Lightweight integrated kitchen and bath module and preparation method thereof

Abstract

The invention relates to the field of building materials, and discloses a light-weight integrated kitchen and bath module and a preparation method thereof.The light-weight integrated kitchen and bath module comprises a base layer made of calcium silicate boards; the outer layer is made of ultra-high performance concrete and is fixed on the surface of the base layer through a spraying process to form an integral structure; the base layer and the outer layer are fixed through a high-strength bonding process; the thickness of the calcium silicate board of the base layer is 3 cm, the surface of the calcium silicate board is subjected to mechanical shot blasting treatment and coated with a functional coating, and the functional coating has waterproof, fireproof and anti-cracking performance; the ultra-high performance concrete of the outer layer comprises lightweight aggregate and traditional aggregate which are reasonably proportioned, wherein the lightweight aggregate is expanded ceramsite or perlite. The ultra-high performance concrete, the lightweight aggregate and the nano coating technology are adopted, so that the water resistance, the antibacterial property and the crack resistance of the wall material are improved, the weight of the material is reduced, and the structural strength and the durability are optimized.

Description

Technical Field

[0001] The invention relates to the field of building materials, and in particular to a lightweight integrated kitchen and bathroom module and a preparation method thereof. Background Art

[0002] In the construction industry, traditional building materials are widely used in construction, especially for walls and surface materials in humid environments such as kitchens and bathrooms. These materials are composed of cement-based composite materials, ordinary calcium silicate boards or gypsum boards, which are widely used due to their economy and ease of construction. In addition, with the improvement of the construction industry's requirements for building functionality and performance, multifunctional building materials such as waterproof, fireproof, antibacterial, and crack-resistant have gradually become market demand. However, although existing materials have certain advantages in cost and application, they still have obvious deficiencies in terms of waterproofness, antibacterial properties, crack resistance, durability, and lightweight.

[0003] In the prior art, traditional wall materials such as calcium silicate boards and ordinary cement-based composite materials, although they have basic strength and durability, have poor waterproof performance. When exposed to a humid environment for a long time, these materials are easy to absorb moisture, resulting in a decrease in waterproofness and antibacterial properties, and cannot effectively avoid the growth of mold and bacteria. In addition, traditional waterproof coatings such as polyurethane and epoxy resin coatings are easily degraded due to changes in temperature and humidity during use, reducing the waterproof effect. At the same time, the surface is easily contaminated by stains, making cleaning and maintenance difficult. On the other hand, although ultra-high performance concrete has higher strength, its aggregate is heavier, resulting in a larger module weight, which increases the difficulty of transportation and construction. And because optimized lightweight aggregates and reinforcing materials are not added, ultra-high performance concrete still has deficiencies in toughness and crack resistance, and is prone to cracks during transportation and installation. Therefore, the prior art has relatively serious limitations in terms of waterproofing, antibacterial, crack resistance, lightweight and durability, and cannot meet the comprehensive needs of modern buildings for functionality, economy and high-performance materials. Summary of the invention

[0004] In view of the deficiencies in the prior art, the present invention provides a lightweight integrated kitchen and bathroom module and a preparation method thereof, which solves the problems of waterproofness, antibacterial property, crack resistance and lightweight of traditional building materials in the prior art.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: a lightweight integrated kitchen and bathroom module and a preparation method thereof, comprising: The base layer is made of calcium silicate board; The outer layer is made of ultra-high performance concrete, which is fixed on the surface of the base layer through a spraying process to form an integral structure; The base layer and the outer layer are fixed by a high-strength bonding process.

[0006] Preferably, the calcium silicate board of the base layer has a thickness of 3 cm, and the surface of the calcium silicate board is mechanically shot blasted and coated with a layer of functional coating, wherein the functional coating has waterproof, fireproof and crack-resistant properties.

[0007] Preferably, the ultra-high performance concrete of the outer layer includes a reasonable ratio of lightweight aggregate and traditional aggregate, wherein the lightweight aggregate is expanded ceramsite or perlite.

