A concrete module and a method of manufacturing the same

Abstract

The present application relates to the technical fields of modular integrated building, and especially relates to a concrete module and a manufacturing method thereof, a second connecting assembly comprises a second anchoring steel bar and a second fixing plate, the second anchoring steel bar extends in the prefabricated bottom plate along the horizontal direction, and one side of the second fixing plate is fixedly connected with the second anchoring steel bar; the first fixing plate and the second fixing plate are partially exposed with respect to the prefabricated side plate and the prefabricated bottom plate respectively, and the exposed part of the first fixing plate and the exposed part of the second fixing plate are fixedly connected with the connecting plate respectively. Its beneficial effects are that the concrete module is cooperated with the first anchoring steel bar, the second anchoring steel bar, the first fixing plate, the second fixing plate and the connecting plate through pre-buried, the production efficiency of the concrete module is accelerated, the inner container module is fixedly connected with the mold table, therefore, the inner container module does not need to be repeatedly assembled, the risk of deformation of the repeatedly assembled inner container module is reduced, the production precision stability of the concrete module is improved, and the work load and work difficulty of workers are greatly reduced.

Description

Technical Field

[0001] This invention relates to the field of modular integrated building technology, and more particularly to a concrete module and its manufacturing method. Background Technology

[0002] Accelerated global urbanization presents traditional construction industries with challenges such as low construction efficiency, difficulty in quality control, severe pollution, and labor shortages. Prefabricated building technology is becoming a trend, with Modular Integrated Construction (MiC) driving the industry towards industrialization, digitalization, and green development due to its high efficiency, environmental friendliness, and intelligence. MiC technology breaks down buildings into independent functional modules, completing all structural, finishing, and plumbing processes in a factory before transporting them to the site for rapid assembly. Compared to traditional construction methods, it offers advantages such as shorter construction cycles, reduced on-site wet work, less reliance on weather and labor, improved building quality and safety, and reduced construction waste and carbon emissions. Concrete modules are widely used in residential construction and other fields due to their durability, fire resistance, waterproofing, and low maintenance costs; for example, the proportion of concrete modular buildings in Singapore has increased significantly in recent years. However, existing MiC technologies still have limitations in concrete module production processes.

[0003] In existing technology, a concrete module includes a precast top slab, a precast bottom slab, and multiple precast side slabs. Therefore, the molds for the precast bottom slab and multiple precast side slabs are assembled first. The molds for the multiple precast side slabs include an outer formwork and an inner mold. The mold for the precast bottom slab is a mold platform, forming a pouring space for casting the precast bottom slab and multiple precast side slabs. Concrete is poured into the pouring space to form an integrated precast bottom slab and multiple precast side slabs. The mold is then disassembled and removed. Multiple wall reinforcement bars are reserved on the precast side slabs for lapping with the top slab reinforcement bars. Subsequently, the mold for the precast top slab is assembled, and the wall reinforcement bars are connected to the top slab reinforcement bars. Concrete is then poured into the precast top slab mold to finally form the concrete module. Therefore, there are problems such as a complex production process, low mold utilization efficiency (the mold platform can only be removed after the concrete module is manufactured), and insufficient production precision and quality control (each formwork is prone to deformation after long-term disassembly and assembly). This results in low module installation efficiency and poor precision (deformed templates can easily cause the flatness and verticality of the concrete modules to fail to meet requirements). In addition, the existing concrete module connection methods (such as steel bar welding, grouting, and keyway splicing) are complex, and the construction environment is too confined, leading to extended construction cycles, requiring rigorous technical training for workers, and presenting high learning curves.

[0004] In summary, the existing concrete module production process has problems in terms of production flow, mold use, production precision, and connection between wall panels, and urgently needs innovation and transformation to improve production efficiency, quality control level, and sustainability.

[0005] Therefore, we continue to develop a concrete module and its manufacturing method that can accelerate production efficiency and ensure the accuracy of the concrete module. Summary of the Invention

[0006] (a) Technical problems to be solved

[0007] In view of the above-mentioned shortcomings and deficiencies of the prior art, the present invention provides a concrete module and its manufacturing method, which solves the technical problems of low production efficiency and unstable precision of concrete modules in the prior art.

[0008] (II) Technical Solution

[0009] To achieve the above objectives, the main technical solutions adopted by the present invention include:

[0010] In a first aspect, embodiments of the present invention provide a concrete module, comprising a first precast slab assembly and a second precast slab assembly. The first precast slab assembly includes four precast side plates, a first connecting assembly embedded in the bottom of the precast side plates, and a connecting plate. The second precast slab assembly includes a precast bottom plate and a second connecting assembly embedded in the precast bottom plate and corresponding to the first connecting assembly. The first connecting assembly includes multiple first anchoring bars and a first fixing plate. The first anchoring bars extend vertically within the precast side plates, and the bottom of the first anchoring bars is fixedly connected to one side of the first fixing plate, while the other side of the first fixing plate is fixedly connected to the connecting plate. The second connecting assembly includes second anchoring bars and a second fixing plate. The second anchoring bars extend horizontally within the precast bottom plate, and one side of the second fixing plate is fixedly connected to the second anchoring bars. The first fixing plate and the second fixing plate are partially exposed relative to the precast side plates and the precast bottom plate, respectively, and the exposed portions of the first fixing plate and the second fixing plate are fixedly connected to the connecting plate.

