An integrated forming template for filling wall cast-in-place thermal insulation

Abstract

This invention provides an integrated formwork for cast-in-place insulation of infill walls, belonging to the field of building construction technology. The invention includes an insulation layer device and a casting panel; the insulation layer device is adapted to the infill wall; the casting panel is movably connected to the inner side of the insulation layer device, with vertical casting holes on the bottom and side casting holes on the sides, forming a multi-directional casting network. This invention achieves simultaneous construction of the infill wall, reinforcement installation, and insulation layer through a dual-hole design of "vertical main casting + side supplementary casting" and a pre-set rebar installation channel. This ensures dense, seamless concrete pouring, convenient and precise rebar installation, and improved wall structural strength. It also achieves deep integration of the insulation layer and structural layer, avoiding thermal bridging risks. Furthermore, the formwork is flexibly adaptable to various wall specifications, easy to disassemble, and reusable, reducing construction costs while meeting the requirements of green industrialized construction.

Description

Technical Field

[0001] This invention relates to the field of building construction technology, and in particular to an integrated molding template for in-situ infill wall insulation. It is applicable to in-situ infill wall construction scenarios in various types of buildings such as residential and commercial buildings, and is especially suitable for industrialized, modular and green low-carbon construction projects. It can realize the simultaneous advancement of infill wall structure forming, insulation layer layout and steel reinforcement. Background Technology

[0002] As a core component of building envelope, infill walls directly determine the overall quality, living comfort, and energy consumption level of a building through their construction efficiency, structural stability, and thermal insulation and energy-saving performance. With the continuous upgrading of national building energy conservation standards, the in-depth implementation of green building policies, and the rapid development of industrialized and modular construction methods, the market has put forward new requirements for infill wall construction: "integration, high efficiency, energy saving, and stability." Traditional segmented construction techniques and simple integrated formwork are no longer sufficient to meet these core needs.

[0003] In existing technologies, the construction of infill walls often adopts a segmented process of "masonry construction - base treatment - insulation layer laying - protective layer construction". This process is cumbersome, with complex procedures and a large amount of wet work and construction waste on site. This not only leads to a longer construction period and increased labor costs, but also has many technical pain points: the bonding strength between the insulation layer and the wall base is insufficient, and under long-term temperature changes, vibration or external forces, it is prone to hollowing, cracking and falling off, which seriously affects the building's thermal insulation and energy-saving effect and structural safety; the splicing gaps and thermal bridge effect formed by segmented construction further reduce the wall's thermal insulation performance and increase building energy consumption, which is inconsistent with the green and low-carbon construction concept.

[0004] To overcome the drawbacks of segmented construction methods, some integrated formwork templates for cast-in-place insulation in infill walls have emerged on the market. However, they still have significant technical defects: First, the pouring design is unreasonable. Most templates only have pouring holes in a single direction, which can easily lead to pouring dead corners, resulting in incomplete concrete filling and forming defects such as honeycomb, pitting, and voids, affecting the structural strength of the wall. Second, there is a lack of targeted reinforcement installation design. Traditional reinforcement installation requires building a framework first and then supporting the formwork, which is cumbersome and prone to problems such as reinforcement displacement and uneven spacing. Although some templates have reserved installation holes, the hole diameter and layout are not scientifically designed, which can easily lead to grout leakage or insecure reinforcement fixation. Third, the adaptability and reusability are poor. Most are designed with fixed specifications, which are difficult to meet the construction needs of different house types and wall thicknesses. Moreover, the connection of each component is cumbersome, disassembly is difficult, and the reuse rate is low, increasing construction costs. Fourth, the synergy between insulation and structure is insufficient. Simply integrating the formwork and insulation materials can easily cause the insulation layer to shift and deform due to the lateral pressure of the concrete, resulting in unstable insulation performance.

