Novel fabricated building wall component

Abstract

The invention discloses a novel fabricated building wall component which comprises a composite structure layer, and the composite structure layer sequentially comprises an outer-layer concrete plate, a vacuum heat insulation core material and an inner-layer fiber reinforced plate from outside to inside. The thickness of the outer-layer concrete slab is 32-48mm, and the compressive strength is greater than or equal to 80MPa; the thickness of the vacuum heat insulation core material is 60-80mm, and the heat conductivity coefficient is less than or equal to 0.008 W / (m.K); the thickness of the inner-layer fiber reinforced plate is 24-40mm, and the bending strength is greater than or equal to 30MPa; the connecting systems are arranged at the top and the bottom of the composite structure layer, and each connecting system comprises a male tenon lock catch, a female tenon lock catch and a leveling support; the self-adaptive joint system comprises an expandable sealing rubber strip and a nano aerogel filling layer, the structure is reasonable, and a wall component is more durable by constructing a multi-material interface transition layer and a broken structural cold and hot bridge.

Description

Technical Field

[0001] The present invention relates to the field of building walls, and in particular to a novel assembled building wall component. Background Art

[0002] Prefabricated buildings are structures whose walls are assembled on-site from prefabricated components. Based on the type of prefabricated components and construction method, they are categorized into five types: block, panel, cassette, skeleton panel, and riser-slab-and-rise.

[0003] Currently, prefabricated walls are mostly fastened with bolts or welds, requiring precise manual positioning. The installation of a single component can take 15-30 minutes, and seismic joints are prone to fatigue failure due to stress concentration. Furthermore, due to precision issues, existing prefabricated walls are prone to cracks at joints, requiring regular maintenance that is time-consuming and labor-intensive. To address these issues, the following solution is proposed. Summary of the Invention

[0004] The purpose of the present invention is to provide a novel assembled building wall component, which has the advantages of being easy to position, being able to automatically fill small cracks, and extending the maintenance cycle.

[0005] The above technical objectives of the present invention are achieved through the following technical solutions:

[0006] A new type of assembled building wall component, comprising:

[0007] The composite structure layer comprises, from outside to inside, an outer concrete slab, a vacuum insulation core material, and an inner fiber reinforced board; the outer concrete slab is 32-48 mm thick and has a compressive strength of 80 MPa or greater; the vacuum insulation core material is 60-80 mm thick and has a thermal conductivity of 0.008 W / (m·K or less); the inner fiber reinforced board is 24-40 mm thick and has a flexural strength of 30 MPa or greater;

[0008] A connection system is provided at the top and bottom of the composite structure layer, the connection system including male and female mortise and tenon locks and leveling supports;

[0009] The adaptive joint system includes an expandable sealing strip and a nano-aerogel filling layer. Preferably, the male and female mortise lock includes a tenon structure, which includes a tenon head and a tenon groove. The tenon has a trapezoidal cross-section design, a length of 50±2mm, an inclination angle of 15°, and the tenon groove is sized to match the tenon head. The surfaces of the tenon head and the tenon groove are both coated with a wear-resistant ceramic coating.

[0010] The positioning sensor includes a three-axis Hall sensor and an infrared radiation device, and is used to detect the horizontal and vertical deviations of adjacent components in real time.

[0011] Preferably, the leveling support includes a base assembly, the base assembly includes a ductile iron base plate and a high-strength rubber shock-absorbing pad, and a pressure sensor is embedded in the ductile iron base plate;

[0012] A laser calibration system includes a cross laser emitter and a CMOS image sensor, and the CMOS image sensor generates three-dimensional leveling data in real time.

[0013] Preferably, the expandable sealing strip has an expansion rate of ≥50% when the humidity is ≥60%; the thermal conductivity of the nano-aerogel filling layer is ≤0.020 W / (m·K), and the compression rebound rate is ≥90%.

[0014] Preferably, the vacuum insulation core material is composed of a multi-layer aluminum foil composite vacuum cavity, and the interior of the cavity is filled with fumed silica particles.

[0015] Preferably, wire grooves are provided on the four side walls of the composite structure layer, and the wire grooves include longitudinal wire grooves and horizontal wire grooves.

[0016] The diameter of the longitudinal trunking is 20 mm and is used for high-voltage lines. A flame-retardant partition is provided inside the longitudinal trunking.

[0017] The diameter of the horizontal wire trough is 10 mm, and it is used for weak current and communication lines. An electromagnetic shielding copper mesh is provided in the horizontal wire trough.

[0018] Preferably, a water guide groove is provided at the edge of the composite structure layer, a hydrophobic nano coating is provided in the water guide groove, and the drainage slope of the water guide groove is ≥3%.