[0011] Optionally, when both the first fixing plate and the second fixing plate are flat, the connecting plate is L-shaped. The L-shaped connecting plate includes a first plate and a second plate that are vertically connected. The first plate is fixedly connected to the other side of the first fixing plate, and the second plate is fixedly connected to the other side of the second fixing plate.

[0012] Optionally, a first recess is provided at the bottom of the precast side plate, one end of the first fixing plate is embedded in the precast side plate, and the first fixing plate extends into the first recess, forming an exposed portion in the first recess; a second recess is provided on the precast bottom plate, one end of the second fixing plate is embedded in the precast bottom plate, and the second fixing plate extends into the second recess, forming an exposed portion in the second recess; a first gap is formed between the inner wall of the second recess and the connecting plate and the second fixing plate, and the first gap is filled by pouring grout.

[0013] Optionally, when both the first fixing plate and the second fixing plate are plates with bends, the connecting plate is flat and has an integrally formed third plate and a fourth plate. The third plate is fixedly connected to the first anchoring steel bar and the second anchoring steel bar, respectively, and the two fourth plates form a connecting plane that connects to the connecting plate. The connecting plane is parallel to the connecting plate.

[0014] Optionally, a third recess is provided on the precast side plate, one end of the first fixing plate is embedded in the precast side plate, and the first fixing plate extends into the third recess, forming an exposed portion in the third recess; a fourth recess is provided on the precast bottom plate, one end of the second fixing plate is embedded in the precast bottom plate, and the second fixing plate extends into the fourth recess, forming an exposed portion in the fourth recess; the two third plates of the corresponding first fixing plate and second fixing plate do not abut against each other, forming a second gap extending in the horizontal direction, and the two third plates are connected by filling the second gap with grout.

[0015] Optionally, a layer of waterproof mortar with a triangular cross-section is poured at the connection between the precast side panel and the precast bottom panel.

[0016] Optionally, the widths of the first and second fixing plates are in the range of 100mm-120mm, the width of the connecting plate is in the range of 80mm-100mm, the fixed connection length between the connecting plate and the first fixing plate is in the range of 25mm-35mm, and the fixed connection length between the connecting plate and the second fixing plate is in the range of 25mm-35mm.

[0017] Secondly, embodiments of the present invention provide a method for manufacturing concrete modules, comprising the following steps;

[0018] S1. An inner mold is fixed on the first mold platform. The first mold platform, the inner mold, and the outer mold form a casting space for the first precast slab assembly. The casting space for the first precast slab assembly includes casting spaces for four precast side plates. A first connecting component is pre-embedded at the bottom of the casting space for the precast side plates. The second mold platform forms a casting space for the precast base plate. A second connecting component is pre-embedded in the casting space of the precast base plate corresponding to the first connecting component. S2. Concrete is poured into the casting space to form a precast base plate and four precast side plates. A connecting plate is fixed on the first fixing plate of the first connecting component to form the first precast slab assembly and the second precast slab assembly, respectively. S3. The second precast slab assembly is demolded and hoisted onto the assembly platform. The first precast slab assembly is demolded and hoisted onto the second precast slab assembly. S4. The connecting plate is fixedly connected to the second fixing plate to form a concrete module.

[0019] Optionally, in step S1, formwork is erected at the first and second recesses to expose the first and second fixing plates; in step S4, grout is poured into the first gap, and then waterproof mortar is applied along the vertical joints of the four precast side plates and the precast bottom plate to cover the space inside the first and second recesses and form a waterproof mortar layer.

[0020] Optionally, in step S1, formwork is erected at the third and fourth recesses to expose the first and second fixing plates; in step S4, after grouting is completed at the second gap, waterproof mortar is applied along the vertical joints of the four precast side plates and the precast bottom plate to cover the space inside the third and fourth recesses and form a waterproof mortar layer.

[0021] (III) Beneficial Effects

[0022] The beneficial effects of this invention are:

[0023] This invention provides a concrete module comprising a first precast slab assembly and a second precast slab assembly. The first precast slab assembly includes four precast side plates, a first connecting component embedded in the bottom of the precast side plates, and a connecting plate. The second precast slab assembly includes a precast bottom plate and a second connecting component embedded in the precast bottom plate and corresponding to the first connecting component. The first connecting component includes multiple first anchoring bars and a first fixing plate. The first anchoring bars extend vertically within the precast side plates, and their bottoms are fixedly connected to one side of the first fixing plate, while the other side of the first fixing plate is fixedly connected to the connecting plate. The second connecting component includes second anchoring bars and a second fixing plate. The second anchoring bars extend horizontally within the precast bottom plate, and one side of the second fixing plate is fixedly connected to the second anchoring bars. The first fixing plate and the second fixing plate are partially exposed relative to the precast side plates and the precast bottom plate, respectively, and the exposed portions of the first fixing plate and the second fixing plate are fixedly connected to the connecting plate. Compared with existing technologies, this concrete module, through the pre-embedded first anchoring steel bar, second anchoring steel bar, first fixing plate, second fixing plate and connecting plate, can enhance the connection strength between the precast bottom plate and side plate and ensure the integrity of the module; the fixed connection between the connecting plate and the second fixing plate facilitates the rapid production of concrete modules and improves construction efficiency; the pre-embedded design can also reduce the amount of on-site work and ensure connection accuracy and structural stability.

