Multifunctional integrated light prefabricated roof panel and modular manufacturing method thereof

Abstract

The invention relates to the technical field of prefabricated roof panels, in particular to a multifunctional integrated light prefabricated roof panel and a modular manufacturing method thereof.The light prefabricated roof panel comprises a heat preservation plate and a roof panel body, the heat preservation plate is arranged on the roof panel body, and a plurality of through holes are formed in a panel body of the roof panel body; a plurality of through holes are formed in the roof board, heating chips are arranged in the through holes respectively and connected through copper wires, the copper wires are connected with a storage battery through connecting rings arranged at the ends of the copper wires, and the heating chips emit heat in the roof board under the energy supply of the storage battery. The prefabricated roof panel has the advantages that through the synergistic effect of the heating cell arranged in the hole of the wall body and the solar power generation panel, the roof panel achieves the self-heat-generation function, and the prefabricated roof panel meets the multifunctional integration requirements of heat preservation, light weight, sound insulation, fire prevention and self-heat-generation.

Description

Technical Field

[0001] The invention relates to the technical field of prefabricated roof panels, and in particular to a multifunctional integrated lightweight prefabricated roof panel and a modular manufacturing method thereof. Background Art

[0002] In high-cold areas, prefabricated public buildings face severe insulation and energy-saving challenges. Traditional building materials and construction methods are often difficult to effectively cope with extreme low temperature environments, resulting in serious heat loss inside the building and huge energy consumption. In order to solve this problem, people have begun to explore new lightweight prefabricated roof panels and their modular manufacturing methods, aiming to improve the thermal insulation performance and energy efficiency of buildings. Most of the existing lightweight prefabricated roof panels use a single insulation material, such as rock wool boards, glass wool boards, etc. Although they have a certain thermal insulation effect, they often have problems such as heavy weight, inconvenient construction, and unstable thermal insulation performance. Especially in high-cold areas, the thermal insulation effect of these materials is often difficult to meet actual needs, resulting in large temperature fluctuations inside the building, affecting the comfort of living and working. In addition, traditional prefabricated roof panels often use more complex processes and a large amount of energy consumption during the manufacturing process, which is not conducive to environmental protection and sustainable development. At the same time, these roof panels are also prone to cracking and deformation during use, affecting the overall durability and safety of the building. Summary of the invention

[0003] The purpose of the present invention is to provide a multifunctional integrated lightweight prefabricated roof panel and a modular manufacturing method thereof according to the above-mentioned deficiencies of the prior art, through the synergistic effect of materials such as cementitious materials, aggregates and alkali activators, so that the dry density of the roof panel reaches 650-700kg / m 3 , 28-day compressive strength is 6.0-7.0MPa, the average sound insulation of the roof panel is 30dB, the fire resistance of the roof panel in a fire is more than one hour, and the heat transfer coefficient of the roof panel is less than 1.5. By setting the heating core and the solar panel in the hole of the wall, the roof panel can realize the self-heating function, so that the prefabricated roof panel meets the requirements of thermal insulation, light weight, sound insulation, fire prevention, and self-heating.

[0004] The purpose of the present invention is achieved by the following technical solutions: A multifunctional integrated lightweight prefabricated roof panel, characterized in that: the lightweight prefabricated roof panel comprises an insulation board and a roof panel, the insulation board is arranged on the roof panel, a plurality of through holes are arranged inside the plate body of the roof panel, a heating chip is respectively arranged inside the plurality of through holes, the heating chips are connected by copper wires, the copper wires are connected to a battery via a connecting ring arranged at the end thereof, and the heating chip generates heat inside the roof panel under the energy supply of the battery.

[0005] The roof panel comprises the following components in parts by weight: 48-55 parts of cementitious material, 2.5-2.9 parts of fine aggregate, 41-48 parts of artificial aggregate, 1.2-1.4 parts of water reducer, 18-20 parts of alkali activator, 6-9.6 parts of water, and 0.1-0.3 parts of anti-cracking fiber; wherein the cementitious material is composed of fly ash, slag, and silica fume.