[0019] 8. The method for producing a novel assembled building wall component according to any one of claims 1 to 7, characterized in that it comprises the following steps:

[0020] S1: Parametric Design

[0021] S11: Extract building structural parameters based on the BIM model and generate component 3D models through topology optimization algorithms.

[0022] Optimization goals include:

[0023] Structural strength ≥ 1.5 times of design load;

[0024] Thermal performance meets the U value ≤ 0.15W / (m 2 K);

[0025] The pipeline channel volume accounts for ≥12%;

[0026] Output component processing data to CNC machine tools;

[0027] S12: The mold is made of a combined steel mold, and a temperature sensor and vibration compensation device are installed inside the mold;

[0028] S2: Through layered pouring process

[0029] S21: Casting of outer concrete slab:

[0030] The mass ratio of concrete is cement: aggregate: nano-enhancer = 1:2.5:0.03;

[0031] Vibration frequency 50Hz, lasting 3 minutes, spray curing agent on the surface after molding

[0032] S22: The vacuum insulation core material is laid using a vacuum infusion process, injecting fumed silica particles into the aluminum foil composite cavity with a vacuum degree of ≤10Pa and an infusion temperature of 25±2℃

[0033] S23: Pressed inner fiber reinforced board. The fiberboard is orthogonally woven with carbon fiber and basalt fiber, impregnated with resin and then hot-pressed.

[0034] S3: Pre-embedded functional components

[0035] S31: Use a six-axis robot to insert the male and female mortise locks into the reserved grooves on the top of the component. The perpendicularity error between the lock axis and the component reference plane is ≤0.1°;

[0036] The leveling support is fixed to the bottom of the component with epoxy resin adhesive, and a 5kN pre-load test is applied after curing;

[0037] S32: Wire duct assembly:

[0038] The longitudinal wire duct and the horizontal wire duct are connected by laser welding;

[0039] S4: Curing and curing: Place the components in the curing kiln.

[0040] For the first 24 hours, the temperature was controlled at 50°C, the relative humidity was 90% ± 5%, and the CO2 concentration was 20%;

[0041] 24 to 48 hours, control the temperature at 30°C and the relative humidity at 60% ± 5%;

[0042] After 48 hours, the temperature was controlled to maintain normal temperature and relative humidity to 60% ± 5%;

[0043] After the maintenance is completed, an ultrasonic detector is used to scan for defects inside the components;

[0044] S5: Intelligent calibration generates 3D point cloud data of components through laser scanning. After comparing with the BIM model, CNC milling correction is performed on areas with size deviation greater than 0.5mm.

[0045] Write the measured parameters into the RFID chip.

[0046] The beneficial effects of the present invention are:

[0047] Structurally, the "sandwich composite layer + electromagnetic lock" design is adopted to increase installation efficiency by 300% and reduce thermal bridge coefficient by 86%;

[0048] In terms of technology, we have developed a vacuum infusion molding process with a flatness error of ≤0.15mm / m, and combined it with robot pre-embedding technology with a positioning accuracy of ±0.1mm, to overcome the difficulties in producing special-shaped components. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Figure 1 It is a structural diagram of an embodiment;

[0050] Figure 2 Schematic diagram of the top view of the embodiment;

[0051] Figure 3 Schematic diagram of the side structure of the embodiment;

[0052] Figure 4 The embodiment is used in a side cross-sectional view.

[0053] Figure numerals: 1. Concrete slab; 2. Vacuum insulation core material; 3. Fiber reinforced board; 4. Expandable sealing strip; 5. Nano aerogel filling layer; 6. Tenon; 7. Mortise; 8. Three-axis Hall sensor; 9. Infrared radiation device; 10. Ductile iron substrate; 11. High-strength rubber shock-absorbing pad; 12. Cross laser emitter; 13. CMOS image sensor; 14. Composite vacuum chamber; 15. Silica particles; 16. Longitudinal wire groove; 17. Horizontal wire groove; 18. Water guide groove. DETAILED DESCRIPTION

[0054] The following is only a preferred embodiment of the present invention, and the scope of protection is not limited to this embodiment. All technical solutions under the concept of the present invention should fall within the scope of protection of the present invention. The same parts are represented by the same figure marks. It should be noted that the words "front", "rear", "left", "right", "up" and "down" used in the following description refer to the directions in the accompanying drawings, and the words "bottom" and "top", "inside" and "outside" refer to the directions toward or away from the geometric center of a specific component, respectively.

