Manufacturing method of super-low energy consumption sandwich thermal insulation outer wall plate with impact resistance

Abstract

The present application relates to the field of building, specifically to a kind of manufacturing method of ultra-low energy consumption sandwich thermal insulation outer wall board with impact resistance, comprising the following steps: S1, design wallboard, determine the thickness of concrete outer leaf plate, concrete inner leaf plate and thermal insulation layer;S2, with the requirement that the two ends of pull connecting cylinder need to be inserted into concrete outer leaf plate and concrete inner compression plate, design the size of pull connecting cylinder, and calculate whether the impact energy absorption and initial stiffness of wallboard meet the design requirements, process the pull connecting cylinder of corresponding size after meeting the requirements;S3, connect each pull connecting cylinder to form a honeycomb structure, and set positioning hole corresponding to the diameter of transverse steel bar on each pull connecting cylinder;S4, groove in the middle of thermal insulation layer, and form a hexagonal layer corresponding to the cross-sectional size of the inner wall of each pull connecting cylinder by cutting the thermal insulation layer peeled off when grooving, the number of hexagonal layers corresponds to the number of pull connecting cylinders, and each hexagonal layer is pasted to the inner wall of corresponding pull connecting cylinder to form an integral structure of pull connecting cylinder and thermal insulation layer;S5, fix the thermal insulation layer, transverse steel bar and longitudinal steel bar with pre-fixed pull connecting cylinder in concrete pouring mold, make each transverse steel bar pass through the positioning hole of corresponding pull connecting cylinder, pour concrete into concrete pouring mold, and then demould after curing, to complete the manufacture of wallboard.The present application improves the initial stiffness and impact resistance of wallboard while improving the thermal insulation performance.

Description

Technical Field

[0001] This invention relates to the field of construction, specifically a method for manufacturing an ultra-low energy consumption sandwich insulated exterior wall panel with impact resistance. Background Technology

[0002] Traditional building wall panels and floor slabs are typically made of solid reinforced concrete slabs. However, due to their poor thermal insulation performance, buildings using solid reinforced concrete slabs often suffer from significant energy losses. To improve the thermal insulation effect of buildings, precast concrete sandwich wall panels have emerged. Precast concrete sandwich wall panels mainly consist of concrete leaf slabs on both sides, a thermal insulation layer in the middle, and tie rods connecting the two concrete leaf slabs. In precast concrete sandwich wall panels, the tie rods, as key components connecting the two concrete leaf slabs, have a significant impact on the overall performance of the precast concrete sandwich wall panel due to their shear force transfer capacity.

[0003] Currently, conventional precast concrete sandwich wall panels typically use concrete blocks or steel bars as tie rods. While these panels achieve high overall performance, they also generate significant thermal bridging, reducing their insulation performance. To address the thermal bridging effect, extruded polystyrene (XPS) materials have been adopted as the insulation layer, along with GFRP (growth galvanized reinforced plastic) plate tie rods to replace traditional concrete blocks or steel bars, thus improving the wall panel's insulation performance. However, this structural approach, while improving insulation performance, often leads to a decrease in the wall panel's initial stiffness and impact resistance; these two aspects cannot be simultaneously improved, thus requiring a solution. Summary of the Invention

[0004] To avoid and overcome the technical problems existing in the prior art, this invention provides a method for manufacturing an ultra-low energy consumption sandwich insulated exterior wall panel with impact resistance. This invention improves both the thermal insulation performance and the initial stiffness and impact resistance of the wall panel.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A method for manufacturing an ultra-low energy consumption sandwich insulated exterior wall panel with impact resistance includes the following steps:

[0007] S1. Design the wall panels and determine the thickness of the outer concrete leaf panel, the inner concrete leaf panel, and the insulation layer.

[0008] S2. Design the dimensions of the tie tube, which requires both ends of the tie tube to be inserted into the outer concrete leaf plate and the inner concrete leaf plate. Calculate whether the impact absorption energy and initial stiffness of the wall panel meet the design requirements. If they meet the requirements, process the tie tube of the corresponding dimensions.

[0009] S3. Connect the tie cylinders to form a honeycomb structure, and open positioning holes on each tie cylinder corresponding to the diameter of the transverse steel bars.