[0006] The mass percentage of the slag in the cementitious material is 35%-45%.

[0007] The fine aggregate is all expanded perlite.

[0008] The artificial aggregate is a sintering-free geopolymer foam artificial aggregate made of foam balls as cores and geopolymer as shells, and the particle size of the aggregate is 5-15 mm.

[0009] The water reducing agent is a polycarboxylic acid water reducing agent.

[0010] The alkaline activator is a solution prepared by mixing sodium hydroxide and sodium silicate in a certain proportion.

[0011] The anti-cracking fiber is polypropylene anti-cracking fiber.

[0012] The heating chip has a resistance wire inside, and the resistance wires of each heating chip are connected in parallel.

[0013] The storage battery is connected to a photovoltaic panel, and the photovoltaic panel is arranged on the thermal insulation board.

[0014] The thermal insulation board is a polystyrene foam board.

[0015] A modular manufacturing method for the above-mentioned multifunctional integrated lightweight prefabricated roof panel, characterized in that the manufacturing method of the roof panel comprises the following steps: S1. Stirring the cementitious material and anti-cracking fiber required for the batching together for 2-3 minutes, then adding the artificial aggregate moistened with clean water and stirring for 2-3 minutes, and then adding the alkali activator, water and water reducing agent required for the batching, and continuing to stir for 3-4 minutes to obtain a slurry mixture; wherein the cementitious material is composed of fly ash, slag and silica fume; S2, add the light aggregate moistened with clean water to the slurry mixture obtained in step S1 and stir for 2-4 minutes, then inject it into the roof panel forming machine through a grouting pump for forming, wait for the concrete to solidify and harden for 4-6 hours before demoulding, and the roof panel is obtained after demoulding, so that the dry density of the roof panel reaches 650-700Kg / m 3 The 28-day compressive strength is 6.0-7.0MPa, the average sound insulation of the roof panel is 30dB, the fire resistance of the roof panel in a fire is more than one hour, and the heat transfer coefficient of the roof panel is less than 1.5.

[0016] The advantages of the present invention are: 1) By using polystyrene foam board as the insulation layer and setting a heating chip inside the roof panel, a double insulation effect is achieved. This design not only improves the thermal insulation capacity of the building, but also provides additional heat for the building in cold weather, effectively reducing energy consumption. Compared with traditional insulation materials, the roof panel of the present invention is more stable and reliable in insulation performance, and can meet the strict requirements of thermal insulation performance in high-cold areas.

[0017] 2) The use of industrial waste such as fly ash, slag, and silica fume as the main cementitious materials not only reduces production costs, but also realizes the recycling of resources, which is beneficial to environmental protection and sustainable development. At the same time, by optimizing the proportion of ingredients and the process flow, the roof panel of the present invention has also improved mechanical properties, making it more durable and safer.

[0018] 3) Through standardized and modular design, the production and installation of roof panels can be completed quickly and efficiently, greatly shortening the construction period and reducing construction costs. At the same time, the modular design also makes it more convenient to repair and replace the roof panels, improving the overall maintainability of the building.

[0019] 4) Through the connection of heating chip and copper wire, the indoor temperature is intelligently regulated. This design not only improves the living comfort, but also further reduces energy consumption and realizes the concept of green building. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 This is a graph showing the variation of thermal conductivity of the present invention; Figure 2 It is a schematic diagram of the layered structure of the present invention; Figure 3 It is a schematic diagram of the overall structure of the present invention; Figure 4 This is a schematic diagram of the structure of the heating core in the present invention; Figure 5 It is a schematic diagram of the resistance wire structure in the present invention; Figure 6 It is a schematic diagram of the connection structure of the present invention. DETAILED DESCRIPTION

[0021] The features of the present invention and other related features are further described in detail below through embodiments in conjunction with the accompanying drawings to facilitate understanding by those skilled in the art: like Figure 1-6 As shown, the marks 1-9 in the figure respectively represent: insulation board 1, roof panel 2, hole 3, heating chip 4, copper wire 5, connecting ring 6, resistance wire 7, photovoltaic panel 8, and battery 9.

