Preparation method of novel insulation board, production method of prefabricated sandwich insulation shear wall and shear wall production line

Abstract

The invention discloses a preparation method of a novel insulation board, a production method of a prefabricated sandwich insulation shear wall and a shear wall production line, relates to the field of shear wall production, and aims to solve the problems of long production period and many insulation layer apertures in the prior art. The outer page layer and the inner page layer are assembled in parallel at the same time, split bolts are not used any more, and when the double-layer heat preservation plate is used, staggered joint laying is conducted. By integrally manufacturing the insulation board and the connecting piece, punching can be avoided in the shear wall production process, the number of holes formed in an insulation layer is reduced, preformed holes of split bolts are omitted, the continuity of a super-thick insulation system is reserved, and the problem of cold and hot bridges is solved; the problem that the heat work performance of the wallboard is reduced due to heat insulation board gaps, board holes and connecting piece penetrating holes is solved; the mode that the PCF board and the inner leaf board are produced and then assembled at the same time is provided, and the production efficiency of the prefabricated sandwich heat preservation wallboard is greatly improved.

Description

Technical Field

[0001] The present invention relates to the technical field of shear wall production, and specifically to a preparation method of a new type of insulation board, a production method of a precast sandwich insulation shear wall, and a shear wall production line. Background Art

[0002] Precast sandwich insulation shear walls are widely used in the construction field. As shown in the structure of the precast shear wall and its production method in Chinese Patent CN104110095A, it includes an inner leaf layer, an outer leaf layer, and an insulation layer, and there are also connectors connecting the three layers.

[0003] During the production process of precast sandwich insulation shear walls, ultra-long FRP connectors are required. In the existing production process of precast shear walls, when the concrete of the outer leaf layer has not yet solidified, holes need to be drilled in the insulation layer, the connectors are inserted and then inserted into the concrete of the outer leaf layer, and then foaming glue is filled at the joint of the connector and the hole in the insulation layer. This method not only makes the connection of the connectors complex, but also poses high requirements for construction operations, especially the hole size and the filling of foaming glue. If the hole is too small, the connector cannot pass through; if the hole is too large or the foaming glue is not filled properly, the insulation effect of the insulation layer will be reduced; and the existing production cycle of precast sandwich insulation shear walls is relatively long. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the existing defects and provide a preparation method of a new type of insulation board, a production method of a precast sandwich insulation shear wall, and a shear wall production line, which can effectively solve the problems in the background art.

[0005] In order to achieve the above purpose, the present invention first discloses a preparation method of a new type of insulation board. The technical solution adopted is as follows:

[0006] Step 1: After the raw materials are pretreated, they are put into an extruder for melting.

[0007] Step 2: The melted material is cooled to the extrusion temperature.

[0008] Step 3: The melted material is extruded into a mold for cooling and forming.

[0009] In the said Step 3, positioning holes are opened on the mold. After the connectors are inserted into the positioning holes, the melted material is extruded into the mold. The melted material and the part of the connectors in the mold are in full contact. After the melted material is cooled and formed, it becomes an integral body with the connectors. After cooling, it is taken out of the mold for shaping. This method can make the connectors and the insulation board into an integral body, so that during the production process, it is possible to avoid drilling holes in the insulation board to penetrate the connectors, thus making it easier to control the subsequent assembly quality. The connectors are made of high heat-resistant materials to ensure that the melted material will not soften or melt the connectors.

[0010] As a preferred technical solution of the present invention, in step 3, the main body of the connecting member is a cross member. There are a first through slot and a second through slot at both ends of the cross member for the anti-pulling rod to pass through. There is a reinforcement plate perpendicular to the cross member in the middle of the cross member. When installing the connecting member in the mold, the reinforcement plate is located in the mold. The reinforcement plate can increase the anti-pulling performance between the cross member and the thermal insulation layer.

[0011] The present invention also discloses a production method of a precast sandwich thermal insulation shear wall using the thermal insulation board prepared by the above-mentioned thermal insulation board preparation method. The adopted technical solution is as follows:

[0012] Step 1: Assemble the outer leaf mold and the window opening mold on the first mold table. There are through rod holes opened on the outer leaf mold, and a pouring port is also arranged on the outer leaf mold; apply a release agent on the outside of the outer leaf mold.

[0013] Step 2: Load a steel mesh into the outer leaf mold; there are slots on the steel mesh, and there are third through slots on the slots corresponding to the position and matching the size of the first through slot of the connecting member used in the thermal insulation board prepared by the preparation method of the new thermal insulation board.

[0014] Step 3: Fix and install the embedded parts of the outer leaf layer.

[0015] Step 4: Uniformly distribute concrete into the outer leaf mold and vibrate it; the height of the concrete distribution shall not be higher than the lowest point of the third through slot port of the slot to prevent the concrete from entering the third through slot and affecting the plugging operation of the connecting member during subsequent assembly operations.

[0016] Step 5: Assemble the thermal insulation layer on the second mold table. The thermal insulation board used for the thermal insulation layer is a combination of a common thermal insulation board and the thermal insulation board prepared by the above-mentioned preparation method of the new thermal insulation board; use the new thermal insulation board at the parts where the connecting rod needs to be set, and use the common thermal insulation board prepared by the existing preparation method, that is, the thermal insulation board without the connecting rod, at other parts.

[0017] Step 6: Take out the pre-assembled thermal insulation layer in step 5 from the thermal insulation board side mold as a whole and put it into the outer leaf mold. When putting it in, make the connecting member installed on the thermal insulation board enter the slot.

