Method for manufacturing foamed ceramic composite wall panels

Abstract

The application discloses a kind of preparation methods of foamed ceramic composite wallboard, comprising the following steps: preparation substrate, open embedded slot, install frame, weld reinforcement net, install positioning piece, fill embedded slot, lay fill layer and splice welding.Using this method, first, outer foamed ceramic wallboard and inner foamed ceramic wallboard are prepared, then the outer foamed ceramic wallboard and the inner foamed ceramic wallboard are spliced and combined through positioning clasp seat and positioning chuck, a double-splicing design is adopted, which is convenient for factory prefabrication, on-site assembly, shortens construction period, reduces construction waste and dust pollution, conforms to the policy guidance of prefabricated building, is conducive to promoting the development of prefabricated building, and is convenient for realizing standardized construction.

Description

Technical Field

[0001] This invention relates to the field of building materials technology, specifically to a method for preparing a foamed ceramic composite wall panel. Background Technology

[0002] Foamed ceramic panels are made from raw materials such as stone powder, fly ash, polishing slag, construction waste, clay, and foaming agents, which are wet-milled, dried, and then fired at high temperatures to create foam. Foamed ceramic panels have advantages such as being lightweight, sound-insulating, heat-insulating, energy-saving, and environmentally friendly. They also possess excellent physical properties such as a low coefficient of thermal expansion, fire resistance, non-combustibility, and corrosion resistance, as well as good mechanical properties such as compressive and shear strength.

[0003] Currently, the application of foamed ceramic panels is mainly limited to interior partition walls. When applied to exterior walls, a single layer of foamed ceramic panels usually cannot meet the requirements. To ensure properties such as fire resistance, load-bearing capacity, and deformation capacity, applying foamed ceramic panels to exterior walls requires the installation of rock wool layers and supporting framing within the wall structure. Finally, after combining the inner and outer foamed ceramic panels with other panels, bolts or self-tapping screws are needed to connect the composite panels. This process is inefficient, hindering production cost reduction. Furthermore, the use of bolts or self-tapping screws to connect the panels detracts from the aesthetics of the composite wall panel and may even affect assembly and installation. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method for preparing foamed ceramic composite wall panels that are easy to prefabricate in the factory and convenient to assemble and construct on site.

[0005] To solve the above-mentioned technical problems, the technical solution of the present invention is as follows: The preparation method of foamed ceramic composite wall panels includes the following steps: S1. Preparation of substrates: Prepare an outer foamed ceramic board substrate and an inner foamed ceramic board substrate respectively. An outer frame support is formed at the four edges of the outer foamed ceramic board substrate, and an inner frame support is formed at the four edges of the inner foamed ceramic board substrate. S2. Creating grooves: Staggered outer panel grooves are created on the inner side of the outer foamed ceramic substrate, and staggered inner panel grooves are created on the outer side of the inner foamed ceramic substrate. S3. Mounting Frame: Install the outer metal frame on the outer frame support of the outer foamed ceramic substrate, and install the inner metal frame on the inner frame support of the inner foamed ceramic substrate. S4. Welded steel mesh: Place the steel bars into the groove of the outer plate, and weld them at the intersections to form the outer steel mesh. Weld the outer steel mesh to the outer metal frame. Place the steel bars into the groove of the inner plate, and weld them at the intersections to form the inner steel mesh. Weld the inner steel mesh to the inner metal frame. S5. Install positioning components: Install the positioning bracket on the inner side of the outer foamed ceramic board substrate and weld it to the outer steel mesh; install the positioning head on the outer side of the inner foamed ceramic board substrate and weld it to the inner steel mesh, wherein the positioning head and the positioning bracket can be engaged. S6. Filling the grooves: Fill the outer panel grooves and inner panel grooves with cement grout and completely fill them; S7. Laying out the filling layer: Laying out the outer filling layer on the inner side of the outer foamed ceramic board substrate and exposing the positioning card position to prepare the outer foamed ceramic wall panel; Laying out the inner filling layer on the outer side of the inner foamed ceramic board substrate and exposing the positioning card position to prepare the inner foamed ceramic wall panel. S8. Splicing and welding: After the outer foamed ceramic wall panel and the inner foamed ceramic wall panel are spliced ​​and positioned by positioning parts, the outer metal frame and the inner metal frame are welded together to obtain the foamed ceramic composite wall panel.

