Concrete panel with surface embedded structure and preparation method

Abstract

The invention provides a concrete panel with a surface embedded structure and a preparation method, the concrete panel comprises a panel and a base layer, the panel is provided with a plurality of bent finger connecting structures formed by stamping and shearing, and the finger connecting structures are embedded into the base layer; one end of the finger connecting structure is a free end, and the other end is connected with the panel. The width of the connecting position of the finger connecting structure and the panel is smaller than the maximum width of the finger connecting structure. According to the invention, the panel is directly stamped and sheared to form the finger connecting structure, and the finger connecting structure is embedded into the base layer structure to form an integrated structure, so that the panel and the base layer are connected into a whole and cannot be separated. And the structure of independently processing and welding the pin is not needed, so that the process is greatly simplified, and the problem of surface deformation caused by welding is also avoided.

Description

Technical Field

[0001] This invention relates to the field of interior and exterior wall decorative panels for building structures, and in particular to a concrete panel with a surface interlocking structure and its preparation method. Background Technology

[0002] Building exterior walls are affected by harsh factors such as ultraviolet radiation, wet and dry cycles, and rain erosion, placing high demands on exterior wall decoration materials. Currently, there is no perfect solution. Traditional exterior wall decoration materials face challenges in terms of cost, durability, safety, and especially the risk of detachment and maintenance costs. Existing exterior wall decoration solutions include: 1. Glass curtain walls: High cost: The materials themselves are expensive, and the strict requirements for structural support, sealing, and installation processes lead to high overall costs. Severe light pollution: Large areas of glass reflect sunlight, easily producing strong glare, affecting the surrounding environment and traffic safety. Relatively weak wind and earthquake resistance: Large glass panels are prone to deformation and breakage under strong winds and earthquakes, posing a safety hazard of falling from heights. Energy consumption issues: Relatively poor thermal insulation performance, easily leading to indoor overheating in summer, increasing air conditioning energy consumption; the cost of using high-performance energy-saving glass structures (such as vacuum glass) is too high and increases safety hazards. High maintenance costs: Cleaning and maintenance are difficult and costly. II. Exterior Wall Coatings: Poor adhesion, prone to peeling: Affected by substrate preparation, coating quality, construction techniques, and environmental factors, exterior wall coatings are prone to peeling, powdering, and flaking. Poor durability: Easily eroded by ultraviolet rays and rainwater, fading and aging, requiring regular renovation and maintenance. Limited decorative effect: Insufficient texture and three-dimensionality, making it difficult to achieve a good decorative effect. III. Exterior Wall Tiles, such as ceramic tiles and marble: High cost: Both material and labor costs are high. Complex construction, long cycle: Requires wet work, high requirements for construction techniques, and low construction efficiency. Prone to detachment later, high safety risk of falling from heights: This is the most prominent disadvantage. Affected by freeze-thaw cycles, aging of adhesive materials, and temperature stress, hollowing and detachment of tiles occur frequently, posing a serious "falling object" threat to pedestrians and property. Poor seismic performance: Prone to overall peeling during earthquakes. IV. Aluminum Composite Panels and Similar Metal Panels, Imitation Stone Panel Curtain Walls: These use frame-fixed structures, which are prone to damage, leading to panel detachment. Their stability depends on the underlying wooden, steel, or aluminum keel frame. Once the frame is damaged due to corrosion, design, or construction issues, the aluminum composite panels are highly susceptible to overall or partial collapse, posing a safety hazard. Difficulty in Curved Surface Forming: The flat panels are difficult to adapt to complex curved shapes, limiting personalized architectural design. On-site construction often fails to achieve the desired design effect, and achieving high flatness is extremely difficult. Poor Fire Resistance, Especially with Inferior Products: Some aluminum composite panels have flammable core materials that may act as accelerants or release toxic gases in a fire. Prone to Dents and Scratches: The panels are relatively thin, and their impact resistance in suspended areas is limited. Current technologies have continuously sought better exterior wall decoration solutions, such as integrated exterior wall insulation and decoration panels, foamed ceramic panels, microcement, and real stone paint. However, these solutions are not fundamentally different from traditional solutions, primarily relying on adhesives or cementitious materials for bonding. Due to adhesive aging and interface issues, these solutions still carry significant risks. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a concrete panel with a surface interlocking structure, which can overcome the difficulties in the prior art. The panel and the substrate are interlocked instead of bonded, which is not limited by the service life of the adhesive, has high bonding strength, high durability, strong weather resistance, and a service life consistent with the life of concrete.