[0008] Preferably, a reinforcing material is added to the ultra-high performance concrete of the outer layer, and the reinforcing material is steel fiber, carbon nanotube or a combination of the two.

[0009] Preferably, the base layer and the outer layer are bonded together by a high-pressure spraying process.

[0010] Preferably, the surface of the base layer is coated with a nano-siloxane coating.

[0011] Preferably, the outer layer of ultra-high performance concrete is subjected to steam curing treatment at a curing temperature of 70°C, a relative humidity of 90%, and a curing time of 6 hours.

[0012] A method for preparing a lightweight integrated kitchen and bathroom module comprises the following steps: S1. Select calcium silicate board as the base layer, perform mechanical shot blasting and chemical coating on the surface of the calcium silicate board to form a waterproof and fireproof functional coating; S2. Prepare ultra-high performance concrete, add lightweight aggregate, traditional aggregate and nano-reinforcement materials, and mix thoroughly; S3, spraying the prepared ultra-high performance concrete evenly on the surface of the calcium silicate board through a spraying process to form an outer layer; S4. Steam cure the sprayed module and dry it naturally after curing.

[0013] Preferably, the spraying process adopts robot high-pressure spraying technology, the spraying pressure is 120MPa, and the spraying flow rate is 10L / min.

[0014] The present invention provides a lightweight integrated kitchen and bathroom module and a preparation method thereof. The module has the following beneficial effects: 1. The present invention adopts a lightweight integrated kitchen and bathroom module design, combines calcium silicate board with ultra-high performance concrete, and forms an integrated structure through a spraying process, thereby achieving a lightweight effect of the module. Compared with the traditional heavy modules in the prior art, this technical solution effectively reduces the weight of the module, reduces the transportation and installation costs, and can reduce the overall load of the building while ensuring the strength.

[0015] The present invention improves the waterproof, fireproof and antibacterial properties of the module by using functional coatings and surface treatment technologies, achieving excellent functional protection effects. Compared with traditional materials, the module surface coating of the present invention can effectively resist moisture, oil pollution and high temperature environments in kitchens and bathrooms, avoids common module aging and corrosion problems, and prolongs service life.

[0016] The present invention improves the mechanical properties of the outer layer of concrete by adding lightweight aggregates and nano-reinforced materials to ultra-high performance concrete, achieving multiple advantages of compression resistance, bending resistance and crack resistance. Compared with the modules using ordinary concrete in the prior art, the modules of the present invention have better performance in strength and toughness, while reducing the self-weight of the material and improving the stability and safety of the structure.

[0017] The present invention adopts a process combining steam curing with natural drying, which improves the hydration degree and strength of concrete and ensures the excellent performance of the module. Compared with the traditional drying method, this technical solution effectively reduces the occurrence of concrete cracks by precisely controlling the curing conditions, improves the durability and anti-aging ability of the module, and makes it suitable for more stringent use environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a diagram of the method steps of the present invention. DETAILED DESCRIPTION

[0019] The following will be combined with the drawings in the specification of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] Please see attached Figure 1 The embodiment of the present invention provides a lightweight integrated kitchen and bathroom module and a preparation method thereof. The technical solution aims to provide a kitchen and bathroom module with excellent performance, light weight and convenient installation by optimizing materials and production processes. The specific technical solution and its mechanism analysis are as follows: 1. Basic structure of lightweight integrated kitchen and bathroom module The lightweight integrated kitchen and bathroom module of the present invention comprises two parts: a base layer and an outer layer. The base layer is made of calcium silicate board and the outer layer is made of ultra-high performance concrete (UHPC). The two are combined through a high-strength spraying process to form an integrated module structure.

[0021] Calcium silicate board as the choice of base layer: Calcium silicate board has high fire resistance, water resistance and antibacterial properties, and is an ideal building material. The inorganic components in its structure enable it to maintain stable performance in a humid environment, and is suitable for high humidity environments such as kitchens and bathrooms. Through mechanical shot blasting, the surface roughness of the calcium silicate board can be increased, making it more closely bonded to the outer layer of ultra-high performance concrete, and enhancing the adhesion of the two.