[0006] As one of the optional technical solutions, in step S1, windows are formed at the center of the outer foamed ceramic substrate and the inner foamed ceramic substrate respectively.

[0007] As one of the optional technical solutions, in step S3, the outer window frame is installed at the window of the outer foamed ceramic substrate, and the inner window frame is installed at the window of the inner foamed ceramic substrate.

[0008] Preferably, in step S8, the outer window frame is welded to the inner window frame.

[0009] Preferably, in step S5, the positioning bracket includes a groove-shaped seat with a flared opening at one end, and a positioning rib is welded to the groove side of the groove-shaped seat.

[0010] Preferably, in step S5, the installation method of the positioning bracket is as follows: first, a positioning groove for the bracket is opened on the outer foamed ceramic substrate so that the positioning groove for the bracket is connected to the groove of the outer plate; then, the positioning rib for the bracket is placed in the positioning groove for the bracket, and the positioning rib for the bracket is welded to the outer steel mesh embedded in the groove of the outer plate.

[0011] Preferably, in step S5, the positioning clamp includes a positioning bolt and a clamp positioning rib welded to the end of the positioning bolt rod. The rod of the positioning bolt can enter from the flared opening of the positioning clamp seat, so that the head end of the positioning bolt is engaged in the groove-shaped seat body.

[0012] Preferably, in step S5, the installation method of the positioning clip is as follows: first, a positioning groove for the clip is opened on the inner foamed ceramic plate substrate so that the positioning groove for the clip is connected to the inner plate groove; then, the positioning rib for the clip is placed in the positioning groove for the clip, and the positioning rib for the clip is welded to the inner steel mesh embedded in the inner plate groove.

[0013] As a preferred embodiment, in step S8, the splicing and positioning method of the outer foamed ceramic wall panel and the inner foamed ceramic wall panel is as follows: the inner side of the outer foamed ceramic wall panel is facing upward and laid flat, the outer side of the inner foamed ceramic wall panel is facing the inner side of the outer foamed ceramic wall panel, the inner foamed ceramic wall panel is horizontally adjusted so that the positioning head is adapted to the positioning seat of the outer foamed ceramic wall panel, and the positioning head is inserted into the positioning seat.

[0014] By adopting the above technical solution, the present invention has at least the following beneficial effects: (1) The method first prepares external foamed ceramic wall panels and internal foamed ceramic wall panels, and then splices the external foamed ceramic wall panels and internal foamed ceramic wall panels together through positioning brackets and positioning heads. The double splicing design is convenient for factory prefabrication and on-site assembly, shortens the construction period, reduces construction waste and dust pollution, conforms to the policy orientation of prefabricated buildings, is conducive to promoting the development of prefabricated buildings, facilitates standardized construction, and greatly improves equipment utilization.

[0015] (2) In this method, the external foamed ceramic wall panel and the internal foamed ceramic wall panel are spliced ​​together by a positioning tenon and mortise structure, which can improve the seismic performance of the splicing node and meet the seismic fortification requirements of 8 degrees.

[0016] (3) Foamed ceramic is an A1 grade non-combustible material. By combining inner and outer double-layer foamed ceramic panels with a lightweight filling layer, the strength and functionality of the wall panel can be taken into account. This solves the limitations of traditional single material performance. The composite structure can meet the fire protection code of high-rise buildings, reduce the risk of fire, is lightweight, easy to construct, has good thermal insulation, good sound insulation, and good overall seismic resistance. The raw materials do not release harmful substances such as asbestos and formaldehyde, which is conducive to improving indoor air quality and enhancing building safety and comfort. Attached Figure Description