[0018] Step 7: Insert a first anti-pulling rod into the first through slot and the third through slot and fill the outer leaf mold with concrete and vibrate it; the first anti-pulling rod can improve the anti-pulling performance between the connecting member and the outer leaf layer, and further improve the anti-pulling performance between the thermal insulation layer and the outer leaf layer; secondary pouring of concrete in the outer leaf mold can make the outer leaf layer finally formed and make the connecting member and the first anti-pulling rod become an integral body.

[0019] Step 8: Assemble the inner leaf mold on the third mold table and accept it.

[0020] Step 9, tying the steel bar skeleton in the inner leaf mold assembled in step 8;

[0021] Step 10, installing the embedded parts and anti-pulling steel bars of the inner leaf layer;

[0022] Step 11, inserting a second anti-pullout rod into a second through groove of the connecting piece of the thermal insulation layer;

[0023] Step 12, integrally assembling and connecting the inner leaf mold and the steel bar skeleton with the outer leaf mold, ensuring that the steel bar skeleton avoids the connecting piece and the second anti-pullout rod;

[0024] Step 13, installing the embedded tooling on the inner leaf mold, and then installing the internal thread sleeve;

[0025] Step 14, spreading concrete and vibrating it with a vibrating rod; this concrete spreading can pour the inner leaf layer while pouring the connecting piece and the second anti-pullout rod into a whole, thereby improving the anti-pullout effect between the insulation layer and the inner leaf layer;

[0026] Step 15, leveling and initial plastering of the wallboard surface, and processing of grooves;

[0027] Step 16, maintenance;

[0028] Step 17, demoulding;

[0029] Step 18, sawing the first anti-pullout rod protruding from the side surface of the outer blade layer, and trimming the side surface of the outer blade layer;

[0030] Step 19, finished product inspection;

[0031] Step 20, storage.

[0032] As a preferred technical solution of the present invention, in step 5, the insulation boards are first arranged and numbered according to the arrangement. When assembling, the insulation boards are extruded and laid in a clockwise direction according to the numbers to ensure that the gap is less than 1 mm.

[0033] As a preferred technical solution of the present invention, in step 7, the first anti-pull-out rod is inserted into the outer leaf mold from the rod hole, and the first anti-pull-out rod is inserted into the first through groove of the connecting piece and the third through groove of the slot; then the outer leaf mold is filled with concrete through the pouring port.

[0034] As a preferred technical solution of the present invention, a plugging cap is installed on the inner side of the rod penetration hole of the outer blade mold; in the step 7, the outer blade mold is first filled with concrete through the pouring port, and before the concrete initially sets, the first anti-pullout rod is inserted from the rod penetration hole, the plugging cap is rammed into the concrete, and the first anti-pullout rod is continued to be inserted so that it passes through the first penetration groove of the connecting piece and the third penetration groove of the slot.

[0035] As a preferred technical solution of the present invention, before pouring concrete, a pressing plate is used to press the thermal insulation layer from above the thermal insulation layer to prevent it from floating and ensure the fixed position of the thermal insulation layer; in the step 12, the pressing plate on the thermal insulation layer is removed first, and then the integral combined connection of the inner leaf mold, the steel bar framework and the outer leaf mold is carried out to avoid interference of the pressing plate on the subsequent combined connection.

[0036] As a preferred technical solution of the present invention, in the step 9, the binding sequence of the steel bar framework is the upper beam steel bars of the window, the column steel bars beside the window, and the wall steel bars under the window, and the column steel bars beside the window are wrapped outside the beam bars; a weight reduction plate is placed before the binding of the steel bar mesh plate in the inner layer of the wall steel bars under the window.

[0037] As a preferred technical solution of the present invention, the step 5 is carried out synchronously with the steps 1-4; the steps 8-10 are carried out synchronously with the steps 1-7. Parallel operation of multiple lines can significantly shorten the production cycle.

[0038] The present invention also discloses a production line applicable to the above production method. The adopted technical solution is that it includes a PCF board production line, an inner leaf board production line, an assembly line and a post-treatment line; the PCF board production line includes an outer leaf mold assembly station, and behind the outer leaf mold assembly station, there are a demoulding agent coating station, an outer leaf steel bar assembly station, a reserved embedding intelligent guiding station and a concrete intelligent supply and precise cloth-feeding station; behind the concrete intelligent supply and precise cloth-feeding station, it is connected to the thermal insulation board installation station through a mold table ferry station, and behind the thermal insulation board installation station, there are an anti-pulling rod piercing and outer leaf mold filling station, an assembly and pouring and vibrating station and a plastering station of the assembly line, and behind the plastering station is the post-treatment line; a thermal insulation layer assembly station is arranged in parallel with the thermal insulation board installation station, and an inner leaf mold and steel bar installation station is arranged in parallel with the assembly and pouring and vibrating station; it also includes a mobile mold table and a fixed mold table. The mobile mold table is the main operation mold table and circulates among the PCF board production line, the inner leaf board production line, the assembly line and the post-treatment line; the fixed mold table is used for assembling the inner leaf mold at the inner leaf mold and steel bar installation station; there are three-dimensional laser projection systems at the outer leaf steel bar assembly station and the reserved embedding intelligent guiding station, which can accurately project the positions of the components to be assembled such as steel bars and embedded parts, so as to make the assembly work faster. There is a high-precision radar at the entrance of the concrete intelligent supply and precise cloth-feeding station, which can obtain the edge position of the outer leaf mold and provide a position reference for subsequent cloth-feeding. There is a concrete cloth-feeding machine at the concrete intelligent supply and precise cloth-feeding station; it also includes a PLC controller, and the PLC controller is electrically connected to the three-dimensional laser projection system, the high-precision radar and the concrete cloth-feeding machine.

