FRP double-layer lattice web sandwich filling wallboard and layered grouting method thereof

Abstract

The invention discloses an FRP (Fiber Reinforce Plastic) double-layer lattice web sandwich filling wallboard and a layered grouting method thereof, mainly comprising an FRP wallboard, an FRP lattice web, an FRP partition plate, filling slurry and a connecting device, and mainly solving the defects of the existing building wallboard material in the aspects of strength, light weight, construction convenience and permeability resistance. According to the wallboard, the light FRP material and the innovative layered grouting technology are adopted, and due to the fact that the FRP material is adopted, the wallboard has the light weight and the high durability and can meet the requirements of high-strength and low-energy-consumption buildings. According to the layered grouting method, each grouting cavity can be uniformly filled, and the structural integrity and safety of the wallboard are improved. The wallboard has remarkable structural strength and durability and is suitable for wallboard structures of modern buildings. In addition, an embedded connection mode is adopted, so that the wallboard can be installed more quickly and stably, the requirements of modern industrial buildings are met, and remarkable technical advantages and market application prospects are achieved.

Description

Technical Field

[0001] The present invention relates to a new type of prefabricated wall panel in the technical field of prefabricated building engineering, specifically a FRP double-layer lattice web sandwich-filled wall panel and its layered grouting method. Background Art

[0002] With the growing demand for high-performance and lightweight wall materials in the construction industry, FRP has gradually become an ideal material for making wall panels. Compared with traditional autoclaved lightweight concrete wall panels (ALC wall panels), FRP wall panels have significant advantages such as lightweight, high strength, corrosion resistance, dimensional stability, and convenient construction. Their tensile and flexural strengths far exceed those of ALC wall panels, while their density is lower, effectively reducing the building load; FRP materials exhibit excellent durability in humid or corrosive environments, avoiding problems such as easy water absorption and cracking of ALC wall panels; in addition, the urgent need for green and efficient modern buildings makes the use of FRP materials a better choice.

[0003] When traditional block wall panels and reinforced concrete cast-in-place wall panels are grouted, the internal grout is uneven; there are easily phenomena of air bubble residues or incomplete cavity filling, and in terms of wall panel assembly, traditional methods all use bolt connection or welding, which is cumbersome to install and has low strength. Summary of the Invention

[0004] To solve the above problems, the present invention discloses a FRP double-layer lattice web sandwich-filled wall panel and its layered grouting method, which uses high-performance FRP materials to make wall panels to overcome the disadvantages of traditional wall panels such as low strength, poor durability, and heavy self-weight; a new layered grouting method is invented to ensure that the grout fills each cavity evenly and avoid backflow, improving the filling quality; an embedded connection device is provided to achieve rapid installation and high-strength connection of wall panels, further improving the installation efficiency of wall panels and the service performance of connectors.

[0005] To achieve the above object, the technical solutions adopted by the present invention are as follows:

[0006] A FRP double-layer lattice web sandwich-filled wall panel and its layered grouting method, including a FRP wall panel, FRP lattice webs, FRP partitions, filling grout, and a connection device;

[0007] The FRP wall panel is divided into upper and lower layers, and a grouting port and a slurry outlet are respectively arranged at its top position. The grouting port is located below the first grouting cavity in the lower layer, and the slurry outlet is located above the last grouting cavity in the upper layer;

[0008] The FRP lattice web includes a horizontal web and a vertical web, which are perpendicularly intersecting and in a "well" shape. The cavity surrounded between the horizontal web and the vertical web is the grouting cavity;

[0009] The top of the side of the grouting cavity is provided with an overflow port, and a hydraulic one-way valve is provided according to the flow direction; through the cooperation of the two, it can be ensured that the filling slurry flows in one direction inside the grouting cavity and is poured into each cavity; at the same time, by utilizing the high-pressure grouting technology, the filling slurry flows in sequence inside the grouting cavity, and some impurities and dust are squeezed into the last grouting cavity during the flow, and discharged through the slurry outlet, thereby ensuring the pouring quality;

[0010] The hydraulic one-way valves are all made of FRP materials and can control the one-way flow of the filling slurry to prevent backflow during high-pressure grouting work;

[0011] The FRP partition is provided with a flow port, which is responsible for opening the connection between the upper and lower layers. After the last grouting cavity of the lower layer is filled, the filling slurry will continue to enter the first grouting cavity of the upper layer through the flow port;