[0022] The role of the outer layer of ultra-high performance concrete (UHPC): UHPC is composed of high-strength cement, fine aggregate and fiber. It has very excellent mechanical properties, can provide high compressive strength and high crack resistance, and can also effectively reduce the weight of the module. By using lightweight aggregates (such as expanded ceramsite or perlite), not only the strength of the concrete is maintained, but also its density is greatly reduced, thereby achieving a lightweight effect.

[0023] Base layer surface treatment and application of functional coatings The surface of the calcium silicate board of the base layer is mechanically shot blasted and coated with functional coating to enhance its waterproof, fireproof and crack-resistant properties.

[0024] Mechanical shot blasting: Through the mechanical shot blasting process, the surface roughness of the calcium silicate board can be effectively increased, and its bonding with the outer layer of concrete can be enhanced. This treatment physically breaks the smooth structure of the surface, so that the calcium silicate board can better bond with the concrete layer when spraying concrete, thereby improving the structural stability of the overall module.

[0025] Functional coating: The functional coating uses nano-siloxane coating, which has waterproof, anti-pollution and self-cleaning functions. This coating can effectively prevent the adhesion of water stains, oil stains and other substances, reducing the difficulty of maintenance and cleaning, and has excellent high temperature resistance and corrosion resistance, especially suitable for special environments such as kitchens and bathrooms.

[0026] Preparation and spraying technology of outer concrete The outer layer of ultra-high performance concrete uses a reasonable ratio of lightweight aggregate and traditional aggregate, adds steel fiber and carbon nanotubes as reinforcing materials, and is evenly sprayed on the surface of the base layer using a high-pressure spraying process.

[0027] Proportion of lightweight aggregate and traditional aggregate: Lightweight aggregate (such as expanded ceramsite and perlite) can effectively reduce the density of concrete without affecting the mechanical properties of concrete. Through reasonable proportion, both the strength of concrete and its lightweight characteristics can be ensured. The combination of traditional aggregate and lightweight aggregate further optimizes the overall performance of concrete.

[0028] Addition of steel fiber and carbon nanotubes: Steel fiber can improve the crack resistance, impact resistance and bending strength of concrete, enhance its toughness and reduce the occurrence of cracks. As a nano-level reinforcement material, carbon nanotubes can significantly improve the tensile strength and bending resistance of concrete and improve its durability with their extremely high specific surface area and excellent mechanical properties. The addition of both makes the outer layer of concrete show better performance when subjected to external loads.

[0029] Spraying process: Robot high-pressure spraying technology is used to spray ultra-high performance concrete evenly and tightly on the surface of the base layer. The spraying pressure is controlled at 120MPa and the spraying flow rate is controlled at 10L / min, which can ensure the uniformity and density of the concrete layer and reduce the defects and gaps that may appear during the construction process, thereby enhancing the structural stability and durability of the module.

[0030] Steam curing and natural drying process The sprayed modules need to be steam cured to ensure sufficient hydration of the concrete, and then naturally dried to improve its strength and stability.

[0031] Steam curing: Steam curing is a curing method that uses steam to provide humidity and heat, which can promote cement hydration reaction and significantly improve the early strength of concrete. This process can accelerate the curing process and ensure that the cement in ultra-high performance concrete is fully hydrated, thereby improving its durability and compressive strength.

[0032] Natural drying: After steam curing, the modules need to be dried naturally to remove excess moisture and ensure the long-term stability of the concrete. Natural drying not only prevents cracks on the concrete surface due to excessive moisture, but also helps the modules maintain stable physical and mechanical properties during long-term use.

[0033] Quality inspection and module forming After the curing and drying, the modules will enter the quality inspection stage to test their compressive strength, bending strength, waterproof performance, fire resistance, etc. to ensure that each module meets the design standards.

[0034] Importance of quality inspection: Through comprehensive inspection of the module, it can be ensured that it can meet the special needs of environments such as kitchens and bathrooms in actual use, including environmental challenges such as high humidity and fire sources. The module's compression resistance, bending resistance, fire resistance and waterproofness are key parameters to ensure its long-term stability and safety.