[0010] S4. A groove is cut in the middle of the insulation layer to fit into the honeycomb structure formed by the tie cylinder. The insulation layer peeled off during the grooving is cut to form a regular hexagonal layer corresponding to the cross-sectional dimensions of the inner wall of each tie cylinder. The number of regular hexagonal layers corresponds to the number of tie cylinders. Each regular hexagonal layer is pasted to the inner wall of the corresponding tie cylinder so that the tie cylinder and the insulation layer form an integral structure.

[0011] S5. Fix the insulation layer with pre-fixed tie cylinders, transverse steel bars and longitudinal steel bars in the concrete pouring mold, so that each transverse steel bar passes through the positioning hole of the corresponding tie cylinder, pour concrete into the concrete pouring mold, cure and demold to complete the manufacturing of the wall panel.

[0012] As a further aspect of the present invention:

[0013]

[0014] in, K L This represents the initial stiffness of the wall panel;

[0015] E L To absorb energy and resist impact for the wall panel;

[0016] B This is the side length of the cross-section of the tie cylinder;

[0017] H L This refers to the length of the tie tube.

[0018] As a further aspect of the present invention: the cross-section of the tie tube is in the form of a regular hexagon, and the body of each tie tube forms a honeycomb layout along the direction perpendicular to the wall panel surface. The tie tubes are made of the same material as the insulation layer.

[0019] As a further embodiment of the present invention: both the outer concrete leaf slab and the inner concrete leaf slab are provided with a steel mesh, the steel mesh including transverse steel bars provided adjacent to the insulation layer and longitudinal steel bars provided away from the insulation layer, and there is a gap between the transverse steel bars and the longitudinal steel bars.

[0020] As a further aspect of the present invention, the diameter of the positioning hole is 6mm to 10mm.

[0021] As a further embodiment of the present invention: the two sections of the tube wall arranged opposite each other are arranged parallel to the two sides of the wall panel.

[0022] As a further embodiment of the present invention: both the tie tube and the insulation layer are extruded polystyrene boards.

[0023] As a further embodiment of the present invention: both the outer concrete leaf plate and the inner concrete leaf plate are filled with rubber aggregate, and the particle size of the rubber aggregate is 10mm to 19mm.

[0024] As a further embodiment of the present invention: the wall thickness of the tie tube is 1mm to 3mm, the side length of the cross-section of the tie tube is 60mm to 120mm, and the thickness of the insulation layer is 50mm to 100mm.

[0025] Compared with the prior art, the beneficial effects of the present invention are:

[0026] 1. This invention sets the tie member as a honeycomb structure and connects and fixes it with the insulation layer to form an integral whole, so that the two ends of the tie cylinder extend into the inner and outer concrete leaf plates. While improving the insulation performance, it also makes the wall panel have better impact resistance and higher initial stiffness.

[0027] 2. By adding rubber aggregate into the concrete leaf slab, the present invention further improves the energy absorption capacity of the wall panel, increases the toughness of the concrete, improves the brittleness of the concrete, and further improves the impact resistance of the wall panel.

[0028] 3. This invention provides a theoretical basis for practical engineering applications by calculating and predicting the initial stiffness and impact energy absorption of the wall panel. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the structure of the present invention.

[0030] In the picture:

[0031] 1. Concrete outer leaf plate; 2. Insulation layer; 3. Concrete inner leaf plate;

[0032] 4. Tie tube; 41. Positioning hole; 51. Horizontal reinforcement; 52. Longitudinal reinforcement. Detailed Implementation

[0033] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] Please see Figure 1In this embodiment of the invention, a method for manufacturing an ultra-low energy consumption sandwich insulated exterior wall panel with impact resistance is disclosed. The wall panel includes an outer concrete leaf panel 1 and an inner concrete leaf panel 3 located on both sides of an insulation layer 2. Both the outer concrete leaf panel 1 and the inner concrete leaf panel 3 are equipped with a reinforcing mesh, which includes transverse reinforcing bars 51 and longitudinal reinforcing bars 52. The transverse reinforcing bars 51 are arranged adjacent to the insulation layer 2, and the longitudinal reinforcing bars 52 are arranged away from the insulation layer 2. There is a gap between the transverse reinforcing bars 51 and the longitudinal reinforcing bars 52, and they are tied and fixed at the joints. Rubber aggregate is added during the pouring of the outer concrete leaf panel 1 and the inner concrete leaf panel 3, and the particle size of the rubber aggregate is controlled between 10mm and 19mm.

