installed on the upper beam 5 and the lower beam 6 respectively. Angle iron 8 is welded to one end of the hook bolts 7 that pass through the upper beam 5 and the lower beam 6. The hook bolts 7 and angle iron 8 are used for the support and fixation of the sandwich structure composite panel. S4. Panel Installation: The sandwich structure composite panel, which has been treated on-site in S2, is embedded into the center of the wall, and gaps are left between the sandwich structure composite panel and the surrounding area. The purpose of leaving gaps here is to achieve a flexible connection between the sandwich structure composite panel and the main wall, which can not only prevent cold bridging, but also further improve the seismic resistance of the structure. After the verticality and flatness are checked, the metal anchors 9 at both ends of the sandwich structure composite panel are firmly welded to the angle irons 8 that are pre-fixed on the upper beam 5 and the lower beam 6. S5. Gap filling: Fill the gaps at the bottom of the sandwich structure composite panel with polystyrene particle insulation mortar to enhance the stability and sealing of the sandwich structure composite panel; fill the gaps at the top and left and right sides of the sandwich structure composite panel with polyurethane foam to further improve the sealing performance of the sandwich structure composite panel. S6. Mesh Filling of Sandwich Composite Panels: A mesh fabric is hung on the outer surface of the sandwich composite panel. Polystyrene particle insulation mortar is evenly applied to the seams of the sandwich composite panel and the joints of the mesh fabric to fill the gaps. This enhances the integrity and aesthetics of the sandwich composite panel. After application, the mortar provides insulation and prevents cold bridging. Simultaneously, filling gaps and installing mesh also improves seismic resistance.

[0025] Polyurethane foam offers significant advantages in joint insulation, primarily due to its high-efficiency insulation performance, excellent sealing properties, and good adhesion. This material rapidly foams to form a dense foam structure, effectively preventing heat loss and the penetration of air and water vapor, thus improving insulation performance. Polyurethane foam is lightweight and high-strength, reducing building load and improving the seismic resistance of the wall structure. Furthermore, polyurethane foam is environmentally friendly and non-toxic, easy and quick to apply, and has good weather resistance, adapting to various climatic conditions and maintaining its insulation performance over a long period. Using polyurethane foam not only effectively reduces building energy consumption and saves energy, but also offers significant economic benefits.

[0026] The surfaces of the hook bolts 7, angle irons 8, and metal anchors 9 are all coated with Teflon. The Teflon (polytetrafluoroethylene) coating offers significant advantages in preventing cold bridges. Cold bridges are areas of heat loss in building structures caused by differences in the thermal conductivity of materials. These areas easily lead to heat loss, thus affecting the building's insulation performance and energy efficiency. Due to its excellent thermal stability and low thermal conductivity, the Teflon coating can effectively isolate heat transfer, thereby reducing the occurrence of cold bridges.

[0027] Another advantage of Teflon coating is its weather resistance and corrosion resistance. Since our walls are the interface between the building and the external environment, they need to be able to resist harsh weather conditions and chemical corrosion to ensure that they maintain their performance for a long time. Therefore, Teflon coating can also significantly improve the durability of the walls and extend their service life.

[0028] Traditional exterior wall insulation materials often use rock wool, which has a flame retardant rating of Class A and does not burn when exposed to open flames. However, it has the following drawbacks: it is heavy, has a high water absorption rate, and is at high risk of falling off. In contrast, the insulation core material 1 used in this application is preferably a modified polyurethane board. Modified polyurethane was originally used in cold storage systems and building exterior insulation, but due to its high cost and its Class B1 flame retardant rating, it is flammable when exposed to open flames, so its use in building exterior insulation has been reduced. However, due to its sandwich structure, the insulation layer is designed between two layers of hydrophobic autoclaved aerated concrete board 3, which will not be exposed to open flames, so there will be no fire problem. Moreover, its insulation performance, lightweight characteristics, and low water absorption are excellent, which can greatly reduce construction difficulty and maintenance costs.

[0029] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A sandwich structure composite panel, comprising a thermal insulation core material (1), with hydrophobic autoclaved aerated concrete panels (3) mounted on both sides of the thermal insulation core material (1) via an adhesive (2), characterized in that: A water repellent is added to the raw materials for preparing the water repellent autoclaved aerated concrete board (3); a steel mesh (4) is installed inside the water repellent autoclaved aerated concrete board (3); and the thermal insulation core material (1) is a modified polyurethane board.

