A prefabricated building outer envelope and thermal insulation integrated light-weight concrete hollow wallboard

Abstract

This invention discloses a lightweight hollow concrete wall panel for integrated thermal insulation of prefabricated building envelopes. The wall panel includes a concrete base, an insulation layer, and a protective layer. An embedded steel mesh is pre-embedded in the concrete base near the insulation layer. Anchor bolts are provided between the insulation layer and the protective layer. A wire mesh is also provided between the insulation layer and the protective layer, laid on the surface of the insulation layer for composite connection with the protective layer. This invention provides a lightweight hollow concrete wall panel for integrated thermal insulation of prefabricated building envelopes. Through a layered design of "concrete base - insulation layer - protective layer," and utilizing the embedded steel mesh in the concrete base, as well as hot-dip galvanized anchor bolts and wire mesh penetrating each layer, the functional layers are firmly combined into a whole.

Description

Technical Field

[0001] This invention relates to the field of prefabricated building technology, and in particular to a lightweight concrete hollow wall panel that integrates thermal insulation for prefabricated building exteriors. Background Technology

[0002] With the rapid development of my country's prefabricated building industry, the promotion of industrialization and green development in the construction industry has been clearly proposed, placing higher demands on the standardized production, integrated functions, and energy-saving performance of building components. As the core enclosure component of prefabricated buildings, exterior wall panels must simultaneously undertake multiple functions such as structural safety, thermal insulation, sound insulation, and fireproofing. Their performance directly affects the building's safety, energy efficiency, comfort, and durability.

[0003] Existing prefabricated building exterior wall panels mostly adopt a combination of "concrete blocks + separate insulation layer", which has the following drawbacks: 1. Poor connection reliability: The connection between the insulation layer and the main wall panel is weak, and long-term use can easily lead to detachment and hollowing, affecting the insulation effect and structural safety.

[0004] 2. Low construction efficiency: The process is complicated, requiring multiple steps such as masonry, insulation layer pasting, and plastering to be completed in sequence, which extends the construction period by more than 40% and increases labor costs by about 50%.

[0005] To address this, a lightweight concrete hollow wall panel integrating prefabricated building envelope insulation is proposed. Summary of the Invention

[0006] Therefore, it is necessary to address the aforementioned technical problems by providing a lightweight hollow concrete wall panel that integrates thermal insulation with prefabricated building envelopes. This panel utilizes a layered design of "concrete base layer - insulation layer - protective layer," and employs embedded steel mesh in the concrete base layer, along with hot-dip galvanized anchors and wire mesh penetrating each layer, to firmly integrate the functional layers into a unified whole. This multi-layered composite anchoring structure effectively avoids the common quality problems of insulation layer detachment and hollowing in traditional split wall panels, significantly improving the integrity, stability, and durability of the wall panel.

[0007] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: A prefabricated building exterior envelope integrated lightweight concrete hollow wall panel includes a wall panel comprising a concrete base layer, an insulation layer, and a protective layer. An embedded steel mesh is pre-embedded in the concrete base layer near the insulation layer. An anchor bolt is provided between the insulation layer and the protective layer. A wire mesh is also provided between the insulation layer and the protective layer, and the wire mesh is laid on the surface of the insulation layer for composite connection with the protective layer. One end of the anchor bolt extends through the wire mesh, the insulation layer, and the embedded steel mesh, extending into the concrete base layer.

[0008] Furthermore, the surface of the wall panel is provided with a connecting tongue and groove, which includes a male connecting part and a female connecting groove, and the male connecting part and the female connecting groove are respectively provided on both sides of the wall panel.

[0009] Furthermore, the concrete base layer has several uniformly distributed circular hollow cavities along its length.

[0010] Furthermore, the wall panel has connecting slots at both the top and bottom, and the wall panel can be connected to an external U-shaped slot connector for assembly with an external support base through the connecting slots.

[0011] Furthermore, the concrete base layer is prepared using lightweight aggregate concrete.

[0012] Furthermore, the insulation layer is made of extruded polystyrene board with a thickness of sixty millimeters.

[0013] Furthermore, the anchor bolt is a hot-dip galvanized metal anchor bolt, and the anchor bolt penetrates the insulation layer and is embedded in the concrete base layer to a depth of more than 35 mm.

[0014] Furthermore, the diameter of the circular hollow cavity is 100 mm, the center-to-center distance between adjacent hollow cavities is 120 mm, and the total cross-sectional area of ​​the hollow cavity accounts for 25% to 30% of the cross-sectional area of ​​the concrete base layer.