[0022] Embodiment 1: Figures 1 to 6 As shown, in this embodiment, the multifunctional integrated lightweight prefabricated roof panel includes an insulation board 1 and a roof panel 2, wherein the insulation board is arranged on the roof panel 2 to play a role of insulation, thereby improving the thermal insulation capacity of the building. There are through holes 3 inside the roof panel 2. Several holes 3 are respectively provided with heating chips 4, and each heating chip 4 is connected by a copper wire 5. The copper wire 5 is connected to a battery 9 through a connecting ring 6 arranged at its end, and the battery 9 is connected to a photovoltaic panel 8, and the photovoltaic panel 8 is arranged on the insulation board 1. There is a resistance wire 7 inside the heating chip 4, and the resistance wires 7 of each heating chip 4 are connected in parallel to achieve an efficient and stable heating function. The insulation board 1 is a polystyrene foam board.

[0023] When in use, the photovoltaic panel 8 converts solar energy into electrical energy through mature solar energy conversion technology and stores it inside the battery 9. The resistance wire 7 of the heating chip 4 generates heat inside the hole 3 of the roof panel 3 under the power supply of the battery 9, so that the roof panel 3 as a whole is heated. In conjunction with the insulation board 1, a double insulation effect is achieved, and additional heat can be provided for the building in cold weather, effectively reducing energy consumption.

[0024] In this embodiment, holes 3 are provided in the roof panel 2 and heating chips 4 are arranged in the holes 3, so that heat can be uniformly transferred from the holes 3 to the surrounding roof panel 2 materials. Compared with the traditional single-sided heating or local heating method, this method can make the overall temperature distribution of the roof panel more uniform, reduce the uneven thermal expansion and contraction of the material caused by local overheating or overcooling, thereby reducing the possibility of cracks, deformation and other problems of the roof panel 2 due to temperature stress, which helps to extend the service life of the roof panel.

[0025] In some humid environments, roof panels easily absorb moisture from the air. Long-term humid conditions can lead to problems such as material corrosion and mold. The hole heating method can increase the temperature of the roof panels to a certain extent, accelerate the evaporation of moisture in the roof panel materials, and keep the roof panels dry. A dry environment can slow down the corrosion rate of the materials, improve the durability of the roof panels, and extend their service life.

[0026] The roof panel 2 is also provided with an insulation board 1, and the holes 3 are heated so that the insulation material can function better. The uniform heat distribution can keep the insulation board 1 itself within a suitable temperature range, avoiding the decrease of insulation performance due to too low temperature, or the influence of the stability of the insulation material due to too high temperature. At the same time, the heated roof panel 2 can reduce the generation of condensed water inside the insulation material and improve the overall performance of the insulation system.

[0027] In addition, roof panels are susceptible to frost heave in winter. The hole heating method can provide heat to the roof panels in a low temperature environment, increase the temperature of the roof panels, prevent the moisture in the roof panel material from freezing and expanding, thereby avoiding damage to the roof panels caused by frost heave, and can improve the reliability and stability of the roof panels in winter.

[0028] In specific use, the hole heating method can be automatically controlled by cooperating with a temperature sensor and a controller. For example, when the temperature sensor detects that the ambient temperature is lower than the set threshold, the signal is transmitted to the controller, and the controller controls the heating chip 4 to start working for heating, thereby realizing accurate control of the heating temperature and time according to actual needs, avoiding unnecessary energy waste. At the same time, since the heat is emitted from the inside of the roof panel 2, the heat loss to the surrounding environment can be reduced, and the energy utilization efficiency can be improved. This not only helps to reduce energy consumption, but also meets the requirements of energy saving and environmental protection.

[0029] In this embodiment, the roof panel 2 comprises the following components in parts by weight: 48-55 parts of cementitious material, 2.5-2.9 parts of fine aggregate, 41-48 parts of artificial aggregate, 1.2-1.4 parts of water reducing agent, 18-20 parts of alkali activator, 6-9.6 parts of water, and 0.1-0.3 parts of anti-cracking fiber.