2. A process for producing a sandwich structure composite panel according to claim 1, characterized in that: The method comprises at least the following steps: S10, preparing a hydrophobic autoclaved aerated concrete board (3), which comprises the following sub-steps: a. Slurry preparation: finely grind silica tailings, desulfurized gypsum, fly ash and river sand to prepare uniform slurry; b. Pre-processing the steel bars: processing the steel bar coils into steel mesh sheets (4), and hanging the processed steel mesh sheets (4) on the steel drill of the drill insertion and extraction equipment; c. Casting: adding lime powder, cement, water repellent and gas generating agent to the slurry prepared in step a, mixing and stirring, and injecting into a mold vehicle; placing the steel bar on which the steel mesh (4) has been hung in step b into the mold vehicle on which the casting has been completed; d. Static curing and mesh extraction: move the mold car after casting in step c into the static room to allow the green body to complete the gas generation, hardening and expansion process; use the drill insertion and extraction equipment to extract the steel drill from the mold car, so that the steel mesh (4) remains in the green body; e. Cutting to size and autoclaving: cutting the green body obtained in step d, conveying the cut green body into an autoclave, allowing the green body to fully complete the hydration reaction, and obtaining a hydrophobic autoclaved aerated concrete board (3); S20, spraying adhesive (2): grab a hydrophobic autoclaved aerated concrete board (3) prepared in S10 and place it on the production line track, and use a glue spraying machine to spray adhesive (2) on the upper surface of the hydrophobic autoclaved aerated concrete board (3); S30, laminating the thermal insulation core material (1): the robot grasps the thermal insulation core material (1) and places it on the hydrophobic autoclaved aerated concrete board (3) sprayed with the adhesive (2) in S20, aligning the four sides and laminating the board; S40, spraying the adhesive (2) again: the glue spraying machine sprays the adhesive (2) on the upper surface of the thermal insulation core material (1) bonded in S30; S50, laminating the hydrophobic autoclaved aerated concrete board (3): the robot grabs another hydrophobic autoclaved aerated concrete board (3), places it on the upper surface of the adhesive (2) sprayed again in S40, and ensures that the four sides are aligned and laminated, and after the lamination is completed, it is transported to the pressing roller for compaction; S60, punching: After compaction, the board is transported to the bottom of the punching machine for punching. After the punching is completed, the sandwich structure composite board is produced.

3. A sandwich structure composite panel production process according to claim 2, characterized in that: In the process of pre-processing the steel bars in step b, the steel bar coils are processed into steel bar mesh (4) and then subjected to anti-corrosion treatment.

4. A method for constructing a building wall of a sandwich structure composite panel according to claim 1, characterized in that: At least the following steps are included: S1, marking the board: marking the board on the existing wall according to the design requirements to determine the specific installation position and size of the sandwich structure composite board; S2. On-site processing of the sandwich structure composite panel: partially cutting the sandwich structure composite panel on-site, and installing metal anchor bolts (9) at the upper and lower ends thereof; S3, fixing the hook bolt (7): installing the hook bolt (7) on the upper beam (5) and the lower beam (6) respectively, and welding an angle iron (8) to one end of the hook bolt (7) passing through the upper beam (5) and the lower beam (6); S4, panel installation: embed the sandwich structure composite panel processed on site in S2 into the center of the wall, and ensure that there are gaps between the sandwich structure composite panel and the surrounding areas, and firmly weld the metal anchor bolts (9) at both ends of the sandwich structure composite panel to the angle irons (8) pre-fixed on the upper beam (5) and the lower beam (6); S5. Gap filling: fill the gaps at the bottom of the sandwich structure composite board with polystyrene particle insulation mortar; use polyurethane foam to fill the gaps at the top and left and right sides of the sandwich structure composite board; S6. Mesh cloth is hung on the outer surface of the sandwich structure composite board, and polystyrene particle insulation mortar is evenly applied to the board seams and mesh cloth joints of the sandwich structure composite board for seam repair.

5. A method for constructing a sandwich structure composite panel building wall according to claim 4, characterized in that: The outer surfaces of the hook bolt (7), angle iron (8) and metal anchor bolt (9) are all spray-coated with Teflon.

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