[0012] The layered grouting method is specifically to use pressurized pouring, first pouring filling slurry from the grouting port of the lower layer of the wall panel to the first grouting cavity, until the first grouting cavity is filled, and then flowing to the next grouting cavity through the overflow port on the FRP lattice web, and a hydraulic one-way valve is arranged on the overflow port to ensure the one-way flow of the filling slurry, after the last grouting cavity of the lower layer is filled, it flows to the first grouting cavity of the upper layer through the flow port, and the grouting process of the upper layer is similar to that of the lower layer. After all the grouting cavities of the upper layer are filled, until the filling slurry flows out of the upper slurry outlet of the wall panel uniformly without bubbles, the wall panel is considered to be filled as a whole, and the upper slurry outlet is sealed with a hole plug, and then the pressure is maintained until the filling slurry is completely solidified. After the grouting work is completed, a layer of fire retardant coating is sprayed on the outer surface of the wall panel;

[0013] The connecting device comprises a plug-in slot and a plug-in plate, and both the plug-in plate and the plug-in slot are provided with locking pin holes for secondary fixing. When two adjacent wall panels are connected, the plug-in plates of the two are respectively and simultaneously embedded in the plug-in slots of the other wall panels for preliminary fixing. After the correct connection, the locking pins are inserted for secondary fixing to ensure the stable connection of the wall panels. The use of the locking pins further enhances the locking effect, thereby improving the earthquake resistance and durability.

[0014] Compared with the prior art, the advantages of the present invention are:

[0015] (1) Rich comprehensive performance

[0016] The present invention uses FRP (Fiber Reinforced Polymer) materials, including carbon fiber reinforced composite materials (CFRP), glass fiber reinforced composite materials (GFRP), etc. as the main component materials, with an upper and lower double-layer multi-cavity design. Compared with traditional concrete and ALC wall panels, etc., it has significant advantages in the following aspects: FRP is lightweight and has high tensile strength. When combined with lightweight porous filling core materials, it can significantly reduce the self-weight. The double-layer cavity design not only improves the flexural stiffness of the wall panel and the toughness against seismic loads, but also can significantly improve its performance indicators such as heat insulation, sound insulation, etc.; FRP materials have excellent corrosion resistance and anti-aging performance, and are not only applicable to harsh environments such as acid, alkali, and humidity, but also can significantly extend the service life and reduce maintenance costs; The outer surface of the present invention is sprayed with fireproof coating, which improves the fire safety of the wall panel and also extends the service life; The wall panel of the present invention adopts an assembled standardized production process. While improving the quality, it greatly shortens the construction period. There is no need for wet operations such as pouring concrete or mortar on-site. It only needs to be assembled according to the reserved interfaces and screw holes, and the installation efficiency is greatly improved.

[0017] The double-layer design provides two-layer skeleton support for the wall panel, enabling it to better withstand loads from different directions. At the same time, the sound insulation effect will be better, and the sound transmission path will be more complex.

[0018] (2) Optimized layered grouting method

[0019] The present invention designs a unique layered grouting method. Through the cooperation of the overflow port and the hydraulic check valve, it ensures the one-way flow and cavity-by-cavity filling of the grout, and the uniformity of the filled grout is guaranteed. Through single-cavity perfusion, the filled grout only flows to the next grouting cavity after the current grouting cavity is filled, avoiding the uneven filling and cavity phenomenon caused by uneven flow in the traditional one-time grouting method; The addition of the hydraulic check valve can ensure that the filled grout does not flow back or cross-flow, which helps to discharge impurities and air and improve the overall filling quality of the wall panel.

[0020] (3) Embedded connection device

[0021] The embedded connection method proposed by the present invention is through the cooperation of the plug-in board, plug-in slot, locking pin, and locking pin hole to provide an efficient and reliable connection method. Among them, the secondary fixation of the locking pin gives high stability to the connection of the wall panel, avoiding the loosening problem of the traditional bolt connection. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is a schematic diagram of the overall structure and its filling of the present invention;

[0023] Figure 2 is a schematic diagram of the internal structure and grouting cavity of the present invention;

[0024] Figure 3 Schematic diagram of the connection device of the present invention;

[0025] Figure 4 Plan schematic diagram of the grouting method of the present invention;

[0026] In the figure: 1, FRP wall panel; 11, grouting port; 12, slurry outlet;

[0027] FRP lattice web; 21, horizontal web; 22, vertical web; 23, grouting cavity; 24, overflow port; 25, hydraulic check valve; 3, FRP partition; 31, communication port; 4, filling slurry; 5, connection device; 51, plug-in board; 52, plug-in groove; 53, locking pin; 54, locking pin hole. Specific embodiments

[0028] The following further clarifies the present invention in conjunction with the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are only used to illustrate the present invention and not to limit the scope of the present invention. It should be noted that the terms "front", "rear", "left", "right", "upper" and "lower" used in the following description refer to the directions in the drawings, and the terms "inner" and "outer" respectively refer to the directions towards or away from the geometric center of a specific component.