[0035] Example 1: Combination of calcium silicate board and ultra-high performance concrete 1. Preparation of base layer: Choose 3cm thick calcium silicate board and cut it into size of 60cm×60cm.

[0036] The surface was mechanically shot blasted at a speed of 5 m / s for 5 min to increase the surface roughness.

[0037] A layer of nanosiloxane coating is applied on the treated calcium silicate board, and the coating thickness is controlled at 0.5mm to ensure uniformity. The coating composition is: 60% nanosiloxane and 40% silane. After coating, it is cured at 50°C for 2 hours.

[0038] External concrete preparation: To prepare ultra-high performance concrete, the proportion of components is: Cement (CEM-I42.5): 30% Lightweight aggregate (expanded ceramsite): 25% Traditional aggregate (fine aggregate): 25% Steel fiber: 3% Carbon nanotubes: 2% Water: 15% A planetary mixer was used for stirring at a speed of 200 r / min for 10 min to ensure that the materials were evenly dispersed.

[0039] Spraying process: Use high-pressure spraying equipment for spraying, with the spraying pressure set to 120MPa and the spraying flow rate set to 10L / min. The spraying thickness is controlled at 2cm to ensure that the surface is flat and free of bubbles.

[0040] Maintenance and drying: After spraying, the module was placed in a steam curing room at a temperature of 70°C and a humidity of 90% for 6 hours.

[0041] After curing, dry naturally for 48 hours at an ambient temperature of 25°C and a humidity of 50%.

[0042] By using a combination of lightweight aggregates and nano-reinforced materials, the module's weight is reduced by 30% while maintaining strength.

[0043] The coating makes the module have good waterproof and anti-pollution properties, making it suitable for use in humid environments.

[0044] Example 2: Application of functional coatings and nano-enhanced materials 1. Base layer preparation: A 3 cm thick calcium silicate board with a size of 80 cm × 80 cm was used, and the surface was sandblasted with a sandblasting particle size of 0.2 mm and a duration of 3 minutes.

[0045] A functional coating was applied, the composition of which was: 40% nano-silicon dioxide, 30% silane, and 30% nano-aluminum oxide. The coating thickness was 0.8 mm and it was cured at 60°C for 3 hours.

[0046] Ultra-high performance concrete mix ratio: The ratio is: Cement (CEM-Ⅲ32.5): 35% Lightweight aggregate (perlite): 20% Traditional aggregate (fine aggregate): 25% Steel fiber: 4% Carbon nanotubes: 2% Water: 14% The stirring speed is 250 r / min and the stirring time is 12 minutes.

[0047] Spraying process: Robot high-pressure spraying technology is used, with a spray pressure of 130MPa, a spray flow rate of 12L / min, and a spray thickness of 2.5cm.

[0048] Maintenance and drying: Steam curing conditions: temperature 75°C, humidity 85%, time 5 hours.

[0049] Natural drying for 72 hours, ambient temperature 25°C, humidity 45%.

[0050] The functional coating provides excellent waterproof and self-cleaning effects, solving the problem of easy contamination on the surface of traditional modules.

[0051] The use of nano-reinforced materials improves the crack resistance and toughness of concrete and enhances the service life of the modules.

[0052] Example 3: Lightweight aggregate optimization and intelligent control 1. Base layer processing: A 3 cm thick calcium silicate board with a size of 100 cm × 100 cm was selected, and the surface was chemically etched with 5% hydrofluoric acid as the etching solution for 5 minutes.

[0053] Apply a layer of nano-siloxane coating with a thickness of 0.6 mm, and the coating composition is: 70% nano-siloxane and 30% silane.

[0054] Concrete preparation: The ratio is: Cement (CEM-I42.5): 28% Lightweight aggregate (expanded ceramsite): 15% Lightweight aggregate (perlite): 15% Traditional aggregate (fine aggregate): 25% Steel fiber: 3% Carbon nanotubes: 2% Water: 12% The stirring speed is 200r / min and the time is 15 minutes.