[0004] The technical problem to be solved by the present invention is a method for preparing a concrete panel with a surface interlocking structure, which can solve the problems of easy detachment of exterior wall decorations and high construction difficulty.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a concrete panel with a surface interlocking structure, including a panel and a base layer, wherein a plurality of bent finger connection structures formed by stamping and shearing are provided on the panel, and the finger connection structures are embedded in the base layer; The finger connection structure has one free end and the other end connected to the panel.

[0006] In the preferred embodiment, the bending angle of the finger connection structure is 20°~160°; The finger connection structure has one or more structures with increased width.

[0007] In a preferred embodiment, the finger connection structure is circular, elliptical, elongated, or rectangular; The width of the connection point between the finger connection structure and the panel is less than the maximum width of the finger connection structure.

[0008] In a preferred embodiment, a through hole is formed at the position where the finger connection structure is stamped and sheared on the panel; A protective film is provided on the outside of the panel, and the base layer is filled in the through holes.

[0009] In a preferred embodiment, the panel material is an aluminum plate with an oxide layer, a stainless steel plate, a copper plate, a titanium alloy plate, an ABS plate, a PC / AB composite plate, a HIPS plate, a PETG plate, or a PP plate.

[0010] In a preferred embodiment, the panel is made of concrete or gypsum, or a mixture of concrete and gypsum.

[0011] A method for preparing a concrete panel with a surface interlocking structure as described above includes the following steps: S1. Stamp and cut the finger connection structure on the panel, and bend the finger connection structure 20°~160°. S2. Flip the panel to use as the bottom mold, set the side molds, and form a cavity; S3, Components for casting the base layer in the cavity; S4. Before initial setting, clean the smooth surface of the panel to remove any grout leakage. After the base layer solidifies, a concrete panel with a surface interlocking structure is formed.

[0012] A method for preparing a concrete panel with a surface interlocking structure as described above includes the following steps: S01. Stamp and cut the finger connection structure on the panel, and bend the finger connection structure 20°~160°. S02. Apply a film to the smooth surface of the panel; S03. Flip the panel to use it as the bottom mold, set the side molds, and form a cavity; S04, Components for casting the base layer in the cavity; S05. After the base layer solidifies, a concrete panel with a surface interlocking structure is formed.

[0013] A method for preparing a concrete panel with a surface interlocking structure as described above includes the following steps: S11. Stamp and cut the finger connection structure on the panel, and bend the finger connection structure 20°~160°. S12. Bend the panel into the required shape, flip the panel as the bottom mold, set the side molds, and form a cavity; S13, Components of the base layer for plastering in the cavity; S14. Before initial setting, clean the smooth surface of the panel to remove any grout leakage. After the base layer solidifies, a concrete panel with a surface interlocking structure is formed.

[0014] A method for preparing a concrete panel with a surface interlocking structure as described above includes the following steps: S21. Stamp and cut the finger connection structure on the panel, and bend the finger connection structure 20°~160°. S22. Apply a film to the smooth surface of the panel; S23. Bend the panel into the required shape, flip the panel as the bottom mold, set the side molds, and form a cavity; S24. Components of the base layer for plastering in cavities; S25. After the base layer solidifies, a concrete panel with a surface interlocking structure is formed.

