Thermal insulation energy-saving prefabricated floor

Abstract

The application discloses a prefabricated floor with heat preservation and energy saving, which comprises a plate body, wherein the plate body is divided into three layers from top to bottom, the top layer is a composite concrete panel, the bottom layer is a cement-based protective layer, and the middle layer is a heat preservation core material; a plurality of prefabricated trusses are arranged side by side in the heat preservation core material, and the heat preservation core material completely wraps the prefabricated trusses; the plate body is provided with spliced joints at both side edges; the prefabricated truss comprises chord bars arranged at the upper and lower portions, the chord bars are fixed by a plurality of independent web bars in a diagonal direction, the web bars are arranged in a 'person' shape, the chord bars have protruding portions in opposite directions, and the protruding portions are provided with grooves for clamping transverse ribs and longitudinal ribs; the application is convenient to hoist and splice, greatly improves construction efficiency, reduces energy consumption compared with the existing floor, and has good heat preservation effect.

Description

Technical Field

[0001] This invention relates to the field of prefabricated components for prefabricated buildings, specifically a prefabricated floor slab with thermal insulation and energy saving. Background Technology

[0002] With the increasing energy efficiency standards for prefabricated buildings, the structural rationality and thermal insulation effect of prefabricated floor slabs, as core components of building envelope and load-bearing structure, have become key indicators. Existing technologies, such as the "Prefabricated Steel Structure Insulated Floor Slab" (patent number CN221422390U), while disclosing a prefabricated structure including a load-bearing frame and insulation layer, have significant drawbacks: First, the insulation layer and load-bearing frame are separate components, easily forming thermal bridges, and the connection between the frame and the panel lacks reliability, leading to peeling after long-term use; second, the lack of a dedicated splicing and positioning structure results in low on-site splicing efficiency, and gaps can easily lead to insulation failure; third, some components require on-site assembly, resulting in low prefabrication and increased construction energy consumption and costs. Summary of the Invention

[0003] To address the aforementioned problems, this invention designs a thermally insulated and energy-saving precast floor slab. Through a "three-layer slab + integrated precast truss" design, it achieves continuous insulation, structural robustness, and convenient splicing. The design scheme is as follows: It includes a slab body, which is divided into three layers from top to bottom: a top layer of composite concrete panel, a bottom layer of cement-based protective layer, and a middle layer of thermal insulation core material; several precast trusses are arranged side-by-side within the thermal insulation core material, completely enclosing the precast trusses; splicing tongue-and-groove joints are provided on both sides of the slab body; the precast truss includes upper and lower chord members, which are fixed together by multiple diagonally independent web members arranged in a "V" shape. The chord members have protrusions in opposite directions, and the protrusions have grooves for engaging transverse and longitudinal reinforcement bars.

[0004] Preferably, the prefabricated truss includes: multiple parallel chords arranged in pairs, each chord having a core rod, an insulation layer, and an outer layer arranged sequentially from the inside out; each pair of chords has a raised strip protruding in opposite directions on its outer layer, with a longitudinal groove and multiple transverse grooves on the raised strip; the longitudinal reinforcement is engaged in the longitudinal groove, and the transverse reinforcement is engaged in the transverse groove; multiple independent web members connect the chords, with both ends of the independent web members connected to the chords via connecting blocks; the lower part of the connecting block has a circular groove and a mating surface, the circular groove matching the diameter of the longitudinal reinforcement, and the mating surface matching the outer surface of the raised strip; the insulation layer uses polyurethane insulation material.

[0005] Preferably, the outer layer is integrally formed with the convex strip, and the independent web members are integrally formed with the connecting blocks at both ends; the axial angle between the independent web members and the connecting blocks is 45°-60°, and they are arranged in a "human" shape and continuously between each pair of chord members.

[0006] Preferably, the inner wall of the circular groove of the connecting block is fitted with the outer wall of the longitudinal rib, the fitting surface is completely fitted with the outer surface of the protrusion, and the connecting block is provided with through screw holes on both sides, the screw holes leading from one side of the connecting block to the middle of the fitting surface.

[0007] Preferably, the convex strip is provided with mounting holes corresponding to the screw holes. When the mating surface of the connecting block is mated with the surface of the convex strip, the mounting holes and screw holes can be coaxially aligned, and the connecting block can be fixed to the chord by bolts.