[0024] Another aspect of the present invention proposes a method for manufacturing a concrete module, comprising the following steps: S1, an inner mold is fixed on a first mold platform, the first mold platform, the inner mold, and the outer mold form a casting space for a first precast slab assembly, the casting space for the first precast slab assembly includes casting spaces for four precast side plates, a first connecting component is pre-embedded at the bottom of the casting space for the precast side plates, a second mold platform forms a casting space for a precast bottom plate, and a second connecting component is pre-embedded in the casting space for the precast bottom plate corresponding to the first connecting component; S2, by pouring concrete into the casting space, a precast bottom plate and four precast side plates are formed, and a connecting plate is fixed on the first fixing plate of the first connecting component, thereby forming a first precast slab assembly and a second precast slab assembly; S3, the second precast slab assembly is demolded and hoisted onto an assembly platform, the first precast slab assembly is demolded and hoisted onto the second precast slab assembly; S4, the connecting plate is fixedly connected to the second fixing plate to form a concrete module. Compared to existing technologies, precast side panels and precast bottom panels can be demolded immediately after forming, increasing the fluidity of the first and second mold platforms and accelerating the production efficiency of concrete modules. The inner mold is fixedly connected to the first mold platform, so there is no need to repeatedly assemble the inner mold, reducing the risk of deformation due to repeated assembly and improving the production accuracy and stability of concrete modules. Moreover, directly fixing the first and second connecting components can achieve the same effect as fixing the precast side panels and precast bottom panels, greatly reducing the workload and difficulty for workers. Attached Figure Description

[0025] Figure 1 This is a structural schematic diagram of Embodiment 1 of the concrete module of the present invention. In order to clearly show the connection structure, the precast side plate and the precast top plate are transparent, the first fixing plate and the second fixing plate are flat, and the connecting plate is L-shaped.

[0026] Figure 2 for Figure 1 The diagram shows the structure of the concrete module, in which the precast side panels and precast top panel are transparent, the first fixing plate and the second fixing plate are plates with bends, and the connecting plate is flat.

[0027] Figure 3 This is a partial structural schematic diagram of the manufacturing method for concrete modules according to Embodiment 2 of the present invention, wherein the first precast slab assembly and the second precast slab assembly are in an unconnected state;

[0028] Figure 4 for Figure 3 The diagram shows a partial structural schematic of a method for manufacturing concrete modules, in which the precast side panels and precast top panels are transparent, and the first precast panel assembly and the second precast panel assembly are connected.

[0029] Figure 5 for Figure 3 The diagram shows a structural schematic of a method for manufacturing concrete modules, in which the precast side panels and precast top panels are transparent, and the first precast panel assembly and the second precast panel assembly are not connected.

[0030] Figure 6 for Figure 3 The diagram shows a structural schematic of a method for manufacturing concrete modules, in which the precast side panels and precast top panels are transparent, and the first precast panel assembly and the second precast panel assembly are connected.

[0031] Explanation of reference numerals in the attached figures

[0032] 1: First precast slab assembly; 11: Precast side panel; 111: First notch; 112: Third notch; 12: First connecting assembly; 121: First anchoring rebar; 122: First fixing plate; 1221: Third plate; 1222: Fourth plate; 13: Connecting plate; 131: First plate; 132: Second plate;

[0033] 2: Second precast slab assembly; 21: Precast base plate; 211: Second recess; 212: Fourth recess; 22: Second connecting assembly; 221: Second anchoring reinforcement; 222: Second fixing plate;

[0034] 3: First gap;

[0035] 4: Second gap. Detailed Implementation

[0036] To better explain and facilitate understanding of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0037] To better understand the above technical solutions, exemplary embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present invention are shown in the drawings, it should be understood that the present invention can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the present invention can be understood more clearly and thoroughly, and that the scope of the present invention can be fully conveyed to those skilled in the art.

[0038] Example 1:

[0039] Traditional concrete modules are manufactured in concrete module factories. Each module consists of a precast top slab, a precast bottom slab 21, and four precast side panels 11, assembled to form a hexahedral structure. This traditional method involves first fabricating the precast top slab, bottom slab 21, and four side panels 11, followed by a secondary pour, which is labor-intensive, time-consuming, and prone to problems such as loose connections between the precast panels during the secondary pour. This embodiment solves these problems.

[0040] Reference Figure 1 and Figure 2 This embodiment provides a concrete module used to connect the precast top slab, precast side slabs 11, and precast bottom slab 21, which serve as the main structure of a building, during the production of the concrete module. Specifically, the concrete module in this embodiment includes a first precast slab assembly 1 and a second precast slab assembly 2, as detailed below.

[0041] Reference Figure 1 , Figure 1 The diagram shows the structure of the concrete module. The first precast slab assembly 1 includes a precast top slab (not shown), four precast side slabs 11, multiple first connecting components 12, and multiple connecting plates 13. The precast top slab and the four precast side slabs 11 are integrally cast. The multiple first connecting components 12 and multiple connecting plates 13 are connected one-to-one, and at least one first connecting component 12 is embedded in the bottom of each precast side slab 11. The second precast slab assembly 2 includes a precast bottom slab 21 and multiple second connecting components 22 embedded in the precast bottom slab 21 and corresponding one-to-one with the multiple first connecting components 12.