[0017] The following figures are intended only to illustrate and explain the present invention and do not limit the scope of the invention. Wherein: Figure 1 This is a structural schematic diagram of an externally foamed ceramic substrate and an internally foamed ceramic substrate. Figure 2 This is a schematic diagram of the structure of the externally foamed ceramic substrate and the internally foamed ceramic substrate after grooves have been made. Figure 3 This is a schematic diagram of the structure after the externally foamed ceramic substrate and the internally foamed ceramic substrate are installed with the frame. Figure 4 This is a schematic diagram of the structure of the externally foamed ceramic substrate and the internally foamed ceramic substrate after the installation and positioning components are attached. Figure 5 This is a schematic diagram of the structure after the outer foamed ceramic substrate and the inner foamed ceramic substrate are laid flat and filled with layers. Figure 6This is a schematic diagram of the structure after the externally foamed ceramic wall panel and the internally foamed ceramic wall panel are spliced ​​and welded together. Figure 7 This is an installation diagram of the positioning bracket; Figure 8 This is a diagram illustrating the installation of the positioning clip. Figure 9 This is a reference diagram showing the state when the positioning card head is inserted into the positioning card holder; Figure 10 This is a schematic diagram of a composite structure consisting of externally foamed ceramic wall panels and internally foamed ceramic wall panels. Detailed Implementation

[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments. In the following detailed description, only certain exemplary embodiments of the invention are described by way of illustration. Undoubtedly, those skilled in the art will recognize that various modifications can be made to the described embodiments without departing from the spirit and scope of the invention. Therefore, the drawings and description are illustrative in nature and not intended to limit the scope of the claims.

[0019] like Figures 1 to 6 As shown, the preparation method of foamed ceramic composite wall panels includes the following steps: S1. Preparation of substrate: Reference Figure 1 An outer foamed ceramic substrate 11 and an inner foamed ceramic substrate 21 are prepared respectively. An outer frame support 12 is formed at each of the four edges of the outer foamed ceramic substrate 11, and an inner frame support 22 is formed at each of the four edges of the inner foamed ceramic substrate 21. In this embodiment, windows are formed at the centers of the outer foamed ceramic substrate 11 and the inner foamed ceramic substrate 21 respectively. Of course, windows may not be provided; this design is based on engineering needs and should all fall within the protection scope of this invention. S2. Create a recessed groove: (Refer to...) Figure 2 An interleaved outer panel groove 13 is provided on the inner side of the outer foamed ceramic substrate 11, and an interleaved inner panel groove 23 is provided on the outer side of the inner foamed ceramic substrate 21. S3, Mounting Frame: Reference Figure 3 The outer metal frame 14 is installed at the outer frame support 12 of the outer foamed ceramic substrate 11, and the inner metal frame 24 is installed at the inner frame support 22 of the inner foamed ceramic substrate 21; the outer window frame 15 is installed at the window of the outer foamed ceramic substrate 11, and the inner window frame 25 is installed at the window of the inner foamed ceramic substrate 21. S4. Welding steel mesh: Place the steel bars into the groove 13 of the outer plate, and weld them at the intersections to form an outer steel mesh. Weld the outer steel mesh to the outer metal frame 14. Place the steel bars into the groove 23 of the inner plate, and weld them at the intersections to form an inner steel mesh. Weld the inner steel mesh to the inner metal frame 24. S5. Installation positioning components: (Refer to...) Figure 4 Four to six positioning brackets 16 are installed on the inner side of the outer foamed ceramic substrate 11 and welded to the outer steel mesh; a corresponding number of positioning heads 26 are installed on the outer side of the inner foamed ceramic substrate 21 and welded to the inner steel mesh, wherein the positioning heads 26 and the positioning brackets 16 can be engaged. S6. Filling the grooves: Fill the outer panel groove 13 and the inner panel groove 23 with cement grout and completely fill them; S7, Laying Fill Layer: Reference Figure 5 An outer filling layer 17 is laid flat on the inner side of the outer foamed ceramic substrate 11, and the positioning card 16 is cut out to expose the position, thus preparing an outer foamed ceramic wall panel 10; an inner filling layer 27 is laid flat on the outer side of the inner foamed ceramic substrate 21, and the positioning card 26 is cut out to expose the position, thus preparing an inner foamed ceramic wall panel 20; both the outer filling layer 17 and the inner filling layer 27 are preferably made of glass wool, but rock wool or aerogel can also be used.

[0020] S8. Joint welding: Reference Figure 6 After the outer foamed ceramic wall panel 10 and the inner foamed ceramic wall panel 20 are spliced ​​and positioned by the positioning bracket 16 and the positioning bracket 26, the outer metal frame 14 and the inner metal frame 24 are welded together, and the outer window frame 15 and the inner window frame 25 are welded together to obtain the foamed ceramic composite wall panel.