[0055] Spraying process: The spraying pressure is 120MPa, the flow rate is 10L / min, and the spraying thickness is 3cm.

[0056] The Internet of Things control system is used to monitor temperature and humidity during spraying to ensure uniformity of spraying.

[0057] Maintenance and drying: Steam curing conditions: temperature 80°C, humidity 90%, time 6 hours.

[0058] Natural drying for 48 hours, ambient temperature 30°C, humidity 40%.

[0059] The optimized ratio of lightweight aggregates significantly reduces the weight of the modules, making them easier to transport and install.

[0060] The application of intelligent monitoring system ensures the stability of the production process and reduces errors caused by human operation.

[0061] Example 4: Improvement of reinforcement materials and spraying process 1. Base layer processing: A 3 cm thick calcium silicate board with a size of 120 cm × 80 cm was used, and the surface was treated by a combination of chemical etching and mechanical shot blasting.

[0062] A composite coating of nano-siloxane and titanium dioxide is applied, with a thickness of 0.7 mm and coating composition: 50% nano-siloxane and 50% nano-titanium dioxide.

[0063] Concrete mix ratio: The ratio is: Cement (CEM-II42.5): 30% Lightweight aggregate (expanded ceramsite): 20% Traditional aggregate (fine aggregate): 25% Steel fiber: 3% Carbon nanotubes: 2% Water: 20% The stirring speed is 300r / min and the time is 10 minutes.

[0064] Spraying process: The spraying pressure is 135MPa, the flow rate is 15L / min, and the spraying thickness is 2.5cm.

[0065] During the spraying process, the nozzle angle is controlled at 45° to ensure the uniformity and density of the spray layer.

[0066] Maintenance and drying: Steam curing conditions: temperature 75°C, humidity 85%, time 8 hours.

[0067] Natural drying for 72 hours, ambient temperature 20°C, humidity 50%.

[0068] The application of composite coating significantly improves the waterproof, fireproof and antibacterial properties of the module.

[0069] By improving the reinforced materials and spraying process, the compression and bending resistance of the module has been improved by more than 20%, solving the problems of easy cracking and insufficient strength of traditional modules.

[0070] Comparative Example 1: Comparative Example without Nanocoating on Base Layer The difference between the embodiment 1 and the embodiment 1 is as follows: In this comparative example, the surface of the calcium silicate board is not coated with nano-siloxane coating, but directly coated with traditional waterproof coating, the coating thickness is 1mm, and the coating composition is mainly polyurethane. Different from Example 1, this comparative experiment ignores the advantages of nano-materials in waterproofing, antibacterial, high temperature resistance, etc.

[0071] Preparation steps: Base layer preparation: A 3cm thick calcium silicate board with a size of 60cm×60cm was selected.

[0072] The surface was sandblasted with a particle size of 0.3 mm and a duration of 3 minutes.

[0073] A layer of traditional polyurethane waterproof coating is applied on the surface of the treated calcium silicate board. The coating thickness is 1 mm and the coating drying time is 4 hours.

[0074] External concrete preparation: The concrete mix ratio is the same as that in Example 1, and the components are: Cement (CEM-I42.5): 30% Lightweight aggregate (expanded ceramsite): 25% Traditional aggregate (fine aggregate): 25% Steel fiber: 3% Carbon nanotubes: 2% Water: 15% Spraying process: The spraying pressure is 120 MPa, the spraying flow rate is 10 L / min, and the spraying thickness is 2 cm.

[0075] Maintenance and drying: After spraying, the module enters the steam curing stage with a curing temperature of 70°C, a humidity of 90%, and a time of 6 hours.

[0076] The drying phase lasted 48 hours at 25°C and 50% humidity.

[0077] Comparative Example 2: Comparative Example without Using Lightweight Aggregate The difference between the comparison and Example 2 is: In this comparative example, the concrete does not use lightweight aggregates (such as expanded ceramsite and perlite), but instead uses entirely traditional fine aggregates, resulting in a significant increase in the density of the concrete, and a different balance between strength and weight compared to the optimized lightweight aggregate ratio in Example 2.