[0039] Compared with the prior art, the beneficial effects of the present invention are as follows: By integrally manufacturing the insulation board and the connecting piece, the present invention can avoid drilling during the production process of shear walls, making the production of shear walls faster and the quality easier to control. The connecting piece adopts a cross structure, with better shear resistance, and the inserted anti-pulling rod can greatly improve the anti-pulling performance between the insulation layer and the outer leaf layer and the inner leaf layer.

[0040] Furthermore, multi-line parallel operation can improve production efficiency and shorten the production cycle. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 Schematic diagram of the connecting piece structure of the first embodiment of the present invention;

[0042] Figure 2 Schematic diagram of the wall structure of the first embodiment of the present invention;

[0043] Figure 3 Schematic diagram of the insulation layer structure of the first embodiment of the present invention Figure 1 ;

[0044] Figure 4 Enlarged structure schematic diagram at position A of the first embodiment of the present invention;

[0045] Figure 5 Schematic diagram of the insulation layer structure of the first embodiment of the present invention Figure 2 ;

[0046] Figure 6 Enlarged structure schematic diagram at position B of the first embodiment of the present invention;

[0047] Figure 7 Schematic diagram of the structure of the insulation layer connecting the outer leaf layer of the first embodiment of the present invention Figure 1 ;

[0048] Figure 8 Schematic diagram of the structure of the insulation layer connecting the outer leaf layer of the first embodiment of the present invention Figure 2 ;

[0049] Figure 9 Schematic diagram of the internal structure of the outer leaf layer of the first embodiment of the present invention Figure 1 (Concrete is not fully shown);

[0050] Figure 10 Schematic diagram of the internal structure of the outer leaf layer of the first embodiment of the present invention Figure 2 (Concrete is not fully shown);

[0051] Figure 11 Enlarged structure schematic diagram at position C of the first embodiment of the present invention;

[0052] Figure 12Schematic diagram of the partial structure of the outer leaf mold for the first embodiment of the present invention Figure 1 ;

[0053] Figure 13 Schematic diagram of the partial structure of the outer leaf mold for the first embodiment of the present invention Figure 2 ;

[0054] Figure 14 Schematic diagram of the production line layout for the first embodiment of the present invention;

[0055] Figure 15 Schematic diagram of the intelligent guiding station for the first embodiment of the present invention;

[0056] Figure 16 Schematic diagram of the intelligent supply and precise placing of concrete for the first embodiment of the present invention;

[0057] Figure 17 Schematic diagram of the intelligent curing station for the first embodiment of the present invention;

[0058] Figure 18 Schematic diagram of the intelligent inspection station for the finished products of the first embodiment of the present invention;

[0059] Figure 19 Process flow chart of the production for the first embodiment of the present invention;

[0060] Figure 20 Schematic diagram of the connection member structure for the second embodiment of the present invention;

[0061] Figure 21 Schematic diagram of the grooving structure for the second embodiment of the present invention;

[0062] Figure 22 Schematic diagram of the partial structure of the grooving for the second embodiment of the present invention;

[0063] Figure 23 Schematic diagram of the wall structure for the second embodiment of the present invention.

[0064] In the figure: 1. Outer leaf layer; 2. Thermal insulation layer; 3. Inner leaf layer; 4. Connector; 401. Cross member; 411. First connecting body; 412. Second connecting body; 402. Reinforcing plate; 403. First through slot; 404. Second through slot; 405. Positioning slot; 406. Pulling slot; 461. First slot body; 462. Second slot body; 407. Tie rod; 408. Flow through hole; 5. Exposed reinforcement; 6. Grouting port; 7. Grout outlet; 8. Bolt embedded part; 9. Demoulding lifting point and temporary fixing embedded part; 10. Window temporary fixing embedded part; 11. Lifting embedded part; 12. Beam bottom formwork bolt connection embedded part; 13. Reinforcement mesh; 14. First uplift rod; 15. Slot; 1501. Slot opening; 1502. Third through slot; 16. Second uplift rod; 17. Outer leaf mould; 18. Rod through hole; 19. Plug cap; 20. Guide pipe; 21. Mould table cleaning station; 22. Mould table spraying station; 23. Outer leaf mould assembly station; 24. Demoulding agent coating station; 25. Outer leaf reinforcement assembly station; 26. Reserved and embedded intelligent guiding station; 27. Detection station; 28. Concrete intelligent supply and precise placing station; 29. Mould table ferry station; 30. Thermal insulation board installation station; 31. Assembly and pouring vibration station; 32. Inner leaf mould and reinforcement installation station; 33. Plastering station; 34. Intelligent curing station; 35. Component stacker; 36. Stacking and curing station; 37. Demoulding station; 38. Finished product intelligent detection station; 39. Three-dimensional laser projector; 40. Support frame; 41. Torpedo ladle; 42. Concrete placer; 43. High-precision radar; 44. Kiln body; 45. Steam generator; 46. Temperature and humidity sensor; 47. Blower; 48. Three-dimensional laser scanner; 49. Fixed support; 50. Wall panel support; 51. Movable mould table; 52. Wall panel; 53. Base; 54. Rotating shaft; 55. Side constraint structure; 56. Thermal insulation layer assembly station; 57. Uplift rod threading and outer leaf mould filling station; 58. Uplift rod sawing station. Specific embodiments

[0065] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0066] Embodiment 1

[0067] As Figures 1 to 19 shown, the first implementation manner of the present invention is disclosed. First, a preparation method of a new type of thermal insulation board is disclosed. The technical solution adopted is as follows:

[0068] Step a: After screening and cleaning raw materials such as polystyrene, talcum powder, and masterbatch, take them in proportion and put them into a twin-screw extruder for melting. The temperature of the first extrusion section of the twin-screw extruder as the plasticizing section is 200°C, where the raw materials are sheared and melted, and carbon dioxide is introduced as a foaming agent according to the dosage in the first extrusion section. The pressure inside the twin-screw extruder is controlled at 22 Mpa;