[0029] Example:

[0030] As Figures 1-4 shown, a kind of FRP (Fiber Reinforced Polymer) double-layer lattice web sandwich-filled wall panel and its hierarchical grouting method, the wall panel assembly includes: FRP wall panel 1, FRP lattice web 2, FRP partition 3, filling slurry 4, connection device 5;

[0031] Furthermore, as Figure 1 shown, the outer surface of the wall panel is a continuous and smooth FRP panel, and a grouting port 11 and a slurry outlet 12 are provided at the top;

[0032] Furthermore, as Figure 2 shown, the interior of the wall panel adopts an "X" - shaped FRP lattice web 2, including horizontal webs 21 and vertical webs 22. The vertical webs 22 are arranged longitudinally along the length of the wall panel, and the horizontal webs 21 are arranged between adjacent vertical webs 22 along the width of the wall panel. A grouting cavity 23 is formed between adjacent horizontal webs 21 and vertical webs 22, and a plurality of overflow ports 24 and hydraulic check valves 25 are provided on the webs;

[0033] Furthermore, a hydraulic check valve 25 needs to be installed in each grouting cavity 23, and its function is to prevent the filling slurry under high pressure from flowing back, resulting in uneven filling of the grouting cavity 23 and generation of air bubbles;

[0034] Furthermore, the overflow ports 24 are provided by drilling holes in the FRP lattice webs 2 at the upper part of each grouting cavity. The filling slurry 4 flows through them to the next grouting cavity 23. A hydraulic check valve 25 is installed on each overflow port 24 according to the flow direction of the filling slurry 4 to ensure the one-way flow of the filling slurry 4 without backflow or cross-flow.

[0035] Furthermore, as Figure 2 shown, a circulation port 31 is provided on the FRP partition 3, which is located at the top of the last grouting cavity 23 at the lower layer of the wall panel and is responsible for connecting the upper and lower layers. After the last grouting cavity 23 at the lower layer is filled, the filling slurry will continue to enter the first grouting cavity 23 at the upper layer through the circulation port 31.

[0036] As Figure 3 shown, the connecting device 5 includes a plug-in plate 51, a plug-in groove 52, a locking pin 53 and a locking pin hole 54. The plug-in plate and the plug-in groove are both equipped with locking pin holes 54 for secondary fixation. An embedded connecting device is adopted. When two adjacent wall panels are connected, their plug-in plates 51 are respectively embedded into the plug-in grooves 52 of the other wall panel for preliminary fixation. After correct connection, the surface of the locking pin 53 is soaked with environmentally friendly glue and inserted into the locking pin hole 54 for secondary fixation to ensure the stable connection of the wall panels and excellent tensile and anti-pulling properties.

[0037] Furthermore, the filling slurry 4 described above can use self-compacting filling materials such as foam concrete, polyurethane foam or polystyrene foam.

[0038] Furthermore, as Figure 4 shown, during the grouting work, pressure grouting is adopted. First, the filling slurry 4 is poured into the first grouting cavity 23 from the grouting port 11 at the lower layer of the wall panel until the first grouting cavity 23 is filled, and then it flows to the next grouting cavity 23 through the overflow port 24 on the FRP lattice web. A hydraulic check valve 25 is arranged on the overflow port 24 to ensure the one-way flow of the filling slurry 4 without backflow or cross-flow. After the last grouting cavity 23 at the lower layer is filled, it flows to the first grouting cavity 23 at the upper layer through the circulation port 31. The upper layer grouting process is similar to that of the lower layer until the filling slurry 4 evenly flows out of the slurry outlet 12 at the upper layer of the wall panel without bubbles, which is regarded as the whole being filled. The slurry outlet 12 at the upper layer is sealed with a hole plug, and then the pressure maintaining work is carried out.

[0039] Further, all components of the wall panel except the filling slurry 4 are made of FRP materials, where the FRP materials include carbon fiber reinforced polymer (CFRP), glass fiber reinforced polymer (GFRP), basalt fiber reinforced polymer (BFRP), aramid fiber reinforced polymer (AFRP), and hybrid fiber reinforced composites composed of two or more of the above materials.

[0040] The technical means disclosed in the solution of the present invention are not limited to the technical means disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features.