[0030] Among them, the cementitious material is composed of fly ash, slag and silica fume; it is a cement-free cementitious material with the characteristics of green and environmental protection, and the geopolymer has the characteristics of light weight and early strength, which has higher early strength for prefabricated components and is conducive to lifting.

[0031] The mass percentage of slag in the cementitious material is 35%-45%. All fine aggregates are expanded perlite, which improves the thermal insulation performance and lightweight characteristics of the wall. The artificial aggregate is a sinter-free geopolymer foam artificial aggregate made of foam balls as cores and geopolymer as shells, and the particle size of the aggregate is 5-15mm; it not only reduces the weight of the wall, but also has good mechanical properties and thermal insulation properties. The water reducer is a polycarboxylic acid water reducer. The alkali activator is a solution made of sodium hydroxide and sodium silicate in proportion. The anti-cracking fiber is a polypropylene anti-cracking fiber, which enhances the anti-cracking performance of the wall, especially the roof panel 2 generates temperature stress due to heating to produce cracks, deformation and other problems, and improves the durability of the wall.

[0032] In this embodiment, the synergistic effect between the heating chip 4 and the roof panel 2 material is integrated. On the one hand, the heating effect of the heating chip 4 is guaranteed through the system design of the roof panel 2 material. On the other hand, the temperature stress generated by the heating chip 4 due to the heat is resisted to a certain extent, thereby improving the structural performance of the roof panel 2.

[0033] The roof panel 2 in this embodiment includes the following steps during modular manufacturing: Weigh the raw materials by weight: 30.8 parts of fly ash, 18.0 parts of slag, 2.6 parts of silica fume, 2.6 parts of fine aggregate, 45.5 parts of artificial aggregate, 1.3 parts of water reducer, 19.3 parts of alkali activator, 0.1 parts of anti-cracking fiber, and 9.0 parts of water.

[0034] After the raw materials are weighed, the preparation method is as follows: 1) The cementitious material and anti-cracking fiber required for the batch are put together and stirred for 2-3 minutes, and then the artificial aggregate moistened with clean water is added and stirred for 2-3 minutes, and then the alkali activator, water and water reducing agent required for the batch are added thereto, and the stirring is continued for 3-4 minutes to obtain a slurry mixture; wherein the cementitious material is composed of fly ash, slag and silica fume; 2) Add the light aggregate moistened with clean water to the slurry mixture obtained in step 1) and stir for 2-4 minutes, then inject it into the pre-hole roof panel forming machine through a grouting pump for forming, wait for the concrete to solidify and harden for 4 hours before demoulding, and the prefabricated roof panel is obtained after demoulding. The dry density of the roof panel reaches 650kg / m 3 The 28-day compressive strength is 6.0MPa, the average sound insulation of the roof panel is 30dB, the fire resistance of the roof panel in a fire is up to 1.5 hours, and the heat transfer coefficient of the roof panel is 1.4, which meets the multifunctional integrated requirements of prefabricated roof panels for thermal insulation, light weight, sound insulation and fire prevention.

[0035] When applied, this embodiment includes the following installation steps: 1) A heating chip 4 connected in series by a copper wire 5 is placed in the hole 3 of the roof panel 2, and a connecting ring 6 is provided at one end of the copper wire 5 away from the heating chip 4.

[0036] 2) When the house is constructed, the photovoltaic panel 8 is installed on the roof panel 2 where the heating chip 4 is installed in step 2), and connected to the battery 9, and the battery 9 is connected to the connecting ring 6 of the heating chip 4.

[0037] Example 2: The difference between this example and Example 1 is that the material composition of the roof panel 2 is different, including 26.4 parts of fly ash, 23.7 parts of slag, 2.64 parts of silica fume, 2.64 parts of fine aggregate, 46.9 parts of artificial aggregate, 1.4 parts of water reducer, 19.8 parts of alkali activator, 0.1 parts of anti-cracking fiber, and 6.6 parts of water.