[0055] like Figures 1 to 4 As shown, a new type of prefabricated building wall component includes the following structure and preparation method:

[0056] S1: Parametric design and mold preparation

[0057] S11: BIM model input

[0058] Use Revit to build a building information model and extract wall geometry data;

[0059] Run the ANSYS topology optimization module to optimize the target. Under the extreme wind pressure of 0.55kN / m 2 And under the earthquake load of 0.3g, the stress concentration factor of the component is ≤1.2;

[0060] Output results: The average component weight was reduced by 18%, and the pipeline channel volume ratio increased to 14.5%.

[0061] S12: Mold processing

[0062] The combined steel mold is processed using a five-axis CNC machine tool, and the inner surface of the mold is sprayed with a titanium nitride coating, with a friction coefficient of 0.08 and a mold parting accuracy of ±0.05mm;

[0063] The mold has a built-in piezoelectric vibration sensor. The model used in this design is PCB-352C03, which monitors the pouring density in real time.

[0064] S2: Layered pouring process

[0065] S21: Casting of outer concrete slab

[0066] Material ratio: P.O52.5 cement 650kg / m 3 , the graded aggregate is 5-10mm granite, the dosage is 1650kg / m 3 , nano-silica reinforcement 20kg / m 3 ;

[0067] Pouring control: Use a high-frequency vibrator with a frequency of 150 Hz for 4 minutes, and spray the surface with silane impregnant, model SI-30, with a penetration depth of 3.2 mm;

[0068] Forming inspection: The rebound hammer test strength reaches 82.5MPa.

[0069] S22: Vacuum Insulation Core Infusion

[0070] Process parameters: The fumed silica (Cabot TS-530) and the aluminum foil with a thickness of 0.2 mm were composited in a vacuum chamber (10 -2 Pa) perfusion, perfusion rate 20g / s;

[0071] Quality verification: The flatness error of the core material detected by infrared thermal imager is 0.15mm / m, and the thermal conductivity coefficient is measured to be 0.0073W / (m·K).

[0072] S23: Inner fiber reinforced board pressing

[0073] Material composition: T700 carbon fiber (warp) and Basalttex basalt fiber (weft) woven at 0° / 90° orthogonal angle, impregnated with epoxy resin (EPON828);

[0074] Hot pressing parameters: pressure 5.2 MPa, temperature 125°C, time 32 minutes;

[0075] Performance test: three-point bending strength 38.7MPa, combustion performance reaches A1 level (GB8624-2012).

[0076] S3: Pre-embedded functional components

[0077] S31: Smart Connect System Installation

[0078] The male and female mortise locks were implanted using an ABBIRB6700 robot with an implant depth of 50.2 mm and a tolerance of ±0.1 mm. The coaxiality error was calibrated with a laser tracker and was ≤0.05°.

[0079] Leveling support fixation: Use HiltiHY270 adhesive, the shear strength after curing is 17.3MPa, and the pre-compression test load is loaded to 5.5kN with no displacement.

[0080] S32: Integrated cavity welding

[0081] The vertical pipe gallery and horizontal cable duct are welded by fiber laser welding (IPGYLS-4000), with a weld penetration depth of 1.8mm and a 100% pass rate for X-ray inspection.

[0082] S4: Differentiated maintenance and quality inspection

[0083] Maintenance process:

[0084] Stage 1 (0-24h): temperature 50°C, humidity 95%, CO2 concentration 20%, surface carbonization depth 0.53mm;

[0085] Stage 2 (24-72h): Temperature 30°C, humidity 60%, natural ventilation;

[0086] Carbonization test: After 28 days of rapid carbonization test, the carbonization depth is ≤0.1mm (GB / T50082-2009).

[0087] S5: Intelligent Calibration

[0088] 3D scanning: Using a FARO Focus S350 laser scanner, point cloud data was generated and compared with the BIM model, with a maximum deviation of 0.43mm.

[0089] RFID data writing: storage component weight (standard parts 286 ± 1.2 kg), installation coordinate XYZ axis error ≤ 0.5 mm, thermal parameter U value 0.143 W / (m 2 ·K).

[0090] Performance verification and comparison:

[0091]

[0092] The specific embodiments described above further illustrate the technical problems, technical solutions and beneficial effects solved by the present invention. It should be understood that the above are only specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A new type of assembled building wall component, characterized in that: include: The composite structure layer comprises, from outside to inside, an outer concrete slab, a vacuum insulation core material, and an inner fiber reinforced board; the outer concrete slab is 32-48 mm thick and has a compressive strength of 80 MPa or greater; the vacuum insulation core material is 60-80 mm thick and has a thermal conductivity of 0.008 W / (m·K or less); the inner fiber reinforced board is 24-40 mm thick and has a flexural strength of 30 MPa or greater; A connection system is provided at the top and bottom of the composite structure layer, the connection system including male and female mortise and tenon locks and leveling supports; Adaptive seam system, including expandable sealing strips and nano-aerogel filling layer.

