A prefabricated insulated composite wall structure

Abstract

This invention provides a prefabricated insulated composite wall structure, belonging to the technical field of prefabricated building components. It includes both a concrete wall panel and an insulated wall panel, both prefabricated. A first steel mesh is embedded inside the concrete wall panel, and several first steel trusses are uniformly embedded on one side. Several second steel trusses are uniformly embedded on the inner side of the insulated wall panel, and a second steel mesh is provided on the outer surface of the inner side and tied to the second steel trusses. All steel trusses are welded from single straight steel bars and single corrugated steel bars, with the straight steel bars embedded in the prefabricated slab. The concrete wall panel and the insulated wall panel's built-in reinforcing steel mesh are assembled facing each other on the side with the corrugated steel bars to form a sandwich cavity. After being filled with concrete, an insulated composite wall is formed. The corrugated bars of the two wall panels do not interfere with each other; the crests of the corrugations of the insulated wall panel press against the surface of the concrete wall panel, providing a positioning function. The vertically arranged corrugated bars also facilitate dense concrete pouring. This invention is convenient to construct and greatly reduces on-site work.

Description

Technical Field

[0001] This invention relates to the field of prefabricated building components, and in particular to a prefabricated insulated composite wall structure. Background Technology

[0002] Composite walls, as the core vertical load-bearing components in prefabricated structural systems, are gradually becoming the mainstream choice in engineering practice. Composite walls are usually composed of precast concrete wall panels and cast-in-place concrete layers, which can fully utilize the advantages of precast components such as factory production, quality control, and rapid construction.

[0003] However, under current technological conditions, composite wall structures still have the following problems in practical engineering applications: 1. The insulation layer of traditional composite walls is mostly installed on the outside of the wall by external application or hanging. The construction process is complicated. The bonding between the insulation material and the structural layer mainly relies on adhesives or anchors. During long-term use, quality problems such as hollowing, cracking or even falling off are prone to occur due to temperature changes, shrinkage deformation or external forces. This not only affects the insulation effect, but also brings great difficulty to the later maintenance of the building.

[0004] In existing composite wall structures, the connection between precast wall panels and cast-in-place layers often relies on a few connectors or simple steel bar extension anchoring methods. Under seismic action or large load conditions, interface slippage or cracking is prone to occur between the precast and cast-in-place parts, affecting the structural performance of co-load bearing.

[0005] In existing composite wall structures, the arrangement of steel trusses is mostly a traditional straight-reinforced structure, which hinders the flow of concrete, is not conducive to pouring and vibration, and affects the compactness of the poured concrete.

[0006] Therefore, a prefabricated insulated composite wall structure is proposed. Summary of the Invention

[0007] In view of this, the present invention provides a prefabricated insulated composite wall structure to solve or alleviate one of the technical problems existing in the prior art, and at least provides a beneficial alternative.

[0008] The technical solution of this invention is implemented as follows: a prefabricated insulated composite wall structure includes a concrete wall panel and an insulated wall panel. A first steel mesh is pre-embedded inside the concrete wall panel, and a plurality of first steel trusses are uniformly pre-embedded on one side of the concrete wall panel. The first steel trusses are arranged vertically. A second steel mesh is pre-embedded inside the insulated wall panel, and a plurality of second steel trusses are uniformly pre-embedded on one side of the insulated wall panel. The second steel trusses are arranged vertically. The first steel trusses and the second steel trusses are wavy. A second steel mesh is fixedly connected to the second steel truss.

[0009] A further preferred embodiment is that a pre-reserved concrete pouring cavity is provided between the concrete wall panel and the thermal insulation wall panel, and all steel trusses are placed within this cavity.

[0010] Further preferred options: Concrete wall panels have no horizontal joints within the floor height range, but vertical joints can be provided, with horizontal reinforcing bars overlapping in the vertical joints; Insulated wall panels can be provided with tight joints as needed, with outward notches at the joints, and the second reinforcing mesh can be extended or overlapped at the tight joints.

[0011] A further preferred embodiment: the bottom of the concrete wall panel is beveled at one corner near the side with the steel truss to form an edge surface with a straight face and a bevel, and the first steel mesh reinforcement extends out and bends on the bevel.

[0012] A further preferred embodiment: the first steel mesh extends into the beam at the top and is anchored therein, and at the bottom it bends up and connects to the bottom of the second steel mesh via a first lapped steel mesh at the top of the beam structure.