[0042] More specifically, the first connecting assembly 12 includes multiple first anchoring steel bars 121 and a first fixing plate 122. The first anchoring steel bars 121 extend vertically within the precast side plate 11, and the bottom of the first anchoring steel bars 121 is fixedly connected to one side of the first fixing plate 122. The other side of the first fixing plate 122 is fixedly connected to the connecting plate 13. The second connecting assembly 22 includes second anchoring steel bars 221 and a second fixing plate 222. The second anchoring steel bars 221 extend horizontally within the precast bottom plate 21, and the second fixing plate... One side of the 222 is fixedly connected to the second anchoring steel bar 221; the first fixing plate 122 and the second fixing plate 222 are partially exposed relative to the precast side plate 11 and the precast bottom plate 21, respectively, and the exposed parts of the first fixing plate 122 and the exposed parts of the second fixing plate 222 are fixedly connected to the connecting plate 13. Meanwhile, along the arrangement direction of the first fixing plate 122, the connecting plate 13 and the second fixing plate 222, the extension direction of the second anchoring steel bar 221 is from the second fixing plate 222 toward the side that continues this arrangement direction.

[0043] Therefore, in this embodiment, the first connecting component 12 is embedded in the bottom of the precast side plate 11 and corresponds to the position of the second connecting component 22 embedded in the precast base plate 21. The precast base plate 21 and the precast side plate 11 can be connected by fixing the first connecting component 12 and the second connecting component 22 together with the connecting plate 13. The connecting plate 13 can be connected to the first connecting component 12 and the second connecting component 22 by welding, screwing, or snapping. The first connecting component 12 is embedded in the bottom of the precast side plate 11, and the first anchoring steel bar 121 extends vertically within the precast side plate 11. The bottom of the first anchoring steel bar 121 is connected to the first connecting component 12 by welding, snapping, or riveting. One side of the first fixing plate 122 is fixedly connected, and the other side of the first fixing plate 122 is fixedly connected to the connecting plate 13 by welding, screwing or snapping. The second anchoring steel bar 221 extends horizontally in the precast base plate 21. The second fixing plate 222 is fixedly connected to the second anchoring steel bar 221 by welding, snapping or riveting. The connecting plate 13 can be fixedly connected to the first fixing member and the second fixing plate 222 by welding, screwing or snapping. The exposed part of the first fixing plate 122 and the second fixing plate 222 is the connecting surface of the first fixing plate 122 and the second fixing plate 222. The remaining part is still pre-embedded in the precast side plate 11 and the precast base plate 21 respectively.

[0044] In summary, compared with existing technologies, this concrete module, through the pre-embedded first anchoring steel bar 121, second anchoring steel bar 221, first fixing plate 122, second fixing plate 222 and connecting plate 13, can enhance the connection strength between the precast base plate 21 and the side plate, ensuring the integrity of the module; the fixed connection between the connecting plate 13 and the second fixing plate 222 facilitates the rapid production of concrete modules and improves construction efficiency; the pre-embedded design can also reduce on-site work and ensure connection accuracy and structural stability.

[0045] In this embodiment, two different structures of first connecting component 12, second connecting component 22, and corresponding connecting plate 13 are provided. These two different structures are outlined by dashed boxes A and B in the accompanying drawings. In actual production, all first connecting components 12 in a concrete module can be as shown in the attached drawings. Figure 1 and attached Figure 2 The diagram shows one structure, and the corresponding second connecting component 22 and connecting plate 13 are also one structure; all the first connecting components 12 in a concrete module may also adopt two different structures, and the corresponding second connecting components 22 and connecting plate 13 may also adopt two different structures.

[0046] The structure outlined by the dashed box A is described below:

[0047] When both the first fixing plate 122 and the second fixing plate 222 are flat, the connecting plate 13 is L-shaped. The L-shaped connecting plate 13 includes a first plate 131 and a second plate 132 that are vertically connected. The first plate 131 is fixedly connected to the other side of the first fixing plate 122, and the second plate 132 is fixedly connected to the other side of the second fixing plate 222.

[0048] Specifically, when the first fixing plate 122 and the second fixing plate 222 are flat, the first fixing plate 122 extends vertically and the second fixing plate 222 extends horizontally. Therefore, the extension lines of the first fixing plate 122 and the second fixing plate 222 intersect perpendicularly. Thus, the connecting plate 13 is L-shaped. The first plate 131 is fixedly connected to the other side of the first fixing block by welding, screwing or riveting, and the second plate 132 is fixedly connected to the other side of the second fixing block by welding, screwing or riveting.

[0049] Furthermore, a first recess 111 is provided at the bottom of the precast side plate 11, one end of the first fixing plate 122 is embedded in the precast side plate 11, and the first fixing plate 122 extends into the first recess 111, forming an exposed portion in the first recess 111; a second recess 211 is provided on the precast bottom plate 21, one end of the second fixing plate 222 is embedded in the precast bottom plate 21, and the second fixing plate 222 extends into the second recess 211, forming an exposed portion in the second recess 211; a first gap 3 is formed between the inner wall of the second recess 211 and the connecting plate 13 and the second fixing plate 222, and the first gap 3 is filled by pouring grout.