[0005] To address the shortcomings of existing technologies, there is an urgent need to develop an integrated formwork that combines efficient pouring, convenient rebar installation, stable thermal insulation support, flexible adaptability, and reusability. This technological innovation will solve industry pain points, simultaneously improve the quality, efficiency, and energy-saving performance of infill wall construction, and promote the innovative upgrading of building construction formwork technology. Summary of the Invention

[0006] In view of this, to address the technical problem of unreasonable pouring design in existing integrated formwork for infill wall construction, this invention provides an integrated formwork for cast-in-place insulation of infill walls. It consists of an adjustable, integrated insulation layer device supporting the frame, and a pouring panel with vertical pouring holes, side pouring holes, and rebar installation holes arranged according to structural mechanics. Through the coordinated design of "vertical main pouring + side supplementary pouring" and pre-set rebar installation channels, simultaneous construction of infill wall pouring, rebar installation, and insulation layer is achieved. This ensures dense, seamless concrete pouring, convenient and precise rebar installation, and improved wall structural strength. It also achieves deep integration of the insulation layer and structural layer, avoiding thermal bridging risks. Furthermore, the formwork is flexibly adaptable to various wall sizes, easy to disassemble, and reusable, reducing construction costs while meeting the requirements of green industrialized construction.

[0007] To achieve the above objectives, the present invention provides the following technical solution: This invention provides an integrated molding template for cast-in-place insulation of infill walls, including an insulation layer device and a casting panel. The insulation layer device and the casting panel work together to form a closed casting chamber, realizing the simultaneous molding of the infill wall and the insulation layer during the cast-in-place construction. The insulation layer device is a frame structure, adapted to infill walls; The casting panel is movably connected to the inner side of the insulation layer device. Vertical casting holes are provided on the bottom surface along the height direction of the casting panel, and side casting holes are provided on the side surface. The vertical casting holes and side casting holes form a multi-directional casting network.

[0008] Preferably, the bottom surface of the cast-in-place panel has holes for installing reinforcing bars, which are arranged in the critical stress areas of the cast-in-place panel.

[0009] Preferably, the wall of the reinforcing bar installation hole is provided with an elastic sealing gasket.

[0010] Preferably, the edges of the reinforcing bar mounting holes are rounded.

[0011] Preferably, both the insulation layer device and the cast panel are made of flame-retardant composite insulation material and have embedded glass fiber reinforced ribs.

[0012] Preferably, the insulation layer device consists of an adjustable frame structure formed by a long insulation layer plate and a short insulation layer plate connected by detachable connectors.

[0013] Preferably, the detachable connector is a bolt or a clip.

[0014] Preferably, both the long and short insulation layers are made of flame-retardant polyurethane composite insulation material.

[0015] Preferably, the edges of the vertical casting hole and the side casting hole are rounded.

[0016] Preferably, the movable connection between the casting panel and the insulation layer device is provided with a positioning buckle and an anti-slip rubber pad layer.

[0017] Compared with the prior art, the present invention has the following beneficial effects: 1. Dual Improvement in Pouring Quality and Efficiency: This invention innovatively adopts a dual-hole collaborative design of "vertical main pouring + side supplementary pouring". The vertical pouring hole uses gravity to achieve rapid concrete flow and filling, while the side pouring hole specifically fills the pouring dead corners. The two form an all-round pouring network, effectively eliminating forming defects such as honeycomb, pitting, and voids, and improving the density and overall strength of the infill wall structure. The edges of the holes are rounded and scientifically designed to ensure the smoothness of concrete pouring and avoid wall residue, simplifying the formwork cleaning process. Combined with multi-point simultaneous pouring operations, the construction cycle is greatly shortened, meeting the needs of efficient construction in industrialized building.

[0018] 2. Convenient and precise rebar installation: The pre-drilled rebar installation holes are arranged according to structural mechanics principles and equipped with elastic sealing gaskets on the hole walls. This allows for the smooth installation of rebars of different specifications and enables rapid positioning and fixing of the rebars. The rebar skeleton can be built without dismantling the formwork, solving the problems of cumbersome rebar installation and easy positional displacement in traditional processes. After the rebars are tightly bonded to the concrete, they can effectively disperse the curing shrinkage stress of the concrete, reduce wall cracks, and enhance the shear, bending and seismic performance of the wall, taking into account both construction convenience and structural safety.

[0019] 3. Excellent thermal insulation and structural synergy: Both the insulation layer and the cast-in-place panel are made of high-strength composite insulation materials, and the cast-in-place panel is directly retained as part of the insulation layer, avoiding the risk of separation between the insulation layer and the structural layer, and eliminating the thermal bridging effect from the root; the internal reinforcing rib structure and detachable frame design of the insulation layer take into account both insulation performance and support strength, can resist the lateral pressure of concrete, and ensure the flatness and verticality of the wall after it is formed, forming an integrated "insulation + load-bearing" structure.