[0078] Preparation steps: Base layer preparation: A 3 cm thick calcium silicate board with a size of 80 cm × 80 cm was selected, and the surface was sandblasted with a particle size of 0.3 mm and a treatment time of 5 minutes.

[0079] Apply a layer of traditional waterproof coating, which is a mixture of polyurethane and epoxy resin. The coating thickness is 1mm and the drying time is 6 hours.

[0080] External concrete preparation: The mix ratio is as follows, without using lightweight aggregate: Cement (CEM-Ⅲ32.5): 40% Traditional aggregate (fine aggregate): 55% Steel fiber: 3% Carbon nanotubes: 2% Water: 10% Spraying process: A spray pressure of 120 MPa, a spray flow rate of 10 L / min and a spray thickness of 2 cm were used.

[0081] Maintenance and drying: After spraying, the module enters the steam curing stage with a temperature of 75°C and a humidity of 90% for 6 hours.

[0082] The drying phase lasted 48 hours at an ambient temperature of 25°C and a humidity of 50%.

[0083] Comparative Example 3: Comparative Example without Using Steel Fiber and Carbon Nanotubes The difference between the embodiment 3 is as follows: The comparative example does not use steel fiber and carbon nanotubes, and the reinforcement effect of concrete is poor. Compared with Example 3, no reinforcement material is added, which may cause the module to have reduced performance in terms of crack resistance, impact resistance and bending resistance.

[0084] Preparation steps: Base layer processing: A 3 cm thick calcium silicate board with a size of 100 cm × 100 cm was selected, and the surface was sandblasted with a sandblasting particle size of 0.3 mm and a treatment time of 4 minutes.

[0085] A waterproof coating is applied, which is a composite coating of silane and epoxy resin with a coating thickness of 0.6mm.

[0086] Drying time is 4 hours, ensuring the coating forms good waterproof properties.

[0087] Concrete mix ratio: The proportions are as follows, without adding steel fibers and carbon nanotubes: Cement (CEM-I42.5): 35% Lightweight aggregate (expanded ceramsite): 20% Traditional aggregate (fine aggregate): 35% Water: 10% Spraying process: The spraying pressure is 130MPa, the spraying flow rate is 12L / min, and the spraying thickness is 3cm.

[0088] Maintenance and drying: After spraying, the module enters the steam curing stage with a curing temperature of 75°C and a humidity of 85% for 5 hours.

[0089] Natural drying for 72 hours, ambient temperature is 30°C, humidity is 45%.

[0090] Comparative Example 4: Comparative Example without Intelligent Monitoring System The difference between the embodiment 4 is as follows: This comparative example does not use an intelligent monitoring system and cannot adjust the production process in real time, which may lead to instability of parameters such as temperature and humidity during the production process. Compared with the intelligent monitoring of Example 4, the stability and consistency of production are poor.

[0091] Preparation steps: Base layer processing: A 3 cm thick calcium silicate board with a size of 120 cm × 80 cm was selected, and the surface was mechanically shot blasted with a particle size of 0.2 mm and a treatment time of 5 minutes.

[0092] Apply a layer of traditional waterproof coating, the coating composition is a mixture of polyurethane and silane, and the coating thickness is 0.7mm.

[0093] The coating cures within 6 hours to ensure its waterproofness.

[0094] Concrete mix ratio: The ratio is as follows: Cement (CEM-II42.5): 30% Lightweight aggregate (expanded ceramsite): 25% Traditional aggregate (fine aggregate): 30% Steel fiber: 3% Carbon nanotubes: 2% Water: 10% Spraying process: The spraying pressure is 120 MPa, the spraying flow rate is 10 L / min, and the spraying thickness is 2.5 cm.

[0095] During the spraying process, no intelligent monitoring system was used and the spraying process relied entirely on manual adjustment.

[0096] Maintenance and drying: After spraying, the module enters the steam curing stage with a curing temperature of 75°C and a humidity of 85% for 6 hours.

[0097] Natural drying for 72 hours, ambient temperature is 25°C, humidity is 50%.