[0069] Step b: The molten material enters the second extrusion section as the cooling section, and the temperature of the molten material is decreased to 150°C;

[0070] Step c: Horizontally open positioning holes on the mold, insert both ends of the connector 4 into the positioning holes. The connector 4 is a phenolic resin connector, and its structure is as Figure 1 shown. Its main body is a cross member 401. There are a first through slot 403 and a second through slot 404 at both ends of the cross member 401 for the anti-pulling rod to pass through. There is a reinforcing plate 402 perpendicular to the cross member 401 in the middle of the cross member 401. When installing the connector 4 in the mold, the reinforcing plate 402 is located in the mold;

[0071] Step d: Squeeze the molten material into the mold at the die orifice temperature of 150°C, and the molten material is in full contact with the part of the connector 4 in the mold;

[0072] Step e: After the molten material is cooled and formed, it becomes an integral body with the connector 4. After cooling, take it out of the mold and further cool it to room temperature, and cure it for 12 hours;

[0073] Step f: Use a cutting machine and a milling machine for shaping to obtain the insulation board with the connector 4.

[0074] This embodiment further discloses a production method of a precast sandwich insulated shear wall using the above-mentioned insulation board with the connector 4, as Figure 19 shown. The adopted technical solution is as follows: including the following steps:

[0075] Step 1: The first mold table is a movable mold table 51. Clean and spray the movable mold table 51 to ensure that the surface of the mold table is clean and tidy; Assemble the outer leaf mold 17 and the window opening mold on the first mold table. There are through holes 18 on the outer leaf mold 17, and there is also a pouring port on the outer leaf mold 17; Apply a release agent on the outside of the outer leaf mold 17;

[0076] Step 2: Import the wall panel drawing information into the 3D laser projection system. The 3D laser projector 39 projects the steel mesh 13 and the contour of the reserved embedded positions onto the mold table. Workers assemble the outer leaf wall panel according to the projected contour, load the steel mesh 13 into the outer leaf mold 17, and place the protective layer gaskets of the same color as the concrete in a plum blossom pattern. There are slots 15 on the steel mesh 13, and on the slots 15, there are third through slots 1502 corresponding to and matching in size the positions of the first through slots 403 of the connectors 4 used for the insulation boards prepared by the above-mentioned preparation method of the new type of insulation board.

[0077] Step 3: Workers fix and install the embedded parts of the outer leaf layer 1 with the tooling with fixing and positioning functions according to the projected contour, conduct concealed acceptance, and proceed to the next process after passing the inspection.

[0078] Step 4: Use the high-precision radar 43 to automatically scan the boundaries of the outer leaf mold 17, the positions and dimensions of the window openings, and feed the scanned information back to the precise batching system. The precise batching system automatically generates the batching trajectory and guides the concrete intelligent supply system and the batching machine to operate. Precisely batch the fair-faced concrete with a slump of 200 ± 20 mm into the outer leaf mold 17, and vibrate it with a flat vibrator at a frequency of 45 HZ for 80 - 100 S. After vibration, check the thickness of the concrete, requiring the thickness to be within 2 mm less than the designed thickness and the surface to be flat. The height of the concrete batching shall not be higher than the lowest point of the third through slot 1502 of the slot 15 to prevent the concrete from entering the third through slot 1502.

[0079] Step 5: Assemble the insulation layer 2 on the second mold table. The insulation boards used for the insulation layer 2 are a combination of ordinary insulation boards and the insulation boards prepared by the above-mentioned preparation method of the new type of insulation board. First, perform the layout of the insulation boards and number the insulation boards according to the layout. Then, according to the layout plan of the insulation boards, use an electric heating cutting tool to cut and number them 2 mm smaller than the designed size requirements to ensure that the sides of the insulation boards are flat and smooth. Assemble and fix the side molds of the insulation boards on the flat mold table, evenly apply a special adhesive on the sides of the insulation boards, and lay them by extrusion in the clockwise direction according to the numbers to ensure that the gaps are less than 1 mm. After assembly, check the outer length, width, diagonal of the insulation boards, as well as the length, width, and diagonal at the window openings to ensure that they are within the allowable error range.

[0080] Step 6: Take out the pre-assembled insulation layer 2 in Step 5 from the side molds of the insulation boards as a whole and put it into the outer leaf mold 17. When putting it in, make the connectors 4 installed on the insulation boards enter the slots 15.

[0081] Step 7: Insert the first anti-pulling bar 14 through the rod-piercing hole 18 into the outer leaf mold 17. The first anti-pulling bar 14 passes through the first through slot 403 of the connecting piece 4 and the third through slot 1502 of the slot 15. Use a pressing plate to press the thermal insulation layer 2 from above to prevent it from floating. The outer leaf mold 17 is equipped with spring buckles, and the pressing plate has hook bodies. The spring buckles can be used to hook the hook bodies to quickly fix the pressing plate. Then, fill the outer leaf mold 17 with concrete through the casting port. When injecting concrete, use a flat vibrator for vibration, with a frequency of 45HZ and a vibration time of 80 - 100S.

[0082] Step 8: Assemble and inspect the inner leaf mold on the third mold table.

[0083] Step 9: Receive materials according to the inner leaf steel bar batching table in the drawing, and bind the steel bar skeleton in the inner leaf mold assembled in Step 8. The binding sequence is the upper beam steel bars of the window, the side column steel bars of the window, and the lower wall steel bars of the window, and wrap the side column steel bars of the window outside the beam bars. Place the weight-reducing plate before binding the steel bar mesh plate in the inner layer of the lower wall steel bars of the window. Step 10: Install the embedded parts and anti-pulling steel bars of the inner leaf layer 3.