[0035] The insulation layer 2 is integrally provided with tie cylinders 4. There are multiple sets of tie cylinders 4. The tie cylinders 4 are in the form of regular hexagons. The tie cylinders 4 are connected in a honeycomb structure. The adjacent tie cylinders 4 share the cylinder wall.

[0036] The length of the tie cylinder 4 is greater than the thickness of the insulation layer 2. When the tie cylinder 4 is fixed to the insulation layer 2, the geometric center of the tie cylinder 4 and the geometric center of the insulation layer 2 are located on the same plane. The overall thickness of the insulation layer 2 is controlled to be 50mm to 100mm.

[0037] The insulation layer 2 and the tie cylinder 4 are made of the same material, extruded polystyrene board. The insulation layer 2 and tie cylinder 4 are integrally formed. During fixing, the insulation layer 2 is first cut to form a ring structure, which wraps around the honeycomb structure of the tie cylinder 4, interlocking with it. After interlocking, they are bonded and fixed. The cut-off sheets from the insulation layer 2 are processed into regular hexagonal sheets, corresponding to the inner wall dimensions of the tie cylinder 4. Each sheet is at the same height as the ring structure of the insulation layer 2, together forming a separate insulation layer 2. These sheets are bonded and fixed to the cylinder wall of the tie cylinder 4.

[0038] The thickness of the tie tube 4 is set to 1mm to 3mm, and the side length of the cross-section of the tie tube 4 needs to be controlled between 60mm and 120mm.

[0039] The tie cylinder 4 is provided with positioning holes 41 on the cylinder body located in the outer concrete leaf plate 1 and the inner concrete leaf plate 3, so that the transverse steel bars 51 in the outer concrete leaf plate 1 and the inner concrete leaf plate 3 can pass through. The diameter of the positioning hole 41 corresponds to the diameter of the transverse steel bar 51, and the diameter of the positioning hole 41 is 6mm to 10mm.

[0040] The honeycomb structure formed by the tie tubes 4 must be located within the outer edge of the insulation layer 2 to avoid positional interference with the edge of the insulation layer 2, and should be arranged as close as possible to the center of the insulation layer 2. After the tie tubes 4 are fixed, it must be ensured that the two opposing sections of the tube wall are arranged parallel to the side of the wall panel.

[0041] The manufacturing process of wall panels includes the following steps:

[0042] S1. Design the wall panels and determine the thickness of the outer concrete leaf panel 1, the inner concrete leaf panel 3, and the insulation layer 2.

[0043] S2. Assuming that both ends of the tie tube 4 need to be inserted into the outer concrete leaf plate 1 and the inner concrete leaf plate 3, design the dimensions of the tie tube 4, and calculate whether the impact absorption energy and initial stiffness of the wall panel meet the design requirements. If they meet the requirements, process the tie tube 4 of the corresponding dimensions.

[0044]

[0045] in, K L This represents the initial stiffness of the wall panel;

[0046] E L To absorb energy and resist impact for the wall panel;

[0047] B Let be the side length of the cross-section of the tie cylinder 4;

[0048] H L The length of the tie tube 4.

[0049] S3. Connect each tie cylinder 4 to form a honeycomb structure. Each tie cylinder 4 has a positioning hole 41 corresponding to the diameter of the transverse steel bar 51.

[0050] S4. A groove is cut in the middle of the insulation layer 2 to engage with the honeycomb structure formed by the tie cylinder 4. The insulation layer 2 peeled off during the grooving is cut to form a regular hexagonal layer corresponding to the cross-sectional size of the inner wall of each tie cylinder 4. The number of regular hexagonal layers corresponds to the number of tie cylinders 4. Each regular hexagonal layer is pasted to the inner wall of the corresponding tie cylinder 4 so that the tie cylinder 4 and the insulation layer 2 form an integral structure.

[0051] The insulation layer 2 and the tie cylinder 4 are pre-bonded with glue. After the concrete is poured, the solidified concrete will clamp the tie cylinder 4.

[0052] S5. Fix the insulation layer 2 with the pre-fixed tie cylinder 4, the transverse steel bar 51 and the longitudinal steel bar 52 in the concrete pouring mold, so that each transverse steel bar 51 passes through the positioning hole 41 of the corresponding tie cylinder 4, pour concrete into the concrete pouring mold, cure and demold to complete the manufacturing of the wall panel.