[0008] Preferably, the depth of the transverse groove is the diameter of the transverse rib plus the radius of the longitudinal rib, and the depth of the longitudinal groove is the radius of the longitudinal rib.

[0009] Preferably, the core rod is a galvanized steel rod; the insulation core material is rigid polyurethane foam, and the thickness of the insulation core material is consistent with the height of the energy-saving prefabricated truss; the cement-based protective layer is mixed with crack-resistant fibers and has a thickness of 5-8mm.

[0010] Preferably, the outer layer is made of glass fiber reinforced plastic, the truss is prefabricated in the factory, and the chords, independent web members, longitudinal ribs and transverse ribs are assembled and shipped as a whole; the thickness of the insulation layer is 15-20mm, the thickness of the outer layer is 5-8mm, and the height of the convex strip is 15-20mm.

[0011] Preferably, the plate is manufactured as a whole in the factory according to the following steps: The first step is to build a prefabricated mold and fix the prefabricated truss in the middle area of ​​the mold according to the design spacing, ensuring that the axis of the truss is consistent with the length direction of the mold; The second step is to inject rigid polyurethane foam raw material into the mold. After the raw material foams and solidifies, it forms a middle layer of insulation core material, which completely wraps the energy-saving prefabricated truss. The third step is to tie a steel mesh on the upper side of the middle layer insulation core material, weld one end of the pre-embedded steel bar to the upper chord of the truss and fix it, and extend the other end upwards out of the steel mesh. Then, pour C30 concrete to form a composite concrete panel with a panel thickness of 80-100mm. The fourth step is to pour cement-based mortar mixed with crack-resistant fibers under the middle layer of insulation core material to form a cement-based protective layer with a thickness of 5-8mm. Fifth step: After the composite concrete panel and cement-based protective layer have cured, process stepped splicing tongue and groove joints on both sides of the panel, and then attach elastic sealing strips to the stepped surfaces of the tongue and groove joints.

[0012] The advantages of this invention are: 1. The panel adopts a three-layer structure of "overlapping panel - insulation core material - protective layer". The insulation core material completely wraps the prefabricated truss, eliminating thermal bridges and ensuring continuous insulation; 2. The chords and web members of the prefabricated truss are integrally formed and fixed with bolts, ensuring reliable connection. The "human"-shaped arrangement of the web members enhances the load-bearing capacity; 3. The stepped splicing tongue and groove on both sides of the panel facilitates on-site positioning, and the elastic sealing strip ensures sealing and insulation at the splice; 4. All components are prefabricated in the factory in an integrated manner, requiring only hoisting and splicing on site, which greatly improves construction efficiency and reduces energy consumption. Attached Figure Description

[0013] Figure 1 is a front view of the present invention; Figure 2 is a three-dimensional view of the prefabricated truss; Figure 3 is a partially enlarged frontal view of the prefabricated truss; Figure 4 is an enlarged schematic diagram of the chord; Figure 5 is a schematic diagram of the independent web member structure.

[0014] Icons: 1 - chord, 2 - independent web member, 3 - longitudinal reinforcement, 4 - transverse reinforcement, 5 - core rod, 6 - insulation layer, 7 - connecting block, 8 - outer layer, 9 - protruding strip, 10 - longitudinal groove, 11 - transverse groove, 12 - circular groove, 13 - mating surface, 14 - screw hole, 15 - composite concrete panel, 16 - insulation core material, 17 - cement-based protective layer, 18 - precast truss. Detailed Implementation