[0084] Step 11: Insert the second anti-pulling bar 16 through the second through slot 404 of the connecting piece 4 of the thermal insulation layer 2.

[0085] Step 12: Remove the pressing plate on the thermal insulation layer 2, hoist the inner leaf mold and the steel bar skeleton onto the outer leaf mold 17 and make an overall combined connection with the outer leaf mold 17. Seal the out-of-rib area of the inner leaf side mold with foam strips, and arrange the internal steel bars in a plum blossom shape with gaskets to ensure that the steel bar skeleton avoids the connecting piece 4 and the second anti-pulling bar 16.

[0086] Step 13: Install the embedded tooling on the inner leaf mold, and then install the internal thread sleeve. Conduct a concealed inspection after installation. After passing the inspection, enter the next process.

[0087] Step 14: Conduct concrete placing and use a vibrating rod for vibration.

[0088] Step 15: Use a screed bar to level the surface of the wall panel 52, and conduct initial plastering. At the same time, place a grooving flat iron with a thickness of 5mm on the inner leaf edge, and press it down to be flush with the surface of the wall panel 52 through tools, and then conduct surface finishing of the wall panel 52.

[0089] Step 16: After the inner leaf concrete begins to set, remove the grooving flat iron, and use a grooving trowel to finish and straighten along the side mold, eliminate the air bubbles on the grooving surface, and ensure that the 5mm groove line is straight.

[0090] Step 17: In spring, summer and autumn, cover with plastic film for static curing and moist curing. The film should be closely attached to the concrete surface, and the film area should be slightly larger than the concrete surface area. Fix the four corners of the film with clips. In winter, adopt intelligent steam curing method. The wall panel 52 is placed in the kiln body 44 by the component stacking machine 35 for constant temperature and humidity curing.

[0091] Step 18: When the strength of the same-condition curing test block reaches 75% of the design strength, the component is ready for demoulding. Lift the plastic film to ensure that the temperature difference between the final concrete surface temperature and the external temperature ≤ 20°C. Remove the inner leaf edge formwork, outer leaf edge formwork, and window opening formwork in sequence. Due to the large adsorption force of the window opening edge formwork, use a chain hoist for tensioning to separate the edge formwork from the concrete inward through horizontal tension.

[0092] Step 19: Saw the first anti-pulling rod 14 protruding from the side of the outer leaf layer 1, and trim the side of the outer leaf layer 1.

[0093] Step 20: Automatically scan and detect the dimensions, flatness, and pre-embedded position of the wall panel 52 by the 3D laser scanner 48, and transmit the scanned information to the 3D laser intelligent detection system for automatic comparison with the drawing information. When the deviation is large, give an automatic warning and mark it, and form a record.

[0094] Step 21: Transport the wall panel 52 to the outdoor storage yard for at least 14 days of natural curing.

[0095] To shorten the production cycle, Step 5 is carried out synchronously with Steps 1 - 4; Steps 8 - 11 are carried out synchronously with Steps 1 - 7.

[0096] This embodiment also discloses a production line for the above production method, as Figures 14 to 18 shown. The adopted technical solution is that it includes a PCF board production line, an inner leaf board production line, an assembly line, and a post-treatment line; the outer leaf mold 17 is on the moving mold table 51 and circulates among the above PCF board production line, inner leaf board production line, assembly line, and post-treatment line.

[0097] The PCF board production line includes a mold table cleaning station 21 and a mold table spraying station 22. An outer leaf mold assembly station 23 is arranged behind the mold table spraying station 22, and a mold release agent coating station 24 is arranged behind the outer leaf mold assembly station 23. This part is the operation station for Step 1. Behind the mold release agent coating station 24, there are an outer leaf steel bar assembly station 25, a pre-embedded intelligent guiding station 26, and a detection station 27. This part is the operation station for Steps 2 and 3. Behind the detection station 27, there is a concrete intelligent supply and precise batching station 28. This part is the operation station for Step 4. The outer leaf steel bar assembly station 25 and the pre-embedded intelligent guiding station 26 are equipped with 3D laser projection systems, as Figure 15As shown in the figure, it includes a support frame body 40. A three-dimensional laser projector 39 is installed on the support frame body 40. The three-dimensional laser projector 39 projects the steel bar mesh 13 and the contour of the reserved embedded position onto the moving formwork 51, and workers assemble the outer leaf wall panel according to the projected contour. As Figure 16 As shown in the figure, the intelligent concrete supply and precise concrete placing station 28 includes a steel structure. A high-precision radar 43 is installed at the entrance of the intelligent concrete supply and precise concrete placing station 28 to scan the outer leaf mold 17 on the moving formwork 51. A torpedo ladle 41 and a concrete placing machine 42 are also installed on the steel structure. It also includes a PLC controller, and the PLC controller is electrically connected to the three-dimensional laser projection system, the high-precision radar 43, and the concrete placing machine 42.

[0098] The intelligent concrete supply and precise concrete placing station 28 is connected to the insulation board installation station 30 through the formwork ferry station 29 at the rear. The insulation board installation station 30 is the operation station for step 6. Behind the insulation board installation station 30, there are provided the anti-pulling rod threading and outer leaf mold filling station 57, the assembly and pouring vibration station 31, and the plastering station 33 of the assembly line. The anti-pulling rod threading and outer leaf mold filling station 57 is the operation station for step 7. The assembly and pouring vibration station 31 is the operation station for steps 10 to 14; the plastering station 33 is the operation station for steps 15 and 16.