[0015] Furthermore, the protective layer is a crack-resistant fiber polymer cement mortar finishing layer with a thickness of 30 mm. The polymer cement mortar is composed of cement, quartz sand, acrylic emulsion and crack-resistant fiber mixed in a mass ratio of 1:2:0.2:0.01.

[0016] Furthermore, the wire mesh is made of hot-dip galvanized steel wire mesh with a wire diameter of five millimeters, and the wire mesh is tightly bonded to the insulation layer by anchor bolts.

[0017] Compared with the prior art, the present invention has the following beneficial effects: The prefabricated building envelope integrated lightweight concrete hollow wall panel provided by this invention utilizes a layered design of "concrete base layer - insulation layer - protective layer," and employs embedded steel mesh in the concrete base layer, as well as hot-dip galvanized anchors and wire mesh penetrating each layer to firmly bond the functional layers into a whole. This multi-layer composite anchoring structure effectively avoids the common quality problems of insulation layer detachment and hollowing in traditional split wall panels, significantly improving the integrity, stability, and durability of the wall panel.

[0018] The tongue-and-groove joints on both sides of the wall panel and the pre-installed connecting slots at the top and bottom provide a standardized and modular interface for quick installation. This design enables precise positioning and rapid assembly of the wall panel during construction, transforming complex on-site wet work into efficient dry assembly, thereby greatly simplifying the construction process, shortening the construction period, and reducing labor costs.

[0019] Through the synergistic design of lightweight aggregate concrete and built-in steel mesh, combined with an optimized circular hollow cavity arrangement structure, the self-weight of the wall panel is significantly reduced, and the load-bearing pressure on the main building structure is reduced, while ensuring that the wall panel has excellent mechanical properties. The linear arrangement of the circular hollow cavities at equal intervals can effectively disperse the stress under external force, avoid stress concentration, improve the overall load-bearing capacity and deformation resistance of the wall panel, and meet the safety requirements of the external envelope structure.

[0020] A 60mm thick Class A fire-resistant extruded polystyrene board is used as the insulation layer. Its excellent thermal insulation performance (thermal conductivity ≤0.038W / (m·K)) combined with the air insulation layer formed by the circular hollow cavity creates a highly efficient dual insulation system. This significantly improves the thermal insulation performance of the building envelope, helps reduce building energy consumption, and meets the energy-saving requirements of green buildings.

[0021] The protective layer uses crack-resistant fiber polymer cement mortar combined with hot-dip galvanized steel wire mesh, effectively enhancing the surface layer's crack resistance and impact resistance. All metal connectors (such as anchors) are hot-dip galvanized to ensure long-term corrosion resistance. This integrated protective design extends the wall panel's service life, enabling it to better resist external environmental erosion. Attached Figure Description

[0022] Figure 1 A schematic diagram of the structure of the prefabricated building exterior insulation integrated lightweight concrete hollow wall panel provided by the present invention. Figure 2 A schematic diagram of the disassembly structure of the prefabricated building exterior insulation integrated lightweight concrete hollow wall panel provided by the present invention. Figure 3 The prefabricated building exterior insulation integrated lightweight concrete hollow wall panel provided by this invention Figure 1 Enlarged structural diagram at point A in the middle; Figure 4 A schematic diagram of the assembly structure of the prefabricated building exterior insulation integrated lightweight concrete hollow wall panel provided by the present invention. Figure 5 A schematic diagram of the U-shaped slot connector structure for the prefabricated building exterior insulation integrated lightweight concrete hollow wall panel provided by the present invention. Figure 6A structural schematic diagram of the first construction assembly state of the prefabricated building exterior insulation integrated lightweight concrete hollow wall panel provided by the present invention. Figure 7 A schematic diagram of the second construction assembly state of the prefabricated building exterior insulation integrated lightweight concrete hollow wall panel provided by the present invention. Figure 8 This is a structural diagram of the third construction assembly state of the prefabricated building exterior insulation integrated lightweight concrete hollow wall panel provided by the present invention.

[0023] The markings in the diagram are explained as follows: 1. Concrete base layer; 10. Connecting slot; 11. U-shaped slot connector; 2. Built-in steel mesh; 3. Insulation layer; 4. Protective layer; 5. Circular hollow cavity; 6. Anchor bolts; 7. Wire mesh; 8. Tongue and groove connector; 81. Male connector; 82. Female connector groove; 9. Wall panels. Detailed Implementation