2. A novel assembled building wall component according to claim 1, characterized in that: The male and female mortise and tenon lock comprises A tenon structure comprising a tenon and a tenon groove. The tenon adopts a trapezoidal cross-section design, the tenon length is 50±2 mm, the inclination angle is 15°, the size of the tenon groove matches the tenon, and the surfaces of the tenon and the tenon groove are both coated with a wear-resistant ceramic coating; The positioning sensor includes a three-axis Hall sensor and an infrared radiation device, and is used to detect the horizontal and vertical deviations of adjacent components in real time.

3. A novel assembled building wall component according to claim 1, characterized in that: The leveling support includes A base assembly, the base assembly comprising a ductile iron base plate and a high-strength rubber shock-absorbing pad, wherein a pressure sensor is embedded in the ductile iron base plate; A laser calibration system includes a cross laser emitter and a CMOS image sensor, and the CMOS image sensor generates three-dimensional leveling data in real time.

4. A novel assembled building wall component according to claim 1, characterized in that: The expansion rate of the expandable sealing strip is ≥50% when the humidity is ≥60%; The thermal conductivity of the nano-aerogel filling layer is ≤0.020 W / (m·K), and the compression rebound rate is ≥90%.

5. A novel assembled building wall component according to claim 1, characterized in that: The vacuum insulation core material is composed of a multi-layer aluminum foil composite vacuum cavity, and the interior of the cavity is filled with fumed silica particles.

6. A novel assembled building wall component according to claim 1, characterized in that: The four side walls of the composite structure layer are provided with wire grooves, which include longitudinal wire grooves and horizontal wire grooves. The diameter of the longitudinal trunking is 20 mm and is used for high-voltage lines. A flame-retardant partition is provided inside the longitudinal trunking. The diameter of the horizontal wire trough is 10 mm, and it is used for weak current and communication lines. An electromagnetic shielding copper mesh is provided in the horizontal wire trough.

7. A novel assembled building wall component according to claim 1, characterized in that: A water guide groove is provided at the edge of the composite structure layer, a hydrophobic nano coating is provided in the water guide groove, and the drainage slope of the water guide groove is ≥3%.

8. The method for producing a novel assembled building wall component according to any one of claims 1 to 7, characterized in that: The following steps are included: S1: Parametric Design S11: Extract building structural parameters based on the BIM model and generate component 3D models through topology optimization algorithms. Optimization goals include: Structural strength ≥ 1.5 times of design load; Thermal performance meets the U value ≤ 0.15W / (m 2 K); The pipeline channel volume accounts for ≥12%; Output component processing data to CNC machine tools; S12: Mold preparation Adopt combined steel mold, and set temperature sensor and vibration compensation device inside the mold; S2: Through layered pouring process S21: Casting of outer concrete slab: The mass ratio of concrete is cement: aggregate: nano-enhancer = 1:2.5:0.03; Vibration frequency 50Hz, lasting 3 minutes, spray curing agent on the surface after molding S22: Laying vacuum insulation core material The fumed silica particles are injected into the aluminum foil composite cavity using a vacuum infusion process with a vacuum degree of ≤10Pa and an infusion temperature of 25±2℃. S23: laminated inner fiber reinforced board The fiberboard is made of orthogonally woven carbon fiber and basalt fiber, impregnated with resin and then hot-pressed; S3: Pre-embedded functional components S31: Use a six-axis robot to insert the male and female mortise locks into the reserved grooves on the top of the component. The perpendicularity error between the lock axis and the component reference plane is ≤0.1°; The leveling support is fixed to the bottom of the component with epoxy resin adhesive, and a 5kN pre-load test is applied after curing; S32: Wire duct assembly: The longitudinal wire duct and the horizontal wire duct are connected by laser welding; S4: Curing and maintenance Place the components in the curing kiln. For the first 24 hours, the temperature was controlled at 50°C, the relative humidity was 90% ± 5%, and the CO2 concentration was 20%; 24 to 48 hours, control the temperature at 30°C and the relative humidity at 60% ± 5%; After 48 hours, the temperature was controlled to maintain normal temperature and relative humidity to 60% ± 5%; After the maintenance is completed, an ultrasonic detector is used to scan for defects inside the components; S5: Intelligent Calibration The three-dimensional point cloud data of the components is generated by laser scanning and compared with the BIM model. Perform CNC milling correction on areas with size deviations greater than 0.5mm. Write the measured parameters into the RFID chip.

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