[0050] Specifically, refer to Figure 1 The L-shaped connecting plate 13 is fixedly connected to the first fixing plate 122 and the second fixing plate 222 respectively. Therefore, the bottom surface of the second plate 132 that is not connected to the second fixing plate 222 forms a first gap 3 between the inner wall of the second recess 211 and the second fixing plate 222. Pouring grout at the first gap 3 can fill the gap between the first connecting component 12 and the second connecting component 22, and can also connect the prefabricated side plate 11 and the prefabricated bottom plate 21, thereby enhancing the connection strength between the prefabricated side plate 11 and the prefabricated bottom plate 21.

[0051] The first notch 111 is a right quadrangular prism. A "right quadrangular prism" is a hexagon formed by two bases and four sides. The two bases are composed of two congruent quadrilaterals that are parallel to each other. Each side is rectangular, and the edge formed by the intersection of any two sides is perpendicular to the base. In this embodiment, the four sides of the right quadrangular prism first notch 111 are, in sequence, a first side, a second side, a third side, and a fourth side. The first side of the right quadrangular prism first notch 111 forms a sidewall within the prefabricated side plate 11, to which the first fixing plate 122 is attached. The third side of the right quadrangular prism first notch 111 is parallel to the first side and penetrates the inner surface of the prefabricated side plate 11, forming an opening for receiving the connecting plate 13. The two bases, the second side, and the fourth side of the right quadrangular prism first notch 111 form sidewalls within the prefabricated side plate 11. Meanwhile, the cross-section of the first recess 111 in the shape of a right square prism is a right trapezoid. The two sides containing the right angle are located on the first lateral surface of the first recess 111 and the second lateral surface at the bottom of the precast side plate 11. The upper base is located on the first lateral surface of the right square prism, and the lower base is located on the third lateral surface of the precast side plate 11. In describing the shape of the first recess 111, the bottom and lateral surfaces are defined using the common concept of "right square prism," not based on the actual geographical location of the concrete module. Along the direction from the first lateral surface of the first recess 111 to the third lateral surface of the right square prism, the cross-sectional area gradually increases.

[0052] The second recess 211 is rectangular, and its cross-section is larger than that of the second fixing plate 222. This facilitates the fixed connection between the second plate 132 and the second fixing plate 222. The top surface of the rectangular second recess 211 penetrates the inner surface of the precast base plate 21, forming an opening for receiving the connecting plate 13. The bottom surface of the rectangular second recess 211 is located inside the precast base plate 21, forming a bottom surface. The bottom surface of the second fixing plate 222 is attached to this bottom surface. The four sides of the rectangular second recess 211 are located inside the precast base plate 21, forming sidewalls. When describing the shape of the second recess 211, the top and bottom are defined based on the actual geographical location of the concrete module.

[0053] The structure enclosed by the dashed box in section B is described below:

[0054] When both the first fixing plate 122 and the second fixing plate 222 are plates with bends, the connecting plate 13 is flat and has an integrally formed third plate 1221 and a fourth plate 1222. The third plate 1221 of the two plates is fixedly connected to the first anchoring steel bar 121 and the second anchoring steel bar 221 respectively, and the two fourth plates 1222 form a connecting plane that connects to the connecting plate 13. The connecting plane is parallel to the connecting plate 13.

[0055] Specifically, refer to Figure 2 The third plate 1221 of the first fixing plate 122 extends vertically, and the third plate 1221 of the second fixing plate 222 extends horizontally. The angle formed by the fourth plate 1222 and the third plate 1221 in the first fixing plate 122 is the same as the angle formed by the fourth plate 1222 and the third plate 1221 in the second fixing plate 222. At the same time, the two fourth plates can form a connecting plane, which can be fixedly connected to the connecting plate 13 by welding, screwing or snapping.

[0056] Furthermore, a third recess 112 is provided on the precast side plate 11, one end of the first fixing plate 122 is embedded in the precast side plate 11, and the first fixing plate 122 extends into the third recess 112, forming an exposed portion in the third recess 112; a fourth recess 212 is provided on the precast bottom plate 21, one end of the second fixing plate 222 is embedded in the precast bottom plate 21, and the second fixing plate 222 extends into the fourth recess 212, forming an exposed portion in the fourth recess 212; the two third plates 1221 of the corresponding first fixing plate 122 and second fixing plate 222 do not abut against each other, and there is a second gap 4 in the horizontal direction. The two third plates 1221 are connected by pouring grout to fill the second gap 4.

[0057] Specifically, the third notch 112 is in the shape of a right quadrangular prism. The "right quadrangular prism" is a hexagon formed by two bases and four sides. The two bases are composed of two congruent quadrilaterals that are parallel to each other. Each side is a rectangle, and the edge formed by the intersection of any two sides is perpendicular to the base. In this embodiment, the four sides of the right quadrangular prism-shaped third recess 112 are, in sequence, the first side, the second side, the third side, and the fourth side. The first side of the right quadrangular prism-shaped third recess 112 forms a sidewall within the prefabricated side plate 11, and the third plate 1221 in the first fixing plate 122 is attached to this sidewall. The third side of the right quadrangular prism-shaped third recess 112 is parallel to the first side of the right quadrangular prism-shaped third recess 112. The third side of the right quadrangular prism-shaped third recess 112 penetrates the inner surface of the prefabricated side plate 11, forming an opening for receiving the connecting plate 13. The two bottom surfaces, the second side, and the fourth side of the right quadrangular prism-shaped third recess 112 form a sidewall within the prefabricated side plate 11. Meanwhile, the cross-section of the third recess 112 of the right square prism is trapezoidal. The upper base is located on the first side surface of the third recess 112, and the lower base is located on the third side surface of the third recess 112. In describing the shape of the third recess 112, the base and side surfaces are defined using the common concept of "right square prism," not based on the actual geographical location of the concrete module. Along the direction from the first side surface of the third recess 112 to the third side surface of the third recess 112, the cross-sectional area gradually increases.