[0024] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention. Example

[0025] Please refer to Figures 1-8 As shown, a lightweight hollow concrete wall panel with integrated thermal insulation for prefabricated building envelope includes a wall panel 9. The wall panel 9 includes a concrete base layer 1, an insulation layer 3, and a protective layer 4. An embedded steel mesh 2 is pre-embedded in the concrete base layer 1 near the insulation layer 3. The embedded steel mesh 2 is made of ∅8Q335 steel bars and woven at a spacing of 150mm×150mm. The embedded steel mesh is embedded in the concrete base layer to enhance the overall mechanical properties of the concrete base layer. An anchor bolt 6 is provided between the insulation layer 3 and the protective layer 4. A wire mesh 7 is also provided between the insulation layer 3 and the protective layer 4. The wire mesh 7 is laid on the surface of the insulation layer 3 for composite connection with the protective layer 4, thus forming an integrated structure of "concrete base layer-insulation layer-protective layer". One end of the anchor bolt 6 extends through the wire mesh 7, the insulation layer 3, and the embedded steel mesh 2, extending into the concrete base layer 1. Example

[0026] The prefabricated building envelope integrated thermal insulation lightweight concrete hollow wall panel provided in Example 1 is further optimized, specifically, as follows: Figure 4 As shown, the surface of the wall panel is provided with a connecting tongue and groove 8. The connecting tongue and groove 8 includes a male connecting part 81 and a female connecting groove 82. The male connecting part 81 and the female connecting groove 82 are respectively provided on both sides of the wall panel. The height of the connecting tongue and groove 8 is 50mm. A water-swellable sealing strip (not shown in the figure) is pasted on the inner side of the connecting tongue and groove 8 to improve the air tightness and water tightness of the splice. Example

[0027] The prefabricated building envelope integrated thermal insulation lightweight concrete hollow wall panel provided in Embodiment 1 or 2 is further optimized, such as... Figure 3 As shown, the concrete base layer 1 has several uniformly distributed circular hollow cavities 5 along its length. Example

[0028] The prefabricated building envelope integrated thermal insulation lightweight concrete hollow wall panel provided in Example 3 has been further optimized, such as... Figure 1 As shown, the wall panel has connecting slots 10 at both the top and bottom. The wall panel can be connected to an external U-shaped slot connector 11 through the connecting slots 10 for assembly with an external support base. The wall panel has 5mm thick hot-dip galvanized U-shaped slot connectors 11 at both the top and bottom. The connectors 11 can have connecting through holes with a diameter of 12mm (not shown in the figure) with a spacing of 500mm, which can reliably connect with the main structural frame columns and beams.

[0029] like Figure 8 As shown, this is a construction schematic diagram of the third state in this embodiment. Addressing the technical pain points of stress concentration and easy deformation and cracking in doors and windows, a solid core reinforced pre-embedded molding process is adopted. The solid core reinforcing ribs are made of lightweight concrete of the same material as the wall panel substrate, cast and arranged along the height direction of the opening. The length, width, and thickness of the solid core reinforcing ribs are precisely designed according to the size of the doors and windows and load requirements, which can effectively improve the deformation resistance, installation stability, and durability of the door and window parts, solving the technical problems of cumbersome post-reinforcement procedures and poor reinforcement effects in traditional pre-reserved openings. Example

[0030] The prefabricated building exterior insulation integrated lightweight concrete hollow wall panel provided in Example 4 is further optimized. The concrete base layer 1 is made of lightweight aggregate concrete, which is composed of cement, fly ash, recycled aggregate (aggregate obtained by crushing, washing, grading, and strengthening waste concrete blocks, broken bricks, mortar, etc., which can partially replace natural sand and gravel aggregates, fine aggregates, and coarse aggregates), ceramsite (lightweight aggregate), and water in a mass ratio of 1:0.3:0.2:2.5:0.5, with a bulk density of 1200 kg / m³ and a compressive strength of 18 MPa. The built-in steel mesh is made of ∅8Q335 steel bars with a spacing of 150 mm × 150 mm.

[0031] The aforementioned concrete base layer uses lightweight aggregate and incorporates industrial waste such as fly ash and recycled aggregate, realizing the resource reuse of solid waste, reducing cement consumption, and reducing carbon emissions. At the same time, through the combination of lightweight aggregate and circular hollow cavities, the overall lightweight effect of the wall panel is achieved. Furthermore, all materials used are environmentally friendly, with no release of harmful gases, and the combustion performance reaches Class A, which is in line with the development concepts of green building and ultra-low energy consumption building, and has good social and environmental benefits.

[0032] The insulation layer 3 is made of extruded polystyrene board with a thickness of 60 mm. The insulation layer uses extruded polystyrene board (XPS) as the composite insulation material with a thermal conductivity of ≤0.038W / (m·K) and a fire performance rating of Class A.