[0015] Example 1: The specific implementation of the thermal insulation and energy-saving prefabricated floor slab of the present invention will be described in detail below with reference to the accompanying drawings: Prefabrication of precast trusses: Prefabricated truss 18 is prepared according to the design dimensions: First, the chord 1 is processed. The chord 1 is arranged from the inside to the outside with a core rod 5, an insulation layer 6, and an outer layer 8. The core rod 5 is made of galvanized steel rod, the insulation layer 6 is made of polyurethane insulation material, and the outer layer 8 is made of glass fiber reinforced plastic. On the outer layer 8, a raised strip 9 is integrally formed in opposite directions. The raised strip 9 is 18mm high. A longitudinal groove 10 and multiple transverse grooves 11 are opened on the raised strip 9. The depth of the longitudinal groove 10 is the radius of the longitudinal rib 3 (the longitudinal rib 3 is made of 12mm diameter threaded steel, so the groove depth is 6mm). The depth of the transverse groove 11 is the diameter of the transverse rib 4 plus the radius of the longitudinal rib 3 (the transverse rib 4 is made of 12mm diameter threaded steel, so the groove depth is 18mm). The longitudinal rib 3 is inserted into the longitudinal groove 10, and the transverse rib 4 is inserted into the transverse groove 11.

[0016] Independent web members 2 are prepared, with both ends of the independent web members 2 integrally formed with connecting blocks 7. The axial angle between the independent web members 2 and the connecting blocks 7 is 50°. A circular groove 12 and a mating surface 13 are opened at the lower part of the connecting blocks 7. The diameter of the circular groove 12 is adapted to the longitudinal rib 3, and the curvature of the mating surface 13 matches the outer surface of the protrusion 9. Through screw holes 14 are opened on both sides of the connecting blocks 7. The circular groove 12 of the connecting blocks 7 is fitted with the longitudinal rib 3, and the mating surface 13 is mated to the outer surface of the protrusion 9. Mounting holes corresponding to the screw holes 14 are opened on the protrusion 9. The connecting blocks 7 are fixed to the chord members 1 by bolts passing through the screw holes 14 and the mounting holes, so that the independent web members 2 are arranged continuously in a "human" shape between the chord members 1, completing the prefabrication of the precast truss 18, and the whole assembly is shipped out.

[0017] Factory prefabrication of the slabs: The first step is to build a precast mold and fix the precast truss 18 in the middle of the mold at 600mm intervals, ensuring that the axis of the precast truss 18 is consistent with the length direction of the mold to avoid offset; The second step is to inject rigid polyurethane foam raw material into the mold and wait for the raw material to foam and cure for 4 hours at 25-30℃ to form the insulation core material 16. The insulation core material 16 completely wraps the prefabricated truss 18 to ensure no gaps. The third step is to tie a φ8@200 bidirectional steel mesh to the upper side of the insulation core material 16, weld one end of the pre-embedded steel bar to the chord 1 on the upper side of the precast truss 18 (weld length 50mm), and extend the other end upwards 150mm out of the steel mesh. Then, pour C30 concrete, vibrate and compact it, and cure it for 7 days to form a composite concrete panel 15 with a thickness of 90mm. The fourth step is to pour M15 cement-based mortar mixed with 0.9 kg / m³ crack-resistant fiber under the insulation core material 16, with a thickness of 6 mm, and cure it naturally for 5 days to form a cement-based protective layer 17. Fifth step: After the composite concrete panel 15 and cement-based protective layer 17 have completely cured, process stepped splicing tongue and groove joints (25mm wide, height consistent with the panel) on both sides of the panel edge, and attach EPDM elastic sealing strips to the stepped surface of the tongue and groove joints to complete the panel prefabrication and ship the whole assembly.

[0018] On-site assembly and construction: The precast floor slabs are hoisted to the construction site, and the stepped tongue and groove joints of adjacent floor slabs are interlocked. The elastic sealing strips at the tongue and groove joints are pressed together to seal the gaps. Micro-expansion concrete is poured into the tongue and groove joints to enhance the connection strength. Finally, a 50mm thick C30 fine stone concrete surface layer is poured on the upper surface of the composite concrete panel 15 and cured for 28 days to complete the construction.

[0019] In this embodiment, the heat transfer coefficient of the plate is 0.23 W / (m²・K), which meets the energy-saving requirements of extremely cold regions; the anti-seepage pressure at the splice is ≥0.3 MPa, with no leakage; the bonding strength between the prefabricated truss 18 and the insulation core material 16 is ≥0.8 MPa, with no delamination between layers, and the structural stability meets the standards.