[0021] refer to Figure 7 In this embodiment, the positioning bracket 16 includes a groove-shaped seat 161 with a flared opening 163 at one end, and a bracket positioning rib 162 is welded to the groove side of the groove-shaped seat 161. The installation method of the positioning bracket 16 is as follows: First, a bracket positioning groove 18 is opened on the outer foamed ceramic substrate 11, so that the bracket positioning groove 18 is connected to the outer plate embedding groove 13. Then, the bracket positioning rib 162 is placed in the bracket positioning groove 18, and the bracket positioning rib 162 is welded to the outer steel mesh embedded in the outer plate embedding groove 13. This facilitates the positioning and installation of the positioning bracket 16, and connects the positioning bracket 16 to the outer steel mesh through the bracket positioning rib 162, which greatly improves the stress performance of the joint.

[0022] refer to Figure 8 and Figure 9In this embodiment, the positioning clamp 26 includes a positioning bolt 261 and a clamp positioning rib 262 welded to the end of the positioning bolt 261. The rib of the positioning bolt 261 can enter from the flared opening 163 of the positioning clamp seat 16, thereby allowing the head end of the positioning bolt 261 to engage with the groove-shaped seat 161. The installation method of the positioning clamp 26 is similar to that of the positioning clamp seat 16, specifically as follows: First, a clamp positioning groove 28 is opened on the inner foamed ceramic substrate 21, so that the clamp positioning groove 28 is connected to the inner plate groove 23. Then, the clamp positioning rib 262 is placed in the clamp positioning groove 28, and the clamp positioning rib 262 is welded to the inner steel mesh embedded in the inner plate groove 23. This facilitates installation and improves the stress performance of the joint.

[0023] refer to Figure 9 and Figure 10 The splicing and positioning method of the outer foamed ceramic wall panel 10 and the inner foamed ceramic wall panel 20 is as follows: Lay the outer foamed ceramic wall panel 10 flat with its inner side facing upwards. Place the outer side of the inner foamed ceramic wall panel 20 facing the inner side of the outer foamed ceramic wall panel 10. Horizontally adjust the inner foamed ceramic wall panel 20 so that the positioning clip 26 aligns with the positioning bracket 16 of the outer foamed ceramic wall panel 10. Then, horizontally move the inner foamed ceramic wall panel 20 until the positioning clip 26 is engaged with the positioning bracket 16. This achieves the splicing and positioning of the outer foamed ceramic wall panel 10 and the inner foamed ceramic wall panel 20. This positioning-type mortise and tenon structure splicing of the outer and inner foamed ceramic wall panels improves the seismic performance of the splicing joint, meeting the seismic fortification requirements of intensity 8.

[0024] This method first prepares externally foamed ceramic wall panels and internally foamed ceramic wall panels, and then splices and combines them using positioning brackets and positioning heads. The double-splicing design facilitates factory prefabrication and on-site assembly, shortens the construction period, reduces construction waste and dust pollution, conforms to the policy guidance of prefabricated buildings, promotes the development of prefabricated buildings, facilitates standardized construction, and greatly improves equipment utilization.

[0025] Foamed ceramics are A1-grade non-combustible materials. By combining inner and outer double-layer foamed ceramic panels with a lightweight filler layer, the strength and functionality of the wall panel can be balanced, overcoming the limitations of traditional single-material performance. The composite structure can meet the fire protection specifications for high-rise buildings, reducing the risk of fire. It is lightweight, easy to construct, has good thermal insulation, excellent sound insulation, and good overall seismic resistance. The raw materials do not release harmful substances such as asbestos and formaldehyde, which helps improve indoor air quality and enhance building safety and comfort.

[0026] The above description is merely an illustrative embodiment of the present invention and is not intended to limit the scope of the invention. Any equivalent changes and modifications made by those skilled in the art without departing from the concept and principles of the present invention should fall within the scope of protection of the present invention.