[0033] The anchor bolt 6 is a hot-dip galvanized metal anchor bolt. The anchor bolt consists of a screw, a disc, and an expansion tube. The screw diameter is 8mm, the disc diameter is 50mm, and the anchor bolt penetrates the insulation layer and is embedded in the concrete base layer to a depth of ≥30mm. The horizontal and vertical spacing of the anchor bolts is 300-500mm, and the number of anchor bolts per square meter is ≥8. The arrangement is preferably in a staggered pattern to avoid stress concentration caused by a straight arrangement.

[0034] The diameter of the circular hollow cavity 5 is 100 mm, the center-to-center distance between adjacent hollow cavities is 120 mm, and the total cross-sectional area of ​​the hollow cavity accounts for 25% to 30% of the cross-sectional area of ​​the concrete base layer 1. The circular hollow cavity 5 can reduce its own weight (30%-50% lighter than traditional wall panels) while forming an air insulation layer, improving the thermal insulation efficiency by 15%-20%, and also has sound insulation and noise reduction functions (sound insulation reaches more than 45 dB). The design principle of the circular hollow cavity 5: The circular structure is uniformly stressed and can effectively disperse the stress concentration under the action of external forces. Compared with the square cavity, the stress peak of the circular cavity is reduced by more than 30%. The linear arrangement with equal spacing (100mm) keeps the total proportion of the hollow cavity at 25%-30%. While maximizing weight reduction, it retains the continuous stress path of the concrete base. With the built-in steel mesh, a "steel-concrete-hollow cavity" collaborative stress system is formed.

[0035] The protective layer 4 is a crack-resistant fiber polymer cement mortar finishing layer with a thickness of 30 mm. The polymer cement mortar is made of cement, quartz sand, acrylic emulsion and crack-resistant fiber mixed in a mass ratio of 1:2:0.2:0.01.

[0036] The wire mesh 7 is made of hot-dip galvanized steel wire mesh with a wire diameter of 5 mm. The wire mesh 7 is tightly bonded to the insulation layer 3 by anchor bolts 6. The mesh size is 12.7 mm × 12.7 mm. The wire mesh 7 is tightly bonded to the insulation layer by anchor bolt discs. The protective layer 4 is bonded to the wire mesh 7 by adhesive mortar with a bonding strength ≥ 0.3 MPa.

[0037] In this embodiment, the combination of the above structures achieves a multi-functional integration of "structural enclosure + thermal insulation + lightweighting + prefabricated installation + fireproofing and sound insulation", which not only ensures structural safety, but also takes into account energy saving and construction efficiency. It is suitable for various prefabricated civil and industrial buildings, especially for ultra-low energy consumption buildings, high-rise buildings and public buildings (schools, hospitals and office buildings) with high requirements for sound environment and fire protection performance.

[0038] The wall panel manufacturing process in this embodiment is as follows: 1. Material preparation: Prepare each component of lightweight aggregate concrete according to the mix proportion; the steel mesh is made of ∅8Q335 steel bars, extruded polystyrene board is prepared as the main insulation material, and U-shaped slot connectors and other accessories are prepared.

[0039] 2. Mold assembly and embedded part installation: Steel molds are used to assemble wall panel forming molds, and release agent is applied to the inside of the molds; according to the design position of the hollow cavity, a circular hollow airbag with a diameter of 65mm is installed in the mold, and the two ends of the core mold are firmly fixed; U-shaped slot connectors 7 are embedded in the tongue and groove positions at the top and bottom of the mold to fix them to the mold and ensure accurate positioning; the prepared built-in steel mesh 7 is placed in the mold and fixed by the positioning bracket to ensure that the steel mesh is located under the concrete base layer 1.

[0040] 3. Concrete base layer pouring: Pour the well-mixed lightweight aggregate concrete mixture into the mold. During the pouring process, use an immersion vibrator to compact the concrete at a frequency of 50Hz and a vibration time of 20-30s / min to prevent the core mold from shifting. After pouring, smooth the concrete surface, cover it with geotextile, and place it in a curing room with a temperature of 20±2℃ and a relative humidity of ≥90% for 7 days. Then remove the core mold and continue curing for 21 days until the concrete strength reaches 100% of the design strength, forming a concrete base layer 1 with a circular hollow cavity.

[0041] 4. Installation and fixing of insulation layer: Apply environmentally friendly adhesive evenly to the outside of the concrete base (covering area ≥30%), embed the cut extruded polystyrene board (insulation layer 3), adjust its position to make it fit tightly against the concrete base 1, and initially form a connection between the concrete base 1 and the insulation layer 3; then use an electric drill to embed the hot-dip galvanized metal anchors 6 into the concrete base to a depth of 35mm, so that the insulation layer 3 is firmly connected to the concrete base 1. The spacing of the anchors 6 is set to 500mm×500mm, with 4 anchors 6 arranged per square meter.