[0020] 4. Significantly optimized adaptability and turnover: The insulation layer device uses detachable connectors to build an adjustable frame, which can flexibly adapt to the construction of infill walls of different thicknesses and heights, eliminating the need for multiple specifications of templates and reducing material management costs; the movable connection structure between the cast panel and the insulation layer device facilitates quick installation and disassembly, with high template reuse rate and convenient cleaning after disassembly, further reducing construction costs and conforming to the concept of green construction. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the disassembled structure of the present invention; Figure 3 This is a schematic diagram of the cast panel structure of the present invention; Figure 4 This is a schematic diagram of the thermal insulation layer device of the present invention.

[0022] In the diagram, 1 is the insulation layer device; 2 is the pouring panel; 3 is the vertical pouring hole; 4 is the side pouring hole; 5 is the rebar installation hole; 6 is the long insulation layer plate; and 7 is the short insulation layer plate. Detailed Implementation

[0023] The technical solutions in the embodiments of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0024] like Figure 1-4 As shown, the present invention provides an integrated molding template for cast-in-place insulation of infill walls, including an insulation layer device 1 and a casting panel 2. The insulation layer device 1 and the casting panel 2 work together to form a closed casting chamber, realizing the simultaneous molding of the infill wall and the insulation layer. The casting panel 2 serves as both a retaining structure for the concrete pouring and can be directly retained as part of the wall insulation layer after construction, without the need for additional insulation layer later, thus achieving a deep integration of insulation and structure. The insulation layer device 1 is a frame structure, adapted to infill walls; The casting panel 2 is movably connected to the inner side of the insulation layer device 1. The bottom surface is provided with vertical casting holes 3 (preferably with a diameter of 80-120mm) arranged along the height direction of the casting panel 2, and the side surface is provided with side casting holes 4 (preferably with a diameter of 50-80mm). The vertical casting holes 3 and the side casting holes 4 form a multi-directional casting network.

[0025] In this invention, the insulation layer device 1, acting as a support frame, together with the pouring panel 2 movably connected to the inner side, forms a closed chamber. During concrete pouring, the vertical pouring holes 3, distributed along the height, serve as the main channels for transporting concrete by gravity. The side pouring holes 4 supplement the concrete supply to difficult-to-pour areas such as corners. Together, they form a multi-directional feeding network to simultaneously complete the infill wall pouring and insulation layer formation. Structurally, this achieves simultaneous completion of infill wall construction and insulation layer installation, eliminating the need for a separate insulation layer application process. The multi-directional pouring network completely eliminates pouring dead corners, preventing defects such as honeycomb and voids in the concrete, ensuring the density of the wall formation, and significantly improving construction efficiency.

[0026] In one specific embodiment of the present invention, the bottom surface of the casting panel 2 is provided with reinforcing bar installation holes 5, which are arranged in the key stress areas of the casting panel 2. The hole diameter is set to 16-25mm according to the specifications of commonly used building reinforcing bars. During construction, the reinforcing bars can be directly inserted into the casting chamber through the installation holes without disassembling the formwork, thus completing the construction of the reinforcing bar skeleton. This eliminates the cumbersome process of first building the reinforcing bar skeleton and then supporting the formwork in the traditional process, avoids the problem of positional displacement of the reinforcing bars during installation, achieves rapid and accurate positioning of the reinforcing bars, improves the efficiency and rationality of reinforcing bar installation, and enhances the overall structural strength of the wall.

[0027] In one specific embodiment of the present invention, the wall of the rebar installation hole 5 is provided with an elastic sealing gasket. When the rebar is inserted into the installation hole, the sealing gasket adheres to the outer wall of the rebar due to its own elasticity, filling the gap between the rebar and the hole wall. This effectively prevents grout from overflowing from the gap between the rebar and the hole wall during concrete pouring, reducing material waste and wall surface defects caused by grout leakage, while not affecting the normal rebar insertion operation, thus balancing sealing effect and construction convenience.

[0028] In one specific embodiment of the present invention, the edges of the reinforcing bar installation hole 5 are rounded to eliminate sharp corners at the opening. This prevents sharp edges from scratching the anti-rust coating on the surface of the reinforcing bar during installation, ensuring the durability of the reinforcing bar; at the same time, it prevents concrete debris from being scraped off by the corners of the opening, reduces residual material, facilitates cleaning after use of the formwork, and extends the turnover life of the formwork.