[0098] Comparative Example 5: Comparative Example without Composite Coating The difference between the comparison and Example 2 is: This comparative example does not use a composite material coating, but only a single traditional waterproof coating, which fails to fully utilize the synergistic effect of nanomaterials and functional coatings, and may result in insufficient waterproof, antibacterial and surface cleaning performance.

[0099] Preparation steps: Base layer preparation: A 3-cm-thick calcium silicate board with a size of 80 cm × 80 cm was selected, and the surface was mechanically shot blasted with a particle size of 0.3 mm for a duration of 4 minutes.

[0100] Only one layer of traditional waterproof coating is applied, the coating thickness is 1mm, and the coating drying time is 6 hours.

[0101] External concrete preparation: The ratio is: Cement (CEM-Ⅲ32.5): 40% Lightweight aggregate (expanded ceramsite): 20% Traditional aggregate (fine aggregate): 25% Steel fiber: 3% Carbon nanotubes: 2% Water: 10% Spraying process: The spraying pressure is 120 MPa, the spraying flow rate is 10 L / min, and the spraying thickness is 2.5 cm.

[0102] Maintenance and drying: After spraying, the module enters the steam curing stage with a temperature of 75°C and a humidity of 90% for 6 hours.

[0103] Natural drying for 72 hours, ambient temperature 25°C, humidity 50%.

[0104] Experimental example Experimental Procedure Experimental Materials Experimental group (Example): B1: Optimized Nano-Coating B2: Optimize lightweight aggregate ratio B3: Optimizing Nano-Enhanced Materials B4: Optimize the spraying process Control group (comparison ratio): A1: No nano coating used A2: No lightweight aggregate used A3: No steel fiber and carbon nanotubes are used A4: No intelligent monitoring system is used Base Materials: Calcium silicate board (different thickness and surface treatment) Functional coating materials (nano-siloxane, silane, nano-titanium dioxide, etc.) Ultra-high performance concrete formulation (cement, lightweight aggregate, traditional aggregate, steel fiber, nano-reinforcement materials, etc.) Experimental equipment: Reaction rate tester Material Stability Analyzer High-precision temperature control equipment Microstructure Analyzer Experimental procedures 1. Base layer preparation Experimental Group: Use 3cm thick calcium silicate board, cutting size 60cm×60cm~120cm×80cm.

[0105] Improve surface roughness by mechanical shot blasting, sand blasting or chemical etching.

[0106] Apply different nano-functional coatings (such as siloxane, silane, nano-titanium dioxide, etc.) to form a waterproof and fireproof layer.

[0107] Control group: Use traditional waterproof coatings (such as polyurethane, epoxy resin) and ignore the advantages of nanomaterials.

[0108] Ultra-High Performance Concrete (UHPC) Formulation Experimental Group: Optimize the mix ratio, such as using lightweight aggregates (expanded ceramsite, perlite) to reduce density.

[0109] Nano-reinforced materials (carbon nanotubes, nano-silicon) are used to improve crack resistance and toughness.

[0110] The stirring parameters were adjusted, using a planetary mixer with a rotation speed of 200-300 r / min and a time of 10-15 minutes.

[0111] Control group: Only conventional aggregates are used, no lightweight aggregates or nano-reinforcements.

[0112] Spraying process Experimental Group: High-pressure spraying equipment, spray pressure 120135MPa, spray flow rate 1015L / min.

[0113] Adopt intelligent monitoring system to adjust spraying parameters in real time to ensure uniformity and density.

[0114] Control group: No intelligent monitoring system is used, the spraying process relies on manual operation, and the uniformity is poor.

[0115] Curing and drying Experimental Group: Steam curing (temperature 70-80°C, humidity 85-90%, time 5-8 hours).

[0116] Natural drying (ambient temperature 2530°C, humidity 4050%, time 48~72 hours).

[0117] Control group: Traditional natural drying method does not optimize curing conditions.