[0053] In the actual pouring process, the leaf plate on one side of the insulation layer 2 is poured first, then the wall panel is flipped 180 degrees and the leaf plate on the other side is poured. The positioning hole 41 can be drilled after the insulation layer 2 is fixed in the concrete pouring mold. When pouring the concrete leaf plate on the corresponding side, the positioning hole 41 is opened on the corresponding side of the tie cylinder 4.

[0054] In this embodiment, when the wall panel is used as a building curtain wall, the thickness of the outer concrete leaf 1 is set to 60mm, the thickness of the insulation layer 2 is set to 30mm, and the thickness of the inner concrete leaf 3 is set to 200mm.

[0055] A numerical model of the wall panel was created using LS-DYNA software. The concrete leaf panels, insulation layer, and tie cylinder were all built using 3D solid models. Specifically, the outer concrete leaf panel 1 and the inner concrete leaf panel 3 were each 60mm thick, with a length and width of 1200mm. The insulation layer 2 was 50mm thick, and the overall wall panel thickness was 170mm. A cylindrical drop hammer with a diameter of 200mm and a mass of 100kg was created and set as a rigid body. The contact velocity between the drop hammer and the center of the wall panel surface was set to 6.62m / s.

[0056] In the analysis, the side length of the cross-section of the tie cylinder 4 is... B Five working conditions are set, with side lengths of 60mm, 75mm, 90mm, 105mm, and 120mm respectively. The length of the tie cylinder 4... H L Five working conditions were set up with lengths of 90mm, 100mm, 110mm, 120mm, and 130mm. The corresponding depths D of the tie cylinder 4 extending into the concrete blades at both ends were 20mm, 25mm, 30mm, 35mm, and 40mm. The impact absorption energy obtained through simulation analysis and calculation for different size combinations is shown in Table 1 below. E in Table 1... model E represents the impact energy absorption of the wall panel, as simulated by software. L The calculated impact energy absorption capacity of the wall panel.

[0057] Table 1

[0058]

[0059] It can be seen that the impact absorption energy of the wall panel obtained by simulation is in good agreement with the impact absorption energy of the wall panel obtained by calculation. The impact resistance performance of the wall panel can be predicted well through calculation.

[0060] Under the same size combination, the initial stiffness of the wall panel obtained through simulation analysis and the calculated initial stiffness of the wall panel are shown in Table 2 below. K model This represents the initial stiffness of the wall panel obtained through software simulation. K L This represents the calculated initial stiffness of the wall panel.

[0061] Table 2

[0062]

[0063] It can be seen that the initial stiffness of the wall panel obtained by simulation is in good agreement with the initial stiffness data of the wall panel obtained by calculation. The initial stiffness parameters of the wall panel can be predicted well through calculation.

[0064] With the thicknesses of the outer concrete leaf plate 1, the inner concrete leaf plate 3, and the insulation layer 2 remaining unchanged, the tie cylinder 4 is replaced with the existing GFRP plate tie member. The depths of the GFRP plate tie member extending into the outer concrete leaf plate 1 and the inner concrete leaf plate 3 are consistent with the extension depths of the tie cylinder 4. The GFRP plate tie members are densely distributed with a spacing of 125mm.

[0065] The initial stiffness obtained is 1330.09 KN / mm, which is obviously less than the initial stiffness obtained by the simulation of the wall panel in this application. The impact absorption energy is 661.387 J, which is also less than the impact absorption energy obtained by the simulation of the wall panel in this application. The comprehensive performance of this application is far superior to that of traditional precast wall panels using GFRP plate tie members.

[0066] However, the total absorbed energy is less than that obtained from the simulation of the ultra-low energy consumption sandwich insulated exterior wall panel with impact resistance, therefore this type of wall panel has better impact resistance.

[0067] The basic principles of this application have been described above with reference to specific embodiments. However, it should be noted that the advantages, benefits, and effects mentioned in this application are merely examples and not limitations, and should not be considered as essential features of each embodiment of this application. Furthermore, the specific details disclosed above are for illustrative and facilitative purposes only, and are not limitations. These details do not limit the application to the necessity of employing the aforementioned specific details for implementation.