[0029] In one specific embodiment of the present invention, both the insulation layer device 1 and the casting panel 2 are made of flame-retardant composite insulation material, and have embedded glass fiber reinforcement structures inside. While providing thermal insulation, they also bear the load-bearing requirements during concrete pouring. The material possesses both insulation and structural load-bearing capacity, eliminating the need for additional support structures and insulation layer materials, thus simplifying the formwork structure. The glass fiber reinforcement significantly improves the material's resistance to lateral pressure and deformation, resisting the impact force during concrete pouring and preventing formwork displacement and deformation. Simultaneously, its flame-retardant properties enhance fire safety during construction and use.

[0030] In one specific embodiment of the present invention, the insulation layer device 1 comprises an adjustable frame structure consisting of a long insulation layer plate 6 and a short insulation layer plate 7 connected by detachable connectors. The insulation layer device 1 is divided into two independent components: the long insulation layer plate 6 and the short insulation layer plate 7. These two components are fixed together by detachable connectors. The specifications and connection positions of the long insulation layer plate 6 and the short insulation layer plate 7 can be adjusted according to the thickness and height of the infill wall to be constructed, assembling them into a suitable frame size. This allows for flexible adaptation of the template to infill walls of different specifications, eliminating the need for custom-made templates for each wall size, significantly reducing material procurement and management costs, and broadening the applicability of the template.

[0031] In one specific embodiment of the present invention, the detachable connector is a bolt or a clip. Bolts or clips are used as connectors between the long plate 6 and the short plate of the insulation layer. During installation, tightening the bolts or engaging the clips completes the frame fixation; during disassembly, loosening the bolts or releasing the clips allows for the disassembly of the components. The connection structure is simple and readily available, and the operation is convenient. Assembly and disassembly of the insulation layer frame can be quickly completed without specialized tools, improving the efficiency of on-site construction. Furthermore, damaged connectors are easy to replace, reducing maintenance costs.

[0032] In one specific embodiment of the present invention, both the long insulation plate 6 and the short insulation plate 7 are made of flame-retardant polyurethane composite insulation material. Utilizing the material's low thermal conductivity, lightweight, and strong weather resistance, it balances insulation functionality with structural support requirements. The excellent insulation performance of polyurethane effectively reduces the thermal conductivity of the wall, decreasing energy consumption during building use; simultaneously, the material's lightweight nature reduces the overall weight of the formwork, facilitating on-site handling and installation, while its flame-retardant properties further enhance fire safety.

[0033] In one specific embodiment of the present invention, the edges of the vertical pouring hole 3 and the side pouring hole 4 are rounded to eliminate sharp edges at the hole openings and make the hole walls transition smoothly. This reduces the problem of grout adhering to the hole walls and leaving residue during concrete pouring, improves the smoothness of concrete flow, and prevents hardened residue from clogging the pouring holes. It also facilitates cleaning after the formwork is used, reduces cleaning difficulty, and improves formwork turnover efficiency.

[0034] In one specific embodiment of the present invention, the movable connection between the casting panel 2 and the insulation layer device 1 is provided with a positioning buckle and an anti-slip rubber pad. The positioning buckle at the movable connection is preferably made of stainless steel, and the anti-slip pad is preferably made of wear-resistant rubber. When the casting panel 2 and the insulation layer device 1 are connected, the positioning buckle enables quick alignment and locking of the two, while the anti-slip rubber pad fills the gaps in the connection surface, ensuring accurate connection and enhancing the friction and sealing of the connection surface. This significantly improves the installation and positioning efficiency of the casting panel 2, preventing positional shifts during installation; the anti-slip rubber pad prevents the casting panel 2 from shifting or shaking during casting and seals the connection gaps, preventing grout leakage; simultaneously, the movable connection structure facilitates quick disassembly of the formwork after construction, improving the formwork's reusability.

[0035] The following is an example of a construction and dismantling process: The first step is frame assembly: According to the thickness and height of the infill wall to be constructed, select the corresponding specifications of the long insulation plate 6 and the short insulation plate 7, and fix them together with stainless steel bolts and buckles to assemble the insulation device 1 frame. Place it in the preset construction position, adjust it to a horizontal and stable state, and position it with the ground and wall surface with expansion bolts to ensure firm support.

[0036] The second step is panel installation: the pouring panel 2 is installed inside the insulation layer device 1 using positioning clips, so that the anti-slip pad layer is tightly attached to the joint surface of the two to ensure that the gap is closed and to prevent grout leakage during pouring; check the flatness of the pouring panel 2 to ensure that the vertical pouring hole 3, the side pouring hole 4 and the rebar installation hole 5 are accurately positioned and without deviation.