[0099] The insulation board installation station 30 is provided with a parallel insulation layer assembly station 56 for performing the operation of step 5. The assembly and pouring vibration station 31 is provided with a parallel inner leaf mold and steel bar installation station 32 for performing the operations of steps 8 to 9. There are fixed formworks on both the insulation layer assembly station 56 and the inner leaf mold and steel bar installation station 32. There is a three-dimensional laser projection system on the inner leaf mold and steel bar installation station 32 for intelligently guiding the inner leaf plate assembly.

[0100] Behind the plastering station 33 are the intelligent curing station 34, the stacking and curing station 36, and the demolding station 37 of the post-treatment line. After the demolding station 37, there are the anti-pulling rod sawing station 58 and the finished product intelligent inspection station 38; the intelligent curing station 34 is the winter operation station in step 17, the stacking and curing station 36 is the spring, summer, and autumn operation station in step 17. According to the current season, the moving formwork 51 is transferred between the intelligent curing station 34 and the stacking and curing station 36 through the component stacking machine 35; the demolding station 37 is the operation station for step 18; the anti-pulling rod sawing station 58 is the operation station for step 19, and the finished product intelligent inspection station 38 is the operation station for step 20. As Figure 17As shown, the intelligent maintenance station 34 includes a kiln body 44. A temperature and humidity sensor 46 is installed inside the kiln body 44, and a steam generator 45 and a blower 47 are installed on the kiln body 44, which can adjust the temperature and humidity inside the kiln body 44. The temperature and humidity sensor 46, the steam generator 45, and the blower 47 are all electrically connected to the PLC controller. The finished product intelligent detection station 38 has a three-dimensional laser intelligent detection system, such as Figure 18 As shown, it includes a three-dimensional laser scanner 48 and a wall panel support 50. The three-dimensional laser scanner 48 is installed on a fixed support 49. The wall panel support 50 is an L-shaped frame with side restraint structures 55 on both sides to prevent the wall panel 52 from tipping over. A rotating shaft 54 is hinged below the wall panel support 50, and the rotating shaft 54 is installed on a base 53. The three-dimensional laser intelligent detection system is electrically connected to the PLC controller.

[0101] The precast sandwich insulated shear wall produced by this embodiment is as Figures 2 to 13 As shown, it includes an insulation layer 2. There is an outer leaf layer 1 on one side of the insulation layer 2, and an inner leaf layer 3 is connected to the other side. Window openings with the same size and corresponding positions are provided on the outer leaf layer 1, the insulation layer 2, and the inner leaf layer 3. The insulation layer 2 is as high as the outer leaf layer 1, and each side is shortened by 50 mm compared with the outer leaf layer 1. There are waterproof copings on the upper and lower parts of the outer leaf layer 1. There are exposed steel bars 5 on the inner leaf layer 3. The exposed steel bars 5 are part of the steel bar skeleton of the inner leaf layer 3. There are also grouting ports 6, slurry outlet ports 7, bolt embedded parts 8, demoulding lifting points and temporary fixing embedded parts 9, and beam bottom formwork bolt connection embedded parts 12 on the inner leaf layer 3. There are window opening temporary fixing embedded parts 10 on the inner side of the window opening of the inner leaf layer 3, and lifting embedded parts 11 on the top surface of the inner leaf layer 3.

[0102] There are connectors 4 inside the insulation layer 2. The main body of the connector 4 is a linear cross member 401. The cross-shaped structure has excellent shear resistance. In order to improve the connection strength between the connector 4 and the insulation layer 2, and at the same time improve the anti-pulling performance between the connector 4 and the insulation layer 2, five parallel reinforcement plates 402 are provided in the middle of the cross member 401.

[0103] In order to improve the uplift resistance between the connector 4 and the outer leaf layer 1 and the inner leaf layer 3, a first through groove 403 and a second through groove 404 are opened on the longitudinal plates at both ends of the connector 4. The first through groove 403 is used to connect with the outer leaf layer 1, and the second through groove 404 is used to connect with the inner leaf layer 3. There is a steel mesh 13 in the outer leaf layer 1, and a socket 15 is welded on the steel mesh 13. The socket 15 is a cross-shaped groove, corresponding to the position of the connector 4 and matching in size. In order to facilitate the insertion of the connector 4 into the socket 15, a chamfer is provided at the groove opening 1501 as a guiding surface, and a third through groove 1502 corresponding to the position of the first through groove 403 and matching in size is opened on the socket 15; in order to guide the direction of the first anti-pulling rod 14 when inserting it, a guiding tube 20 is provided outside the rod-passing hole 18 of the outer leaf mold 17. In order to prevent concrete sputtering from blocking the rod-passing hole 18, a plug cap 19 is provided inside the rod-passing hole 18, and the plug cap 19 can be knocked out by the first anti-pulling rod 14 when the first anti-pulling rod 14 is inserted.

[0104] Install the second anti-pulling rod 16 in the second through grooves 404 of the upper and lower rows of connectors 4. Positioning grooves 405 are opened on the side walls of the second through grooves 404. Since the outer leaf layer 1, the insulation layer 2, and the inner leaf layer 3 are produced vertically during the production of the shear wall, the connector 4 is in a vertical state during the production process. In the vertical state, the positioning grooves 405 are opened on the bottom surface of the second through grooves 404. The positioning grooves 405 can prevent the second anti-pulling rod 16 from moving horizontally and disengaging from the second through grooves 404. In order to improve the stability of the second anti-pulling rod 16, the positioning grooves 405 can also adopt the structure of a C-shaped elastic pipe clamp.

[0105] The types of wall panels applicable to this embodiment are as follows:

[0106]

[0107] Embodiment 2

[0108] As Figures 20 to 23 shown, the difference between this embodiment and Embodiment 1 is that the connector 4 used in the preparation method of a new type of insulation board is of a Z-shaped structure, including an L-shaped first connecting body 411 and a straight-line second connecting body 412.