[0042] 5. Finishing Layer Construction and Curing: Lay hot-dip galvanized steel wire mesh 7 on the outside of the insulation layer 3. The overlap width of the steel wire mesh 7 should be ≥50mm. The overlap should be firmly tied with binding wire. The steel wire mesh 7 should be pressed and fixed by anchor bolts 6. Prepare crack-resistant fiber polymer cement mortar according to the ratio. Use a trowel to evenly apply the cement mortar to the steel wire mesh 7 in two layers. The first layer is 10mm thick. After initial setting, apply the second layer to a total thickness of 20mm and smooth it. After the application is completed, cover and cure for 14 days. During the curing period, avoid rain and sun exposure to obtain the finished wall panel.

[0043] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0044] Obviously, the embodiments described above are merely some embodiments of the present invention, not all embodiments. The accompanying drawings show preferred embodiments of the present invention, but do not limit the patent scope of the present invention. The present invention can be implemented in many different forms; rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing specific embodiments, or make equivalent substitutions for some of the technical features. Any equivalent structures made using the content of this specification and drawings, directly or indirectly applied to other related technical fields, are similarly within the patent protection scope of this invention.

Claims

1. A lightweight concrete hollow wall panel for integrated thermal insulation of prefabricated building envelope, characterized in that, The wall panel (9) includes a concrete base (1), an insulation layer (3) and a protective layer (4). A built-in steel mesh (2) is embedded in the concrete base (1) near the insulation layer (3). An anchor bolt (6) is provided between the insulation layer (3) and the protective layer (4). A wire mesh (7) is also provided between the insulation layer (3) and the protective layer (4). The wire mesh (7) is laid on the surface of the insulation layer (3) for composite connection with the protective layer (4). One end of the anchor bolt (6) extends through the wire mesh (7), the insulation layer (3) and the built-in steel mesh (2) into the concrete base (1).

2. The prefabricated building exterior insulation integrated lightweight concrete hollow wall panel according to claim 1, characterized in that, The surface of the wall panel is provided with a connecting tongue and groove (8), which includes a male connecting part (81) and a female connecting groove (82), and the male connecting part (81) and the female connecting groove (82) are respectively provided on both sides of the wall panel.

3. The prefabricated building exterior insulation integrated lightweight concrete hollow wall panel according to claim 1, characterized in that, The concrete base layer (1) has several uniformly distributed circular hollow cavities (5) along its length.

4. The prefabricated building exterior insulation integrated lightweight concrete hollow wall panel according to claim 1, characterized in that, The wall panel is provided with connecting slots (10) at the top and bottom. The wall panel can be connected to the external U-shaped slot connector (11) through the connecting slots (10) for external support base assembly.

5. A lightweight concrete hollow wall panel for integrated thermal insulation of prefabricated building envelope as described in claim 1, characterized in that, The concrete base layer (1) is prepared using lightweight aggregate concrete.

6. A lightweight concrete hollow wall panel for integrated thermal insulation of prefabricated building envelope as described in claim 1, characterized in that, The insulation layer (3) is made of extruded polystyrene board with a thickness of sixty millimeters.

7. A lightweight concrete hollow wall panel for integrated thermal insulation of prefabricated building envelope as described in claim 1, characterized in that, The anchor (6) is a hot-dip galvanized metal anchor, which penetrates the insulation layer (3) and is embedded in the concrete base layer (1) to a depth of more than 35 mm.

8. A lightweight concrete hollow wall panel for integrated thermal insulation of prefabricated building envelope as described in claim 3, characterized in that, The diameter of the circular hollow cavity (5) is 100 mm, the center-to-center distance between adjacent hollow cavities is 120 mm, and the total cross-sectional area of ​​the hollow cavity accounts for 25% to 30% of the cross-sectional area of ​​the concrete base layer (1).

9. A lightweight concrete hollow wall panel for integrated thermal insulation of prefabricated building envelope as described in claim 1, characterized in that, The protective layer (4) is a crack-resistant fiber polymer cement mortar finishing layer with a thickness of 30 mm. The polymer cement mortar is made by mixing cement, quartz sand, acrylic emulsion and crack-resistant fiber in a mass ratio of 1:2:0.2:0.

01.

10. A lightweight concrete hollow wall panel for integrated thermal insulation of prefabricated building envelopes according to claim 1, characterized in that, The wire mesh (7) is made of hot-dip galvanized wire mesh with a wire diameter of five millimeters. The wire mesh (7) is tightly attached to the insulation layer (3) by anchor bolts (6).

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