Claims

1. A FRP double-layer lattice web sandwich-filled wall panel, characterized in that, It includes an FRP wall panel (1). The FRP wall panel (1) is divided into upper and lower layers by an FRP partition (3); a grouting port (11) and a slurry outlet (12) are respectively arranged at the top of the FRP wall panel (1), and two adjacent FRP wall panels (1) are connected by a connecting device (5); an FRP lattice web (2) is provided in each layer of the FRP wall panel (1); the FRP lattice web (2) includes a transverse web (21) and a vertical web (22), and a grouting cavity (23) is formed between adjacent transverse webs (21) and vertical webs (22), and a plurality of overflow ports (24) and hydraulic check valves (25) are arranged on the web (2); a communication port (31) is arranged on the FRP partition (3).

2. The FRP double-layer lattice web sandwich filled wall panel according to claim 1, characterized in that, The connecting device (5) is integrally formed with the FRP wall panel (1), and includes a plug-in board (51), a plug-in groove (52), a locking pin (53) and a locking pin hole (54); the plug-in board (51) and the plug-in groove (52) are arranged side by side on the side of the FRP wall panel (1); when two adjacent FRP wall panels (1) are connected, the plug-in boards (51) of the two are respectively embedded into the plug-in grooves (52) of the other wall panel for preliminary fixation at the same time, and locking pin holes (54) are provided at corresponding positions on the plug-in board (51) and the plug-in groove (52), and a locking pin is used for further fixation after correct connection.

3. The FRP double-layer lattice web sandwich-filled wall panel according to claim 1, characterized in that, The grouting port (11) is at the lower part of the first grouting cavity (23) in the lower layer of the FRP wall panel (1), and the slurry outlet (13) is at the upper part of the last grouting cavity (23) in the upper layer of the FRP wall panel (1).

4. The FRP double-layer lattice web sandwich-filled wall panel according to claim 1, characterized in that The transverse web (11) and the vertical web (12) are perpendicular to each other and form a "well" shape. The vertical web (12) is arranged longitudinally along the length of the wall panel, and the transverse web (11) is arranged between adjacent vertical webs (11) along the width of the wall panel.

5. A kind of FRP double-layer lattice web sandwich filled wall panel according to claim 1, characterized in that, The overflow port (24) is formed by punching holes in the FRP lattice web (2) of each grouting cavity, and the filling slurry (4) flows through it to the next grouting cavity (23), and a hydraulic check valve (25) is installed at each overflow port (24) according to the flow direction of the filling slurry (4).

6. The FRP double-layer lattice web sandwich infilled wall panel according to claim 1, wherein The communication port (31) is located at the top of the last grouting cavity (23) in the lower layer of the FRP wall panel (1), and the filling slurry (4) flows through it to the first grouting cavity (23) in the upper layer of the FRP wall panel (1).

7. A FRP double-layer lattice web sandwich-filled wall panel according to claim 5, characterized in that, The filling slurry (4) includes, but is not limited to, filling materials with self-compacting functions such as foamed concrete, polyurethane foam or polystyrene foam, etc.

8. The FRP double-layer lattice web sandwich-filled wall panel according to claim 1, wherein The component parts of the wall panel, except for the filling slurry (4), are all made of FRP materials. The FRP materials include carbon fiber reinforced composites, glass fiber reinforced composites, basalt fiber reinforced composites, aramid fiber reinforced composites, and hybrid fiber reinforced composites composed of two or more of the above materials; after the wall panel completes the grouting work, a layer of fireproof coating needs to be sprayed on the outer surface.

9. A FRP double-layer lattice web sandwich filled wall panel and its layered grouting method, characterized in that, The specific layered grouting method is as follows: Pressurized perfusion is adopted. First, the filling slurry (4) is poured into the first grouting cavity (23) from the grouting port (11) at the lower layer of the wall panel. After the first grouting cavity (23) is filled, it flows to the next grouting cavity (23) through the overflow port (24) on the FRP lattice web. A hydraulic check valve (25) is arranged on the overflow port (24) to ensure the one-way flow of the filling slurry (4). After the last grouting cavity (23) at the lower layer is filled, it flows to the first grouting cavity (23) at the upper layer through the circulation port (31). The grouting process at the upper layer is similar to that at the lower layer. When the filling slurry (4) flows out evenly from the slurry outlet (12) at the upper layer of the wall panel without bubbles, it is regarded as being completely filled. The slurry outlet (12) at the upper layer is sealed with a hole plug, and then the pressure-holding work is carried out until the filling slurry (4) is completely solidified.

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