[0109] In order to improve the shear resistance and uplift resistance, slotted holes 406 are opened on the first connecting body 411 and the second connecting body 412. The slotted holes 406 include a first slot body 461 on the transverse support plate of the first connecting body 411 and a second slot body 462 on the second connecting body 412. The first slot body 461 is a straight slot, and the second slot body 462 is an L-shaped slot. A communication hole 408 communicating with the outside is opened on one side of the slotted holes 406.

[0110] The steps c of the preparation method are as follows:

[0111] The first connector 411 and the second connector 412 are respectively adapted to two sets of molds. The thickness of the insulation board processed by the mold adapted to the first connector 411 is greater than the thickness of the insulation board processed by the mold adapted to the second connector 412. Positioning holes are transversely opened on one side of the mold. First, use a steel wire keel to preliminarily position the first connector 411 or the second connector 412, and then pass the end with the through groove thereof through the positioning hole, and the other end is in sliding contact with the inner side surface of the mold;

[0112] Step f is as follows:

[0113] Use a cutting machine and a milling machine for shaping, so that the end faces of the first connector 411 and the second connector 412 in contact with the inner side of the mold in the mold are fully exposed, and two kinds of insulation boards respectively with the first connector 411 and the second connector 412 can be obtained.

[0114] A production method of a precast sandwich insulation shear wall using the two kinds of insulation boards with the first connector 411 and the second connector 412 as above, and step 5 thereof is as follows:

[0115] The insulation layer 2 is two layers of insulation boards. First, perform the layout of the insulation boards and number the insulation boards according to the layout. When laying out, ensure that the two layers of insulation boards are arranged with staggered joints. Then, according to the layout plan of the insulation boards, use an electric heating cutting tool to cut according to the design size requirements with a deviation of 2 mm smaller and number them, ensure that the side surfaces of the insulation boards are flat and smooth, and evenly apply a special adhesive on the side surfaces of the insulation boards. Assemble the first layer of insulation boards on the second mold table. The first layer of insulation boards is a combination of a common insulation board and a new type of insulation board with the first connector 411; squeeze and lay according to the number in the clockwise direction to ensure that the gap is less than 1 mm; then assemble the second layer of insulation boards. The second layer of insulation boards is a combination of a common insulation board and a new type of insulation board with the second connector 412; evenly apply a special adhesive on the back and side surfaces of the second layer of insulation boards, and squeeze and lay according to the number in the clockwise direction. When laying, ensure that the first groove 461 and the second groove 462 are opposite, and use a rubber hammer to evenly hammer the surface of the insulation board to make the insulation boards stick tightly to each other; pass the pull rod 407 through the port of the first groove 461, and after contacting the bottom surface, screw the pull rod 407 so that one of the hook-shaped structures at both ends of the pull rod 407 enters the groove section perpendicular to the first groove 461 of the second groove 462, and the other hook-shaped structure hooks the port of the first groove 461 to complete the tension. The pull rod 407 can improve the pull-out resistance and shear resistance of the connector 4; after assembly, check and accept the outer length, width, diagonal of the insulation board, as well as the length, width, and diagonal at the window opening to ensure that they are within the allowable error range.

[0116] In step 14, when performing concrete placement, the concrete enters the pull groove 406 from the port of the first groove 461 and the circulation hole 408, and connects the first connector 411 and the second connector 412 into a whole.

[0117] The circuit and mechanical connections involved in the present invention are common means adopted by those skilled in the art, and technical inspiration can be obtained through a limited number of tests, which belong to common general knowledge.

[0118] The three-dimensional laser projection system, radar scanning and concrete precise placing system, and three-dimensional laser intelligent detection system used in this article are all prior arts, and other components not described in detail are prior arts.

[0119] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for preparing a new type of thermal insulation board, comprising the following steps: Step a: After the raw materials are pretreated, they are put into an extruder for melting. Step b: The melted material is cooled to the extrusion temperature. Step c: The melted material is extruded into a mold for cooling and shaping. It is characterized in that in step c, positioning holes are opened on the mold. After the connecting piece (4) is inserted into the positioning holes, the melted material is extruded into the mold. The melted material is in full contact with the part of the connecting piece (4) in the mold. After the melted material is cooled and shaped, it becomes an integral body with the connecting piece (4), and after cooling, it is taken out of the mold for shaping.

2. The preparation method of the novel thermal insulation board according to claim 1, characterized in that: In step c, the main body of the connecting piece (4) is a cross piece (401). There are a first through slot (403) and a second through slot (404) at both ends of the cross piece (401) for the anti-pulling rod to pass through. There is a reinforcing plate (402) perpendicular to the cross piece (401) in the middle of the cross piece (401). When the connecting piece (4) is installed in the mold, the reinforcing plate (402) is located in the mold.