[0037] The third step is the installation of reinforcing bars: Through the reinforcing bar installation holes 5 on the pouring panel 2, the building reinforcing bars are precisely inserted into the formwork at the preset spacing and position to complete the construction and fixation of the reinforcing bar skeleton; after the reinforcing bars are installed, check the fit between the elastic sealing gasket on the hole wall and the reinforcing bar, and adjust any loose parts to ensure a tight seal.

[0038] The fourth step is concrete pouring: Concrete is injected into the closed cavity through the vertical pouring hole 3, and gravity makes the concrete flow down quickly and fill the bottom of the formwork. At the same time, the corners, gaps and other dead areas of the formwork are supplemented through the side pouring hole 4 to ensure that the concrete is evenly filled to every place. During the pouring process, the flow state of the concrete is observed and the pouring speed and the position of the supplementary pouring are adjusted in time to avoid the retention of air bubbles.

[0039] Step 5, Curing and Dismantling: After the concrete reaches the specified setting strength, dismantle the cast-in-place panel 2 and the insulation layer device 1 in sequence: first, loosen the positioning clips and remove the cast-in-place panel 2, then dismantle the connectors between the long insulation layer plate 6 and the short insulation layer plate 7 to complete the formwork dismantling; clean the dismantled formwork, remove any residual concrete from the surface, let it dry, and then store it for reuse in subsequent construction. At this point, the cast-in-place panel 2 remains on the wall surface, working in conjunction with the insulation structure of the insulation layer device 1 to form a complete insulation system, achieving simultaneous completion of the infill wall structure formation and insulation function.

[0040] In the fifth step, the cast panel 2 can also be left as part of the wall insulation layer without disassembly, without the need for additional insulation layer later, thus achieving a deep integration of insulation and structure.

[0041] This invention effectively solves the problems existing in the background technology through targeted structural innovation and process optimization. It can be widely applied to various building infill wall cast-in-place construction projects, and has significant practical value and promotion significance.

[0042] The above description is merely a preferred embodiment of the present invention. However, the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention should be covered within the scope of protection of the present invention.

Claims

1. An integrated molding template for cast-in-place insulation of infill walls, characterized in that, It includes an insulation layer device and a casting panel. The insulation layer device and the casting panel work together to form a closed casting chamber, so as to realize the simultaneous formation of the infill wall and the insulation layer during the in-situ construction. The insulation layer device is a frame structure, adapted to infill walls; The casting panel is movably connected to the inner side of the insulation layer device. Vertical casting holes are provided on the bottom surface along the height direction of the casting panel, and side casting holes are provided on the side surface. The vertical casting holes and side casting holes form a multi-directional casting network.

2. The integrated molding template for cast-in-place insulation of infill walls according to claim 1, characterized in that, The bottom surface of the cast-in-place panel has holes for installing reinforcing bars, which are arranged in the key stress areas of the cast-in-place panel.

3. The integrated molding template for cast-in-place insulation of infill walls according to claim 2, characterized in that, The wall of the reinforcing bar installation hole is provided with an elastic sealing gasket.

4. The integrated molding template for cast-in-place thermal insulation of infill walls according to claim 2, characterized in that, The edges of the steel bar installation holes are rounded.

5. An integrated molding template for cast-in-place insulation of infill walls according to claim 1, characterized in that, Both the insulation layer device and the cast panel are made of flame-retardant composite insulation material and have embedded glass fiber reinforced ribs.

6. An integrated molding template for cast-in-place thermal insulation of infill walls according to claim 5, characterized in that, The insulation layer device consists of an adjustable frame structure formed by a long insulation layer plate and a short insulation layer plate connected by detachable connectors.

7. An integrated molding template for cast-in-place insulation of infill walls according to claim 6, characterized in that, The detachable connector is a bolt or a clip.

8. An integrated molding template for cast-in-place insulation of infill walls according to claim 6, characterized in that, Both the long and short insulation plates are made of flame-retardant polyurethane composite insulation material.

9. An integrated molding template for cast-in-place insulation of infill walls according to claim 1, characterized in that, The edges of the vertical casting holes and the side casting holes are rounded.

10. An integrated molding template for cast-in-place thermal insulation of infill walls according to any one of claims 1-9, characterized in that, The movable connection between the casting panel and the insulation layer device is provided with positioning buckles and anti-slip rubber pads.

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