[0038] The dry density of the roof panel 2 obtained by manufacturing reaches 680kg / m 3 The 28-day compressive strength is 6.2MPa, the average sound insulation of the roof panel is 30dB, the fire resistance of the roof panel in a fire is up to 1.6 hours, and the heat transfer coefficient of the roof panel is 1.42, which meets the multifunctional integrated requirements of prefabricated roof panels for thermal insulation, light weight, sound insulation and fire prevention.

[0039] Example 3: The difference between this example and Example 1 and Example 2 is that the material composition of the roof panel 2 is different, including 25.8 parts of fly ash, 23.2 parts of slag, 2.57 parts of silica fume, 2.57 parts of fine aggregate, 45.6 parts of artificial aggregate, 1.34 parts of water reducer, 19.3 parts of alkali activator, 0.1 part of anti-cracking fiber, and 9.0 parts of water.

[0040] The dry density of the manufactured roof panel reaches 670kg / m 3 The 28-day compressive strength is 6.1MPa, the average sound insulation of the roof panel is 30dB, the fire resistance of the roof panel in a fire is 1.55 hours, and the heat transfer coefficient of the roof panel is 1.42, which meets the multifunctional integrated requirements of prefabricated roof panels for thermal insulation, light weight, sound insulation and fire prevention.

[0041] Figure 1 The variation of thermal conductivity of prefabricated roof panels with increasing temperature is demonstrated.

[0042] Although the above embodiments have described in detail the concepts and embodiments of the present invention with reference to the accompanying drawings, ordinary technicians in this field can recognize that various improvements and changes can still be made to the present invention without departing from the scope of the claims, so they are not described one by one here.

Claims

1. A multifunctional integrated lightweight prefabricated roof panel, characterized in that: The lightweight prefabricated roof panel includes an insulation board and a roof panel, wherein the insulation board is arranged on the roof panel, a plurality of through holes are arranged inside the plate body of the roof panel, heating chips are respectively arranged inside the plurality of through holes, the heating chips are connected by copper wires, the copper wires are connected to a battery via a connecting ring arranged at the end thereof, and the heating chip generates heat inside the roof panel under the energy supply of the battery.

2. The multifunctional integrated lightweight prefabricated roof panel according to claim 1, characterized in that: The roof panel comprises the following components in parts by weight: 48-55 parts of cementitious material, 2.5-2.9 parts of fine aggregate, 41-48 parts of artificial aggregate, 1.2-1.4 parts of water reducer, 18-20 parts of alkali activator, 6-9.6 parts of water, and 0.1-0.3 parts of anti-cracking fiber; wherein the cementitious material is composed of fly ash, slag, and silica fume.

3. The multifunctional integrated lightweight prefabricated roof panel according to claim 2, characterized in that: The mass percentage of the slag in the cementitious material is 35%-45%.

4. The multifunctional integrated lightweight prefabricated roof panel according to claim 1, characterized in that: The heating chip has a resistance wire inside, and the resistance wires of each heating chip are connected in parallel.

5. The multifunctional integrated lightweight prefabricated roof panel according to claim 1, characterized in that: The storage battery is connected to a photovoltaic panel, and the photovoltaic panel is arranged on the thermal insulation board.

6. The multifunctional integrated lightweight prefabricated roof panel according to claim 1, characterized in that: The thermal insulation board is a polystyrene foam board.

7. A modular manufacturing method for the multifunctional integrated lightweight prefabricated roof panel according to any one of claims 1 to 6, characterized in that: The manufacturing method of the roof panel comprises the following steps: S1. Stirring the cementitious material and anti-cracking fiber required for the batching together for 2-3 minutes, then adding the artificial aggregate moistened with clean water and stirring for 2-3 minutes, and then adding the alkali activator, water and water reducing agent required for the batching, and continuing to stir for 3-4 minutes to obtain a slurry mixture; wherein the cementitious material is composed of fly ash, slag and silica fume; S2, adding the light aggregate moistened with clean water to the slurry mixture obtained in step S1 and stirring for 2-4 minutes, then injecting it into the roof panel forming machine through a grouting pump for forming, and demoulding after the concrete solidifies and hardens for 4-6 hours, and the roof panel is obtained after demoulding.

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