[0118] Experimental data sample Compressive strength (MPa) Flexural strength (MPa) Water absorption (%) Density (kg / m³) Mass reduction (%) Comparative Example A1 85.3±2.1 9.1±0.4 6.5 2200 0 Comparative Example A2 78.±2.0 8.3±0.5 7.2 2450 - Comparative Example A3 81.1±1.8 8.7±0.3 6.8 2300 - Example B1 92.7±2.4 10.5±0.6 3.8 1800 30 Example B2 95.2±1.9 11.2±0.5 4 1750 32 Example B3 94.8±2.1 11.0±0.4 3.9 1780 31 The experimental results clearly show the significant difference between the embodiment and the comparative example. The embodiment uses nano-functional coating, lightweight aggregate, and nano-reinforced material, and has greatly optimized the compressive strength, flexural strength, water absorption, density and other indicators. Especially when the density is reduced, the mechanical properties still remain at a high level, indicating the effectiveness of the optimization scheme of the present invention.

[0119] From the perspective of microscopic mechanism, the introduction of nano-reinforced materials significantly improves the uniformity of the material, reduces the formation of microcracks, and improves the flexural strength. At the same time, the optimization of lightweight aggregates not only reduces the overall density, but also improves the durability of the material, making it suitable for a wider range of construction application scenarios.

[0120] Data trends show that the optimized spraying process and intelligent monitoring system ensure the uniformity and stability of the material, and the error is significantly reduced compared to the traditional manual adjustment method. The innovativeness of this technical path makes it difficult for traditional processes to predict the final optimization degree of this invention, further proving its leading role in the industry.

[0121] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A lightweight integrated kitchen and bathroom module, characterized in that: include: The base layer is made of calcium silicate board; The outer layer is made of ultra-high performance concrete, which is fixed on the surface of the base layer through a spraying process to form an integral structure; The base layer and the outer layer are fixed by a high-strength bonding process.

2. A lightweight integrated kitchen and bathroom module according to claim 1, characterized in that: The calcium silicate board of the base layer has a thickness of 3 cm. The surface of the calcium silicate board is mechanically shot blasted and coated with a layer of functional coating, and the functional coating has waterproof, fireproof and crack-resistant properties.

3. A lightweight integrated kitchen and bathroom module according to claim 1, characterized in that: The ultra-high performance concrete of the outer layer includes a reasonable ratio of lightweight aggregate and traditional aggregate, wherein the lightweight aggregate is expanded ceramsite or perlite.

4. A lightweight integrated kitchen and bathroom module according to claim 3, characterized in that: A reinforcing material is added to the ultra-high performance concrete of the outer layer, and the reinforcing material is steel fiber, carbon nanotube or a combination of the two.

5. The lightweight integrated kitchen and bathroom module according to claim 1, characterized in that: The base layer and the outer layer are bonded by a high-pressure spraying process.

6. A lightweight integrated kitchen and bathroom module according to claim 1, characterized in that: The surface of the base layer is coated with a nano-siloxane coating.

7. The lightweight integrated kitchen and bathroom module according to claim 1, characterized in that: The outer layer of ultra-high performance concrete is subjected to steam curing treatment at a curing temperature of 70°C, a relative humidity of 90%, and a curing time of 6 hours.

8. A method for preparing a lightweight integrated kitchen and bathroom module, used for a lightweight integrated kitchen and bathroom module according to claims 1-7, characterized in that: The following steps are involved: S1. Select calcium silicate board as the base layer, perform mechanical shot blasting and chemical coating on the surface of the calcium silicate board to form a waterproof and fireproof functional coating; S2. Prepare ultra-high performance concrete, add lightweight aggregate, traditional aggregate and nano-reinforcement materials, and mix thoroughly; S3, spraying the prepared ultra-high performance concrete evenly on the surface of the calcium silicate board through a spraying process to form an outer layer; S4. Steam cure the sprayed module and dry it naturally after curing.

9. The method for preparing a lightweight integrated kitchen and bathroom module according to claim 8, characterized in that: The spraying process adopts robot high-pressure spraying technology, the spraying pressure is 120MPa, and the spraying flow rate is 10L / min.

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