[0068] The block diagrams of devices, apparatuses, devices, and systems involved in this application are merely illustrative examples and are not intended to require or imply that they must be connected, arranged, or configured in the manner shown in the block diagrams. As those skilled in the art will recognize, these devices, apparatuses, devices, and systems can be connected, arranged, and configured in any manner. Words such as “comprising,” “including,” “having,” etc., are open-ended terms meaning “including but not limited to,” and are used interchangeably with them. The terms “or” and “and” as used herein refer to the terms “and / or,” and are used interchangeably with them unless the context clearly indicates otherwise. The term “such as” as used herein refers to the phrase “such as but not limited to,” and is used interchangeably with it.

Claims

1. A method for manufacturing an ultra-low energy consumption sandwich insulated exterior wall panel with impact resistance, characterized in that, Includes the following steps: S1. Design the wall panels and determine the thickness of the outer concrete leaf panel (1), the inner concrete leaf panel (3), and the insulation layer (2); S2. As required that both ends of the tie tube (4) need to be inserted into the concrete outer leaf plate (1) and the concrete inner leaf plate (3), design the size of the tie tube (4), and calculate whether the impact absorption energy and initial stiffness of the wall panel meet the design requirements. After meeting the requirements, process the tie tube (4) of the corresponding size. in, K L This represents the initial stiffness of the wall panel; E L To absorb energy and resist impact for the wall panel; B Let be the side length of the cross-section of the tie tube (4); H L The length of the tie tube (4); S3. Connect each tie cylinder (4) to form a honeycomb structure. Each tie cylinder (4) has a positioning hole (41) corresponding to the diameter of the transverse steel bar (51). S4. A groove is cut in the middle of the insulation layer (2) and it is snapped into the honeycomb structure formed by the tie cylinder (4). The insulation layer (2) peeled off during the grooving is cut to form a regular hexagonal layer corresponding to the cross-sectional size of the inner wall of each tie cylinder (4). The number of regular hexagonal layers corresponds to the number of tie cylinders (4). Each regular hexagonal layer is pasted to the inner wall of the corresponding tie cylinder (4) so ​​that the tie cylinder (4) and the insulation layer (2) form an integral structure. S5. Fix the insulation layer (2) with pre-fixed tie cylinder (4), transverse steel bar (51) and longitudinal steel bar (52) in the concrete pouring mold, so that each transverse steel bar (51) passes through the positioning hole (41) of the corresponding tie cylinder (4), pour concrete into the concrete pouring mold, cure and demold to complete the manufacturing of the wall panel.

2. The method for manufacturing an ultra-low energy consumption sandwich insulated exterior wall panel with impact resistance according to claim 1, characterized in that, The cross-section of the tie tube (4) is a regular hexagonal structure. The body of each tie tube (4) forms a honeycomb layout along the direction perpendicular to the wall panel. The tie tube (4) and the insulation layer (2) are made of the same material.

3. The method for manufacturing an ultra-low energy consumption sandwich insulated exterior wall panel with impact resistance according to claim 1, characterized in that, Both the outer concrete leaf slab (1) and the inner concrete leaf slab (3) are equipped with steel mesh. The steel mesh includes transverse steel bars (51) set in the adjacent insulation layer (2) and longitudinal steel bars (52) set away from the insulation layer (2). There is a gap between the transverse steel bars (51) and the longitudinal steel bars (52).

4. The method for manufacturing an ultra-low energy consumption sandwich insulated exterior wall panel with impact resistance according to claim 1, characterized in that, The diameter of the positioning hole (41) is 6mm to 10mm.

5. The method for manufacturing an ultra-low energy consumption sandwich insulated exterior wall panel with impact resistance according to claim 1, characterized in that, The two sections of the tube wall of the tie tube (4) are arranged opposite to each other and are parallel to the two sides of the wall panel.

6. The method for manufacturing an ultra-low energy consumption sandwich insulated exterior wall panel with impact resistance according to claim 1, characterized in that, Both the tie tube (4) and the insulation layer (2) are extruded polystyrene boards.

7. The method for manufacturing an ultra-low energy consumption sandwich insulated exterior wall panel with impact resistance according to claim 1, characterized in that, Both the outer concrete leaf plate (1) and the inner concrete leaf plate (3) are filled with rubber aggregate, and the particle size of the rubber aggregate is 10mm to 19mm.

8. A method for manufacturing an ultra-low energy consumption sandwich insulated exterior wall panel with impact resistance according to claim 1, characterized in that, The wall thickness of the tie tube (4) is 1mm to 3mm, and the side length of the cross section of the tie tube (4) is 60mm to 120mm; the thickness of the insulation layer is 50mm to 100mm.

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