3. A production method of a precast sandwich insulated shear wall, characterized in that, Comprising the following steps: Step 1: Assemble the outer leaf mold (17) and the window opening mold on the first mold table. The outer leaf mold (17) is provided with through holes for rods (18), and the outer leaf mold (17) is also provided with a pouring port; a mold release agent is applied to the outside of the outer leaf mold (17). Step 2: Install a steel mesh (13) and embedded parts into the outer leaf mold (17); there are slots (15) on the steel mesh (13), and there is a third through slot (1502) on the slots (15) corresponding to the position and matching the size of the first through slot (403) of the connecting piece (4) used in the thermal insulation board prepared by the method for preparing a new type of thermal insulation board according to claim 2. Step 3: Uniformly distribute concrete into the outer leaf mold (17) and vibrate it; the height of the concrete distribution shall not be higher than the lowest point of the port of the third through slot (1502) of the slot (15) to prevent the concrete from entering the third through slot (1502). Step 4: Assemble the thermal insulation layer (2) on the second mold table. The thermal insulation board used in the thermal insulation layer (2) is a combination of a common thermal insulation board and the thermal insulation board prepared by the method for preparing a new type of thermal insulation board according to claim 1 or 2. Step 5: Take out the pre-assembled thermal insulation layer (2) in step 4 as a whole from the side mold of the thermal insulation board and put it into the outer leaf mold (17). When putting it in, make the connecting piece (4) installed on the thermal insulation board enter the slot (15); then insert the first anti-pulling rod (14) into the first through slot (403) and the third through slot (1502), and fill the outer leaf mold (17) with concrete and vibrate it. Step 6: Assemble the inner leaf mold on the third mold table, tie the steel bar framework inside the inner leaf mold and install the embedded parts and anti-pulling steel bars of the inner leaf layer (3); insert the second anti-pulling rod (16) into the second through slot (404) of the connecting piece (4) of the thermal insulation layer (2). Step 7: Integrally combine and connect the inner leaf mold and the steel bar framework with the outer leaf mold (17) to ensure that the steel bar framework avoids the connecting piece (4) and the second anti-pulling rod (16); after connection, install the embedded tooling on the inner leaf mold and then install the internal thread sleeve. Step 8: Conduct concrete distribution and vibration. Step 9: Level the surface of the wall panel (52), apply the first plastering, process the grooving, and then cure it; demold after curing until it meets the demolding conditions. Step 10: Saw the first anti-pulling bars (14) protruding from the side of the outer leaf layer (1), and trim the side of the outer leaf layer (1). Step 11: Store in the warehouse after passing the finished product inspection.

4. The production method of the precast sandwich insulation shear wall according to claim 3, characterized in that: In the said Step 4, first layout the insulation boards, number the insulation boards according to the layout. When assembling, extrude and lay the insulation boards in the clockwise direction according to the numbers to ensure that the gap is less than 1 mm.

5. The production method of the precast sandwich insulated shear wall according to claim 3, characterized in that: In the said Step 5, insert the first anti-pulling bar (14) into the outer leaf mold (17) from the rod passing hole (18). The first anti-pulling bar (14) passes through the first slot (403) of the connecting piece (4) and the third slot (1502) of the slot (15); then fill the outer leaf mold (17) with concrete through the casting port.

6. The production method of the precast sandwich insulated shear wall according to claim 3, characterized in that: A plug cap (19) is installed inside the rod passing hole (18) of the outer leaf mold (17); in the said Step 5, first fill the outer leaf mold (17) with concrete through the casting port. Before the concrete begins to set, insert the first anti-pulling bar (14) from the rod passing hole (18), ram the plug cap (19) into the concrete, and continue to insert the first anti-pulling bar (14) so that it passes through the first slot (403) of the connecting piece (4) and the third slot (1502) of the slot (15).

7. The production method of the precast sandwich insulated shear wall according to claim 5 or 6, characterized in that: Before pouring concrete, use a pressing plate to press the insulation layer (2) from above to prevent it from floating; in the said Step 7, first remove the pressing plate on the insulation layer (2), and then perform the overall combined connection of the inner leaf mold, the steel bar framework and the outer leaf mold (17).

8. The production method of the precast sandwich insulated shear wall according to claim 3, characterized in that: In the said Step 6, the binding sequence of the steel bar framework is the steel bars of the upper window beam, the steel bars of the window side column, and the steel bars of the lower window wall, and the steel bars of the window side column are wrapped outside the beam bars; place the weight reduction plate before binding the steel bar mesh panel inside the lower window wall steel bars.

9. The production method of the prefabricated sandwich insulation shear wall according to claim 3, characterized in that: The said Step 4 is carried out synchronously with Steps 1 - 3; the said Step 6 is carried out synchronously with Steps 1 - 5.

10. A production line applicable to the production method of the precast sandwich insulated shear wall as described in claim 3, characterized in that: It includes a PCF board production line, an inner leaf board production line, an assembly line and a post-treatment line; the PCF board production line includes an outer leaf mold assembly station (23), and behind the outer leaf mold assembly station (23), there are a demoulding agent brushing station (24), an outer leaf steel bar assembly station (25), a reserved and embedded intelligent guiding station (26) and a concrete intelligent supply and precise cloth placing station (28); behind the concrete intelligent supply and precise cloth placing station (28), it is connected to a thermal insulation board installation station (30) through a mold table ferry station (29), and behind the thermal insulation board installation station (30), there are a tension bar piercing and outer leaf mold filling station (57), an assembly and pouring and vibration station (31) and a plastering station (33) of the assembly line, and behind the plastering station (33) is the post-treatment line; a thermal insulation layer assembly station (56) is arranged in parallel with the thermal insulation board installation station (30), and an inner leaf mold and steel bar installation station (32) is arranged in parallel with the assembly and pouring and vibration station (31); it also includes a mobile mold table (51) and a fixed mold table. The mobile mold table (51) is the main operation mold table and circulates among the PCF board production line, the inner leaf board production line, the assembly line and the post-treatment line; the fixed mold table is at the inner leaf mold and steel bar installation station (32) and the thermal insulation layer assembly station (56) and is used for the assembly of the inner leaf mold and the assembly of the thermal insulation layer (2); there is a three-dimensional laser projection system at the outer leaf steel bar assembly station (25) and the reserved and embedded intelligent guiding station (26), there is a high-precision radar (43) at the entrance of the concrete intelligent supply and precise cloth placing station (28), and there is a concrete cloth placing machine on the concrete intelligent supply and precise cloth placing station (28); it also includes a PLC controller, and the PLC controller is electrically connected to the three-dimensional laser projection system, the high-precision radar (43) and the concrete cloth placing machine.

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