[0058] Similarly, the fourth recess 212 is in the shape of a right quadrangular prism. In this embodiment, the four sides of the right quadrangular prism fourth recess 212 are, in order, the first side, the second side, the third side, and the fourth side. The first side of the right quadrangular prism fourth recess 212 forms a sidewall inside the prefabricated base plate 21, and the third plate 1221 in the second fixing plate 222 is attached to the top wall. The third side of the right quadrangular prism fourth recess 212 is parallel to the first side of the right quadrangular prism fourth recess 212. The third side of the right quadrangular prism fourth recess 212 penetrates the inner surface of the prefabricated base plate 21, forming an opening for receiving the connecting plate 13. The two bottom surfaces, the second side, and the fourth side of the right quadrangular prism fourth recess 212 form a sidewall inside the prefabricated base plate 21. Meanwhile, the cross-section of the fourth recess 212 of the right square prism is trapezoidal, with the upper base located on the first side surface of the fourth recess 212 and the lower base located on the third side surface of the fourth recess 212. In describing the shape of the fourth recess 212, the bottom and side surfaces are defined using the common concept of "right square prism," not based on the actual geographical location of the concrete module. Along the direction from the first side surface of the fourth recess 212 to the third side surface of the right square prism, the cross-sectional area gradually increases. Since the first fixing plate 122 and the second fixing plate 222 do not abut against each other, the first fixing plate 122, the second fixing plate 222, and the connecting plate 13 enclose and form a second gap 4. Mortar is injected into the second gap 4 and smoothed to fill it and enhance the connection strength between the first fixing plate 122 and the second fixing plate 222.

[0059] Furthermore, the widths of the first fixing plate 122 and the second fixing plate 222 are in the range of 100mm-120mm, the width of the connecting plate 13 is in the range of 80mm-100mm, the fixed connection length between the connecting plate 13 and the first fixing plate 122 is in the range of 25mm-35mm, and the fixed connection length between the connecting plate 13 and the second fixing plate 222 is in the range of 25mm-35mm.

[0060] Example 2:

[0061] Reference Figures 3 to 6 This embodiment also provides a method for manufacturing concrete modules, enabling efficient production of concrete modules. Specifically, the method for manufacturing concrete modules includes the following steps:

[0062] S1. An inner mold is fixed on the first mold platform. The first mold platform, the inner mold, and the outer mold form a casting space for the first precast slab assembly 1. The casting space for the first precast slab assembly 1 includes casting spaces for four precast side panels 11. A first connecting component 12 is pre-embedded at the bottom of the casting space for the precast side panels 11. The second mold platform forms a casting space for the precast base slab 21. A second connecting component 22 is pre-embedded in the casting space for the precast base slab 21 corresponding to the first connecting component 12. S2. By pouring concrete into the casting space, a precast slab is formed. S1. A base plate 21 and multiple precast side plates 11 are made, and a connecting plate 13 is fixedly connected to the first fixing plate 122 of the first connecting assembly 12 to form a first precast slab assembly 1 and a second precast slab assembly 2, respectively; S2. The second precast slab assembly 2 is demolded and hoisted onto the assembly platform, the first precast slab assembly 1 is demolded and hoisted onto the second precast slab assembly 2; S3. The connecting plate 13 is fixedly connected to the second fixing plate 222 to form a concrete module.

[0063] Specifically, refer to Figure 5 and Figure 6 In the prefabrication plant, prefabricated top slabs, prefabricated bottom slabs 21, and four prefabricated side slabs 11 are mass-produced. A mold platform is required for the production of these components. An inner mold is fixed on the first mold platform. Therefore, the outer molds of the prefabricated top slab and the four prefabricated side slabs 11, along with the inner mold and the first mold platform, enclose a casting space. Multiple first connecting components 12 are embedded at the bottom of the casting space of the prefabricated side slabs 11, and the first fixing plate 122 is partially exposed to ensure the connection strength of the first fixing plate 122 and facilitate the connection of the connecting plate 13. Concrete is poured into the casting space, integrally forming the four prefabricated side slabs 11 and the prefabricated top slab. The second mold platform forms the casting space of the prefabricated bottom slab 21. Multiple second connecting components 22, corresponding to the first connecting components 12, are embedded in the casting space of the prefabricated bottom slab 21, and the second fixing plate 222 is partially exposed to ensure the connection strength of the second fixing plate 222 and facilitate the connection of the connecting plate 13. After the cast-in-place concrete has solidified, the formwork is removed. The first precast slab assembly 1 and the second precast slab assembly 2, after being demolded, are hoisted in the following order: first, the second precast slab assembly 2 is hoisted onto the assembly platform, and then the first precast slab assembly 1 is hoisted directly above the second precast slab assembly 2. Therefore, the first and second mold platforms can produce the next concrete module in a timely manner. When connecting the first precast slab assembly 1 and the second precast slab assembly 2, the connecting plate 13, which is pre-attached to the first fixing plate 122, is connected to the second fixing plate 222. After the connection is completed, the first gap 3 and the second gap 4 are grouted to prevent water accumulation or the formation of concrete modules in the gaps.