[0020] Although embodiments of the invention have been described, those skilled in the art can make adjustments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A precast floor slab with thermal insulation and energy saving, characterized in that, The slab comprises: a panel, which is divided into three layers from top to bottom: a top layer of composite concrete panel, a bottom layer of cement-based protective layer, and a middle layer of thermal insulation core material; several prefabricated trusses are arranged side by side within the thermal insulation core material, and the thermal insulation core material completely encloses the prefabricated trusses; the two sides of the panel are provided with splicing tongue and groove joints; the prefabricated trusses include upper and lower chord members, which are fixed together by multiple diagonal independent web members, which are arranged in a "V" shape, and the chord members have protrusions in opposite directions, with grooves on the protrusions for engaging transverse and longitudinal reinforcements; the prefabricated trusses include: multiple parallel chord members arranged in pairs, each chord member having a core rod, a thermal insulation layer, and an outer layer in sequence from the inside to the outside, and each pair of chord members has a protruding strip in opposite directions on the outer layer, with a longitudinal groove and multiple transverse grooves on the protrusion, the longitudinal reinforcements being engaged in the longitudinal grooves and the transverse reinforcements being engaged in the transverse grooves; the chord members are connected by... The system comprises multiple independent web members, each connected to a chord member at both ends via connecting blocks. The lower part of the connecting block has a circular groove and a mating surface. The circular groove matches the diameter of the longitudinal rib, and the mating surface matches the outer surface of the raised rib. The insulation layer uses polyurethane insulation material. The outer layer is integrally formed with the raised rib, and the independent web members are integrally formed with the connecting blocks at both ends. The axial angle between the independent web members and the connecting blocks is 45°-60°, and they are arranged continuously in a "human" shape between each pair of chord members. The inner wall of the circular groove of the connecting block is mated with the outer wall of the longitudinal rib, and the mating surface is completely mated with the outer surface of the raised rib. Through-hole screw holes are provided on both sides of the connecting block, extending from one side of the connecting block to the middle of the mating surface. Mounting holes corresponding to the screw holes are provided on the raised rib. When the mating surface of the connecting block is mated with the surface of the raised rib, the mounting holes and screw holes can be coaxially aligned, and the connecting block is fixed to the chord member by bolts.

2. The precast floor slab with thermal insulation and energy saving according to claim 1, characterized in that, The depth of the transverse groove is the diameter of the transverse rib plus the radius of the longitudinal rib, and the depth of the longitudinal groove is the radius of the longitudinal rib.

3. The precast floor slab with thermal insulation and energy saving according to claim 2, characterized in that, The core rod is a galvanized steel rod; the insulation core material is rigid polyurethane foam, and the thickness of the insulation core material is consistent with the height of the energy-saving prefabricated truss; the cement-based protective layer is mixed with crack-resistant fibers and has a thickness of 5-8mm.

4. The precast floor slab with thermal insulation and energy saving according to claim 3, characterized in that, The outer layer is made of glass fiber reinforced plastic. The truss is prefabricated in the factory. The chords, independent web members, longitudinal ribs and transverse ribs are assembled and shipped as a whole. The thickness of the insulation layer is 15-20mm, the thickness of the outer layer is 5-8mm, and the height of the convex strip is 15-20mm.

5. The precast floor slab with thermal insulation and energy saving according to claim 4, characterized in that, The plate is manufactured in the factory according to the following steps and then shipped as a whole: The first step is to build a prefabricated mold and fix the prefabricated truss in the middle area of ​​the mold according to the design spacing, ensuring that the axis of the truss is consistent with the length direction of the mold; The second step is to inject rigid polyurethane foam raw material into the mold. After the raw material foams and solidifies, it forms a middle layer of insulation core material, which completely wraps the energy-saving prefabricated truss. The third step is to tie a steel mesh on the upper side of the middle layer insulation core material, weld one end of the pre-embedded steel bar to the upper chord of the truss and fix it, and extend the other end upwards out of the steel mesh. Then, pour C30 concrete to form a composite concrete panel with a panel thickness of 80-100mm. The fourth step is to pour cement-based mortar mixed with crack-resistant fibers under the middle layer of insulation core material to form a cement-based protective layer with a thickness of 5-8mm. Fifth step: After the composite concrete panel and cement-based protective layer have cured, process stepped splicing tongue and groove joints on both sides of the panel, and then attach elastic sealing strips to the stepped surfaces of the tongue and groove joints.

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