[0015] This invention provides a concrete panel with a surface-fitting structure and its preparation method. The panel is directly stamped and sheared to create finger-connecting structures, which are then embedded into the base structure to form an integrated structure, ensuring a seamless connection between the panel and the base. This eliminates the need for separate processing and welding of pins, significantly simplifying the process and avoiding surface deformation issues caused by welding. The finger-connecting structures are bent, avoiding the separate processing, transportation, and assembly of pins compared to existing welding-based installation methods. The process is simple and cost-effective: both shearing and bending are completed simultaneously during stamping. Strong connection stability is achieved: the finger-connecting structures are made from the panel material, seamlessly integrated with the panel. Compared to riveting, screwing, and bonding with independent pins, this reduces stress concentration at the connection points. Furthermore, after embedding into the base, multiple finger-connecting structures provide multi-point fixation, enhancing the connection strength between the panel and the base and preventing detachment during use. This invention also allows for the formation of preset patterns through the array arrangement of the finger-connecting structures. The preparation method is also very simple, requiring no additional base mold. Attached Figure Description

[0016] The present invention will be further described below with reference to the accompanying drawings and embodiments: Figure 1 This is a cross-sectional structural diagram of the present invention.

[0017] Figure 2 This is a top view of the present invention.

[0018] Figure 3 This is a partially enlarged schematic diagram of the finger connection structure of the present invention.

[0019] Figure 4 yes Figure 3 A schematic diagram of the AA section.

[0020] Figure 5 yes Figure 3 A cross-sectional schematic diagram of another preferred structure.

[0021] Figure 6 This is a cross-sectional structural diagram of the curved structure of the present invention.

[0022] Figure 7 This is a partially enlarged schematic diagram of the processing panel of the stamping die in this invention.

[0023] In the diagram: 1. Panel, 2. Finger connection structure, 3. Base layer, 4. Through hole, 5. Protective film, 6. Shearing mold, 7. Bottom mold. Detailed Implementation

[0024] Example 1: like Figures 1-5In the present invention, a concrete panel with a surface interlocking structure includes a panel 1 and a base layer 3. The panel 1 is provided with a plurality of bent finger connection structures 2 formed by stamping and shearing, and the finger connection structures 2 are embedded in the base layer 3. In a preferred embodiment, panel 1 is made of concrete or gypsum, or a mixture of concrete and gypsum. The concrete used in this invention includes, but is not limited to, ordinary concrete, foamed concrete, and ultra-high performance concrete (UHPC). In one project, the base layer 3 was UHPC, and panel 1 was an anodized aluminum alloy plate, exhibiting superior strength, corrosion resistance, salt spray resistance, and aesthetic appeal. In the exterior wall of a high-end hotel, foamed concrete was used, and panel 1 was a titanium alloy plate. Besides the finger-connecting structures 2 used to fix panel 1 itself, the array of finger-connecting structures 2 also formed exquisite patterns, resulting in excellent aesthetics. Gypsum includes phosphogypsum. In some interior wall applications, the base layer uses a composite structure of phosphogypsum and concrete, where the concrete uses components of UHPC, and the phosphogypsum addition is 60% by dry weight. The surface layer uses a semi-transparent plastic sheet, such as PETG sheet, with through-holes forming an array pattern, resulting in excellent artistic effects. Due to the large amount of phosphogypsum added, the overall cost is lower, and the construction effect is better. In one interior decoration case, the base layer is made of phosphogypsum, and the panel 1 is made of transparent flexible PET. In addition to the finger connection structure 2 used to fix the panel 1 itself, the array of circular finger connection structures 2 also forms an exquisite array pattern.

[0025] The finger connection structure 2 has one free end and the other end connected to the panel 1.

[0026] Preferred solutions include Figure 3 As shown, the bending angle of the finger connecting structure 2 is 20°~160°; preferably, the bending angle of the finger connecting structure 2 is 90°. The length of the finger connecting structure 2 is preferably 5mm~20mm, with the 5mm structure mainly used indoors and the 20mm structure mainly used outdoors. After the finger connecting structure 2 is bent, it will form an array of holes on the panel 1, and the holes will be filled by the base layer 3 to form a plane.

[0027] like Figure 2 , 4 In section 5, the finger connection structure 2 has one or more structures with increased width. This structure improves the pull-out resistance between the finger connection structure 2 and the base layer 3.