[0064] Preferably, the connecting plate 13 may not be fixedly connected to the first fixing plate 122 during the production of the first precast slab assembly 1. The outer template of the precast top slab and the four precast side slabs 11, together with the inner mold and the first mold platform, form a casting space. The first anchoring steel bar 121 and the first fixing plate 122 are embedded at the bottom of the casting space of the precast side slab 11, with the first fixing plate 122 partially exposed. Concrete is poured into the casting space, and the four precast side slabs 11 and the precast top slab are integrally formed. The second mold platform forms the casting space of the precast bottom slab 21. Multiple second connecting components 22 are embedded in the casting space of the precast bottom slab 21, corresponding to the first connecting components 12, with the second fixing plate 222 partially exposed. This is to ensure the connection strength of the second fixing plate 222 while facilitating the connection of the connecting plate 13. After the cast-in-place concrete has solidified, the formwork is removed. The second precast slab assembly 2, after being demolded, is first hoisted onto the assembly platform. Then, the four precast side panels 11 and the precast top panel, which are integrally formed, are hoisted onto the top of the second precast slab assembly 2. The first fixing plate 122 and the second fixing plate 222 are aligned one by one. Then, the connecting plate 13 is fixed to the first fixing plate 122 and the second fixing plate 222 respectively. After the fixing is completed, the first gap 3 and the second gap 4 are grouted to prevent water from accumulating in the gaps or forming concrete modules.

[0065] Further, in step S1, formwork is erected at the first recess 111 and the second recess 211, exposing parts of the first fixing plate 122 and the second fixing plate 222. In step S4, grout is poured into the first gap 3, and then waterproof mortar is applied along the perpendicular joints of the multiple precast side plates 11 and the precast base plate 21 to cover the space inside the first recess 111 and the second recess 211, forming a waterproof mortar layer. Specifically, before pouring concrete, formwork needs to be erected at the first recess 111 and the second recess 211, fixing the formwork of the first recess 111 and the second recess 211 to the designated positions, and placing the exposed parts of the first fixing plate 122 and the second fixing plate 222 in place in advance. Since the volume of the first recess 111 and the second recess 211 is much larger than the volume required by the first fixing plate 122, the second fixing plate 222 and the connecting plate 13, in addition to the mortar filling the first gap 3, waterproof mortar still needs to be applied to the remaining space to prevent external moisture from entering the first recess 111 and the second recess 211. Thus, a waterproof mortar layer with a triangular cross section is formed to prevent external moisture from stagnating and penetrating into the first recess 111 and the second recess 211.

[0066] Further, in step S1, formwork is erected at the third recess 112 and the fourth recess 212, exposing parts of the first fixing plate 122 and the second fixing plate 222. In step S4, after grouting at the second gap 4, waterproof mortar is applied along the perpendicular joints of the precast side plates 11 and the precast base plate 21 to cover the spaces within the third recess 112 and the fourth recess 212, forming a waterproof mortar layer. Specifically, before pouring concrete, formwork needs to be erected at the third recess 112 and the fourth recess 212, fixing the formwork of the third recess 112 and the fourth recess 212 to the designated positions, and placing the exposed portions of the first fixing plate 122 and the second fixing plate 222 in place in advance. Since the volume of the third recess 112 and the fourth recess 212 is much larger than the volume required by the first fixing plate 122, the second fixing plate 222 and the connecting plate 13, in addition to the mortar filling the first gap 3, waterproof mortar still needs to be applied to the remaining space to prevent external moisture from entering the third recess 112 and the fourth recess 212. Thus, a waterproof mortar layer with a triangular cross section is formed to prevent external moisture from stagnating and penetrating into the third recess 112 and the fourth recess 212.

[0067] In the description of this invention, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0068] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0069] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first and second features are in direct contact, or that they are in indirect contact through an intermediate medium. Furthermore, "above," "over," or "on top" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," or "beneath" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0070] In the description of this specification, the terms "one embodiment," "some embodiments," "embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0071] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make modifications, alterations, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A concrete module, characterized in that: The assembly includes a first precast slab assembly (1) and a second precast slab assembly (2). The first precast slab assembly (1) includes four precast side panels (11), a first connecting component (12) embedded in the bottom of the precast side panels (11), and a connecting plate (13). The second precast slab assembly (2) includes a precast bottom plate (21) and a second connecting component (22) embedded in the precast bottom plate (21) and corresponding to the first connecting component (12). The first connecting assembly (12) includes multiple first anchoring steel bars (121) and a first fixing plate (122). The first anchoring steel bars (121) extend vertically within the precast side plate (11). The bottom of the first anchoring steel bars (121) is fixedly connected to one side of the first fixing plate (122), and the other side of the first fixing plate (122) is fixedly connected to the connecting plate (13). The second connecting assembly (22) includes a second anchoring steel bar (221) and a second fixing plate (222). The second anchoring steel bar (221) extends horizontally within the precast base plate (21), and one side of the second fixing plate (222) is fixedly connected to the second anchoring steel bar (221). The first fixing plate (122) and the second fixing plate (222) are partially exposed relative to the precast side plate (11) and the precast bottom plate (21), respectively, and the exposed portions of the first fixing plate (122) and the second fixing plate (222) are fixedly connected to the connecting plate (13).