Claims

1. A method for preparing foamed ceramic composite wall panels, characterized in that, Includes the following steps: S1. Preparation of substrates: Prepare an outer foamed ceramic board substrate and an inner foamed ceramic board substrate respectively. An outer frame support is formed at the four edges of the outer foamed ceramic board substrate, and an inner frame support is formed at the four edges of the inner foamed ceramic board substrate. S2. Creating grooves: Staggered outer panel grooves are created on the inner side of the outer foamed ceramic substrate, and staggered inner panel grooves are created on the outer side of the inner foamed ceramic substrate. S3. Mounting Frame: Install the outer metal frame on the outer frame support of the outer foamed ceramic substrate, and install the inner metal frame on the inner frame support of the inner foamed ceramic substrate. S4. Welded steel mesh: Place the steel bars into the groove of the outer plate, and weld them at the intersections to form the outer steel mesh. Weld the outer steel mesh to the outer metal frame. Place the steel bars into the groove of the inner plate, and weld them at the intersections to form the inner steel mesh. Weld the inner steel mesh to the inner metal frame. S5. Install positioning components: Install the positioning bracket on the inner side of the outer foamed ceramic board substrate and weld it to the outer steel mesh; install the positioning head on the outer side of the inner foamed ceramic board substrate and weld it to the inner steel mesh, wherein the positioning head and the positioning bracket can be engaged. S6. Filling the grooves: Fill the outer panel grooves and inner panel grooves with cement grout and completely fill them; S7. Laying out the filling layer: Laying out the outer filling layer on the inner side of the outer foamed ceramic board substrate and exposing the positioning card position to prepare the outer foamed ceramic wall panel; Laying out the inner filling layer on the outer side of the inner foamed ceramic board substrate and exposing the positioning card position to prepare the inner foamed ceramic wall panel. S8. Splicing and welding: After the outer foamed ceramic wall panel and the inner foamed ceramic wall panel are spliced ​​and positioned by positioning parts, the outer metal frame and the inner metal frame are welded together to obtain the foamed ceramic composite wall panel.

2. The method for preparing foamed ceramic composite wall panels as described in claim 1, characterized in that: In step S1, windows are formed at the center of the outer foamed ceramic substrate and the inner foamed ceramic substrate respectively.

3. The method for preparing foamed ceramic composite wall panels as described in claim 2, characterized in that: In step S3, the outer window frame is installed at the window of the outer foamed ceramic substrate, and the inner window frame is installed at the window of the inner foamed ceramic substrate.

4. The method for preparing foamed ceramic composite wall panels as described in claim 3, characterized in that: In step S8, the outer window frame is welded to the inner window frame.

5. The method for preparing foamed ceramic composite wall panels as described in claim 1, characterized in that: In step S5, the positioning bracket includes a groove-shaped seat with a flared opening at one end, and a positioning rib is welded to the groove side of the groove-shaped seat.

6. The method for preparing foamed ceramic composite wall panels as described in claim 5, characterized in that: In step S5, the installation method of the positioning bracket is as follows: First, a positioning groove for the bracket is opened on the outer foamed ceramic plate substrate so that the positioning groove for the bracket is connected to the outer plate groove. Then, the positioning rib for the bracket is placed in the positioning groove for the bracket and welded to the outer steel mesh embedded in the outer plate groove.

7. The method for preparing foamed ceramic composite wall panels as described in claim 5, characterized in that: In step S5, the positioning clamp includes a positioning bolt and a clamp positioning rib welded to the end of the positioning bolt. The shank of the positioning bolt can enter from the flared opening of the positioning clamp seat, so that the head end of the positioning bolt is engaged in the groove-shaped seat body.

8. The method for preparing the foamed ceramic composite wall panel as described in claim 7, characterized in that: In step S5, the installation method of the positioning clip is as follows: First, a positioning groove for the clip is opened on the inner foamed ceramic plate substrate so that the positioning groove for the clip is connected to the inner plate groove. Then, the positioning rib for the clip is placed in the positioning groove for the clip and welded to the inner steel mesh embedded in the inner plate groove.

9. The method for preparing the foamed ceramic composite wall panel as described in claim 7, characterized in that: In step S8, the splicing and positioning method of the outer foamed ceramic wall panel and the inner foamed ceramic wall panel is as follows: the inner side of the outer foamed ceramic wall panel is facing up and laid flat, the outer side of the inner foamed ceramic wall panel is facing the inner side of the outer foamed ceramic wall panel, the inner foamed ceramic wall panel is horizontally adjusted so that the positioning head is adapted to the positioning seat of the outer foamed ceramic wall panel, and the positioning head is inserted into the positioning seat.

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