[0028] Preferred solutions include Figure 4 , 5 In the above, the finger connection structure 2 is circular as shown. Figure 5 As shown, oval, oblong, etc. Figure 4The shapes shown are either rectangular or circular; more commonly, they are circular or elongated. Circular shapes allow the through-holes 4 to form an aesthetically pleasing dot matrix pattern. Elongated shapes offer better anti-detachment performance.

[0029] like Figure 4 , 5 As shown, the width of the connection point between the finger connecting structure 2 and the panel 1 is less than the maximum width of the finger connecting structure 2. This structure achieves a balance between ease of processing and pull-out resistance, making it easy to stamp and shear, while also facilitating the formation of aesthetically pleasing patterns.

[0030] Preferred solutions include Figure 3 In the middle, on panel 1, a through hole 4 is formed at the position where the finger connecting structure 2 is stamped and sheared; A protective film 5 is provided outside the panel 1, and the base layer 3 fills the through holes 4. This structure avoids the formation of grooves at the locations of the through holes 4, ensuring a smooth surface for the entire concrete panel. The protective film 5 is made of materials such as PE film or other membranes that can be applied to metal surfaces.

[0031] In the preferred embodiment, panel 1 is made of an aluminum plate, stainless steel plate, copper plate, titanium alloy plate, ABS plate, PC / AB composite plate, HIPS plate, PETG plate, or PP plate with an oxide layer. The aluminum plate with the oxide layer is, for example, anodized aluminum plate, which has a dense oxide film and is alkali-resistant, corrosion-resistant, and UV-resistant. The copper plate includes pure copper plate or copper alloy plate. ABS plate, i.e., acrylonitrile-butadiene-styrene copolymer plate, has excellent thermoplasticity and cold bending properties: it can be bent to a small radius at room temperature, with a bending radius R / material thickness t≈1–2; after heating to 80–100℃, it is easier to stamp complex 3D structures; high surface quality: it can be directly finished with high-gloss, matte, wood grain, brushed metal, and other finishes. PC / AB composite board, or carbonated ABS, combines the high toughness, high transparency, and heat resistance of PC with the easy processing of ABS. Its impact strength is 50% higher than pure ABS, and it is more resistant to bending fatigue. Its heat distortion temperature is higher, approximately 110℃, making it suitable for environments with large temperature differences. It also offers a variety of surface finishes. HIPS board, or high-impact polystyrene, is extremely low-cost and easy to vacuum-form and stamp. Its surface can be covered with PVC film and printed with patterns. PETG board, or glycol-modified, is transparent or translucent, with high gloss and high toughness. It can be cold-bent with an R / t of approximately 2–3. Its chemical resistance and weather resistance are superior to ABS, making it suitable for limited outdoor use, requiring UV stabilizers. It can be laser-engraved and have embedded lighting. PP board, or polypropylene. Metal panels are suitable for exterior walls, while plastic panels are suitable for interior walls.

[0032] Example 2: Based on Example 1, a method for preparing the above-mentioned concrete panel with surface interlocking structure includes the following steps: S1. The finger connecting structure 2 is stamped and cut on panel 1. The finger connecting structure 2 is bent at 20°~160°, preferably 90°. Figure 7 In the process, the stamping die includes a shearing die 6 and a bottom die 7. The shearing die 6 has an arc-shaped structure at one end to allow the finger connecting structure 2 to bend, and an inclined cutting edge on the other side to reduce stamping resistance. The bottom die 7 has a comb-like structure and is supported on both sides of the through hole 4.

[0033] S2. Flip panel 1 to serve as the bottom mold, set the side molds, and form a cavity; S3, the components of the base layer 3 are poured into the cavity; S4. Before initial setting, clean the smooth surface of panel 1 to remove any grout leakage. After the base layer 3 solidifies, a concrete panel with a surface interlocking structure is formed.

[0034] The concrete panel of this invention is used as a formwork structure for the exterior walls of buildings, significantly improving the appearance of the building and resulting in a smooth and aesthetically pleasing structure. The panel 1 is tightly bonded to the base layer 3, making it less prone to detachment.