2. The concrete module as described in claim 1, characterized in that: When both the first fixing plate (122) and the second fixing plate (222) are flat, the connecting plate (13) is L-shaped. The L-shaped connecting plate (13) includes a first plate (131) and a second plate (132) that are vertically connected. The first plate (131) is fixedly connected to the other side of the first fixing plate (122), and the second plate (132) is fixedly connected to the other side of the second fixing plate (222).

3. The concrete module as described in claim 2, characterized in that: The bottom of the prefabricated side panel (11) is provided with a first recess (111), one end of the first fixing plate (122) is embedded in the prefabricated side panel, and the first fixing plate (122) extends into the first recess (111), forming the exposed part in the first recess (111); The precast base plate (21) has a second recess (211), one end of the second fixing plate (222) is embedded in the precast base plate, and the second fixing plate (222) extends into the second recess (211), forming the exposed part in the second recess (211); The inner wall of the second notch (211) forms a first gap (3) between the connecting plate (13) and the second fixing plate, and the first gap (3) is filled by pouring grout.

4. The concrete module as described in claim 3, characterized in that: When the first fixing plate (122) and the second fixing plate (222) are both plates with bends, the connecting plate (13) is flat. The plate has an integrally formed third plate (1221) and a fourth plate (1222). The third plate (1221) of the two plates is fixedly connected to the first anchoring steel bar (121) and the second anchoring steel bar (221) respectively. The two fourth plates (1222) form a connecting plane that connects to the connecting plate (13). The connecting plane is parallel to the connecting plate (13).

5. The concrete module as described in claim 4, characterized in that: The prefabricated side plate (11) has a third recess (112), one end of the first fixing plate (122) is embedded in the prefabricated side plate, and the first fixing plate (122) extends into the third recess (112), forming the exposed part in the third recess (112); The precast base plate (21) has a fourth recess (212), one end of the second fixing plate (222) is embedded in the precast base plate, and the second fixing plate (222) extends into the fourth recess (212), forming the exposed part in the fourth recess (212); The two third plates (1221) of the corresponding first fixing plate and second fixing plate do not abut against each other, forming a second gap (4) extending in the horizontal direction. The two third plates (1221) are connected by pouring grout to fill the second gap (4).

6. The concrete module as described in claim 1, characterized in that: A waterproof mortar layer with a triangular cross-section is also poured at the connection between the precast side plate (11) and the precast bottom plate (21).

7. The concrete module as described in claim 1, characterized in that: The widths of the first fixing plate (122) and the second fixing plate (222) are in the range of 100mm-120mm, the width of the connecting plate (13) is in the range of 80mm-100mm, the fixed connection length between the connecting plate (13) and the first fixing plate (122) is in the range of 25mm-35mm, and the fixed connection length between the connecting plate (13) and the second fixing plate (222) is in the range of 25mm-35mm.

8. A method for manufacturing a concrete module according to claim 5, characterized in that: Includes the following steps: S1. An inner mold is fixed on the first mold platform. The first mold platform, the inner mold and the outer mold form the casting space of the first precast slab assembly (1). The casting space of the first precast slab assembly (1) includes the casting space of four precast side plates (11). The bottom of the casting space of the precast side plates (11) is pre-embedded with a first connecting component (12). The second mold platform forms the casting space of the precast bottom plate (21). The second connecting component (22) is pre-embedded in the casting space of the precast bottom plate (21) corresponding to the first connecting component (12). S2. By pouring concrete into the pouring space, the precast base plate (21) and a plurality of precast side plates (11) are formed, and the connecting plate (13) is fixedly connected to the first fixing plate (122) of the first connecting assembly (12), thereby forming the first precast plate assembly (1) and the second precast plate assembly (2). S3. Demold the second precast slab assembly (2) and hoist the second precast slab assembly (2) onto the assembly platform. Demold the first precast slab assembly (1) and hoist the first precast slab assembly (1) onto the second precast slab assembly (2). S4. The connecting plate (13) is fixedly connected to the second fixing plate (222) to form the concrete module.

9. The method for manufacturing a concrete module as described in claim 8, characterized in that: In step S1, formwork is erected at the first recess (111) and the second recess (211) to expose the first fixing plate (122) and the second fixing plate (222). In step S4, grout is poured into the first gap (3), and then waterproof mortar is applied along the vertical joints of the precast side plates (11) and the precast base plate (21) to cover the space inside the first recess (111) and the second recess (211) to form a waterproof mortar layer.

10. The method for manufacturing a concrete module as described in claim 8, characterized in that: In step S1, formwork is erected at the third recess (112) and the fourth recess (212) to expose the first fixing plate (122) and the second fixing plate (222). In step S4, after grouting the second gap (4), waterproof mortar is applied along the vertical joints of the precast side plates (11) and the precast base plate (21) to cover the space inside the third recess (112) and the fourth recess (212) to form a waterproof mortar layer.

Images