[0035] Example 3: Based on Examples 1 and 2, a method for preparing the above-mentioned concrete panel with surface interlocking structure includes the following steps: S01. The finger connecting structure 2 is stamped and cut on the panel 1, and the finger connecting structure 2 is bent at 20°~160°; preferably, the finger connecting structure 2 is bent at 90°.

[0036] S02, Apply a film to the smooth surface of panel 1; S03. Flip panel 1 to serve as the bottom mold, set the side molds, and form a cavity; S04, The components of base layer 3 are poured into the cavity; S05, after the base layer 3 solidifies, forms a concrete panel with a surface interlocking structure. The structure in this example has a smoother appearance.

[0037] Example 4: Based on Example 1, a method for preparing the above-mentioned concrete panel with surface interlocking structure includes the following steps: S11. The finger connecting structure 2 is stamped and sheared on the panel 1, and the finger connecting structure 2 is bent at 20°~160°; preferably, the finger connecting structure 2 is bent at 90°. The stamping die includes a shearing die 6 and a bottom die 7. One end of the shearing die 6 is provided with an arc-shaped structure to make the finger connecting structure 2 bend, and the other side is provided with an inclined cutting edge to reduce stamping resistance.

[0038] S12. Bend panel 1 into the required shape, flip panel 1 as the bottom mold, set the side mold, and form a cavity. Alternatively, panel 1 can be vertically fixed first, with diagonal bracing provided on the smooth outer surface, and then side molds and top molds can be installed to form a cavity. S13. Apply the components of base layer 3 to the cavity; S14. Before initial setting, clean the smooth surface of panel 1 to remove any grout leakage. After the base layer 3 solidifies, a concrete panel with a surface interlocking structure is formed.

[0039] Example 5: Based on Examples 1 and 4, a method for preparing the above-mentioned concrete panel with surface interlocking structure includes the following steps: S21. Stamp and cut the finger connection structure 2 on panel 1, and bend the finger connection structure 2 by 20°~160°. S22. Apply a film to the smooth surface of panel 1; S23. Bend panel 1 into the required shape, flip panel 1 as the bottom mold, set the side mold, and form a cavity; S24. Apply the components of base layer 3 to the cavity; S25, after the base layer 3 solidifies, it forms a concrete panel with a surface interlocking structure. This invention has better appearance quality.

[0040] Example 6: Based on Examples 1 and 4, a method for preparing the above-mentioned concrete panel with surface interlocking structure includes the following steps: S31. Stamp and cut the finger connection structure 2 on panel 1, and bend the finger connection structure 2 by 20°~160°. S32. Apply a film to the smooth surface of panel 1; S33. Bend panel 1 into the desired shape; S34. Set up the wall modeled in step S33, and apply a sufficiently thick layer of concrete to the wall surface as the base layer 3. The sufficient thickness is the thickness that exceeds the height of the finger connection structure 2 and is sufficient to embed the finger connection structure 2 of the panel 1. S35. Before the concrete has initially set, cover the panel 1 on the base layer 3 and embed the finger connection structure 2 into the base layer 3. Preferably, a surface vibrator can be used to compact the concrete. S36, after the base layer 3 solidifies, it forms a concrete panel with a surface interlocking structure. This invention has better appearance quality.

[0041] Preferably, for the uncoated panel solution, cleaning the through-hole 4 to remove any leaking grout completes the interior wall surface decoration. The operation is very convenient, and the panels exhibit high bonding strength, high surface hardness, and excellent appearance.

[0042] Example 7: Based on the above embodiments, the pattern is input into the computer, and a robotic arm, such as an articulated robotic arm or a Cartesian robotic arm, controls the cutting mold 6 to perform molding and cutting operations according to the pattern to form an array pattern, which has better artistic and commercial promotional effects.

[0043] Although this application has been described in conjunction with specific features and embodiments, it is obvious that various modifications and combinations can be made thereto without departing from the spirit and scope of this application. Accordingly, this specification and drawings are merely illustrative descriptions of the application as defined by the appended claims, and are considered to cover any and all modifications, variations, combinations, or equivalents within the scope of this application. Clearly, those skilled in the art can make various alterations and modifications to this application without departing from its scope. Thus, if such modifications and modifications fall within the scope of the claims and their equivalents, this application is also intended to include such modifications and modifications.

Claims

1. A concrete panel with a surface interlocking structure, characterized in that: It includes a panel (1) and a base layer (3). Multiple bent finger connection structures (2) formed by stamping and shearing are provided on the panel (1). The finger connection structures (2) are embedded in the base layer (3). The finger connection structure (2) has one end as a free end and the other end as a connection to the panel (1).

2. The concrete panel with a surface-fitting structure according to claim 1, characterized in that: The bending angle of the finger connection structure (2) is 20°~160°; The finger connection structure (2) has one or more structures with increased width.

3. The concrete panel with a surface-fitting structure according to claim 1, characterized in that: The finger connection structure (2) is circular, elliptical, elongated, or rectangular; The width of the connection point between the finger connection structure (2) and the panel (1) is less than the maximum width of the finger connection structure (2).

4. The concrete panel with a surface-fitting structure according to any one of claims 1 to 3, characterized in that: On the panel (1), a through hole (4) is formed at the position of the finger connection structure (2) being stamped and sheared. A protective film (5) is provided outside the panel (1), and the base layer (3) is filled in the through hole (4).

5. A concrete panel with a surface-fitting structure according to any one of claims 1 to 3, characterized in that: The material of panel (1) is aluminum plate, stainless steel plate, copper plate, titanium alloy plate, ABS plate, PC / AB composite plate, HIPS plate, PETG plate or PP plate with oxide layer.

6. The concrete panel with a surface-fitting structure according to any one of claims 1 to 3, characterized in that: The material of panel (1) is concrete or gypsum, or a mixture of concrete and gypsum.

7. A method for preparing a concrete panel with a surface-fitting structure as described in any one of claims 1 to 6, characterized in that: Includes the following steps: S1. Stamp and cut the finger connection structure (2) on the panel (1), and bend the finger connection structure (2) by 20°~160°; S2. Flip the panel (1) to form the bottom mold, set the side molds, and form a cavity; S3, the components of the base layer (3) poured into the cavity; S4. Clean the panel before initial setting (1) to remove grout leakage from the smooth surface, and the base layer (3) to form a concrete panel with a surface interlocking structure after solidification.

8. A method for preparing a concrete panel with a surface-fitting structure as described in any one of claims 1 to 6, characterized in that: Includes the following steps: S01. Stamp and cut the finger connection structure (2) on the panel (1), and bend the finger connection structure (2) by 20°~160°; S02, Apply a film to the smooth surface of panel (1); S03. Flip the panel (1) to form the bottom mold, set the side molds, and form a cavity; S04, Components of the base layer (3) poured into the cavity; S05, Base layer (3) After solidification, a concrete panel with a surface interlocking structure is formed.

9. A method for preparing a concrete panel with a surface-fitting structure as described in any one of claims 1 to 6, characterized in that: Includes the following steps: S11. Stamp and cut the finger connection structure (2) on the panel (1), and bend the finger connection structure (2) by 20°~160°; S12. Bend the panel (1) into the required shape, flip the panel (1) as the bottom mold, set the side mold, and form a cavity; S13, Components of the base layer (3) applied in the cavity; S14. Clean the panel before initial setting (1) to remove grout leakage from the smooth surface, and the base layer (3) to form a concrete panel with a surface interlocking structure after solidification.

10. A method for preparing a concrete panel with a surface-fitting structure as described in any one of claims 1 to 6, characterized in that: Includes the following steps: S21. Stamp and cut the finger connection structure (2) on the panel (1), and bend the finger connection structure (2) by 20°~160°; S22. Apply a film to the smooth surface of panel (1); S23. Bend the panel (1) into the required shape, flip the panel (1) as the bottom mold, set the side mold, and form a cavity; S24. Components of the base layer (3) applied in the cavity; S25, Base layer (3) After solidification, a concrete panel with a surface interlocking structure is formed.

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