[0013] A further preferred design: the corrugated steel bars in the insulated wall panel are cut off at the bottom of the beam, leaving one crest to be connected to the beam.

[0014] A further preferred embodiment: when the first and second steel meshes are connected to the concrete wall or column, they are anchored inside the wall or column structure, and at the free end, the steel bars are bent up and anchored inside the insulated composite wall.

[0015] A further preferred embodiment: after the insulation wall panel is installed, the top elevation is higher than the floor beam elevation.

[0016] A further preferred embodiment is that the wavelength of the corrugated steel bars in the thermal insulation wall panel is the same as the spacing of the steel bars in the second steel mesh, and the finished steel mesh can be directly tied and fixed to the corrugated steel bars.

[0017] The embodiments of the present invention have the following advantages due to the adoption of the above technical solutions: I. This invention creates a composite wall structure combining prefabrication and cast-in-place construction by pre-reserving a concrete pouring cavity between concrete wall panels and insulation wall panels. Both the concrete and insulation wall panels are prefabricated components that can be mass-produced in a factory. On-site work only requires hoisting, positioning, and pouring concrete into the cavity, reducing on-site wet work, shortening the construction cycle, and lessening reliance on manual skills. Furthermore, the prefabricated components have smooth surfaces and precise dimensions, facilitating high-precision assembly of building components, ensuring controllable overall wall quality, and making the construction process simple and efficient. It is suitable for various prefabricated building systems.

[0018] II. This invention forms a double-reinforced framework by pre-embedding a first steel mesh and uniformly arranging vertical wavy first steel trusses inside a concrete wall panel, and pre-embedding a second steel mesh and uniformly arranging vertical wavy second steel trusses inside an insulated wall panel. The first and second steel trusses extend to the outside of the precast components, forming an integral load-bearing system with the cast-in-place concrete after the cavity is poured, thus improving the wall's bending, shear, and seismic resistance. Furthermore, the second steel mesh is fixedly connected to the second steel truss, facilitating reliable overlap with adjacent components or the main structure, further enhancing structural continuity and overall stability, resulting in a wall with high load-bearing capacity after molding.

[0019] Third, both the first and second steel trusses of the present invention adopt a wave-shaped vertical arrangement. Compared with traditional straight bars or ordinary truss structures, their wave shape can reduce the obstruction to concrete flow during concrete pouring, reduce the risk of aggregate accumulation, and facilitate the insertion of vibrators, so that the concrete in the cavity and component joint can be fully compacted, avoiding quality defects such as honeycomb and holes, which is conducive to improving pouring efficiency and molding quality.

[0020] The above overview is for illustrative purposes only and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features of the invention will become readily apparent from the accompanying drawings and the following detailed description. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a vertical sectional view of the present invention; Figure 2 This is a cross-sectional view of the present invention. Figure 3 This is a structural diagram of the concrete wall panel of the present invention; Figure 4 This is a structural diagram of the thermal insulation wall panel of the present invention; Figure 5 This is a structural diagram of a prefabricated insulated composite wall provided for Embodiment 2 of the present invention.

[0023] Reference numerals: 11. Concrete wall panel; 12. First steel truss; 13. First steel mesh; 14. Insulated wall panel; 15. Second steel truss; 17. Second steel mesh; 20. Beam structure; 21. First lapped steel mesh; 22. Column structure. Detailed Implementation

[0024] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0025] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0026] like Figures 1-4 As shown, this embodiment of the invention provides a prefabricated insulated composite wall structure, including a concrete wall panel 11 and an insulated wall panel 14. A first steel mesh 13 is embedded inside the concrete wall panel 11, and a plurality of first steel trusses 12 are uniformly embedded on one side of the concrete wall panel 11. The first steel trusses 12 are arranged vertically. A second steel mesh 17 is embedded inside the insulated wall panel 14, and a plurality of second steel trusses 15 are uniformly embedded on one side of the insulated wall panel 14. The second steel trusses 15 are arranged vertically. The first steel trusses 12 and the second steel trusses 15 are wavy, and the second steel mesh 17 is fixedly connected to the second steel trusses 15.

[0027] The concrete wall panel 11 serves as the main load-bearing layer, while the thermal insulation wall panel 14 serves as the thermal insulation functional layer. Together, they form a precast and cast-in-place composite system. The thermal insulation wall panel 14 is made of thermal insulation materials such as foamed concrete and has good thermal insulation performance. The first steel mesh 13 is used to enhance the integrity and crack resistance of the concrete wall panel 11. The first steel truss 12 and the second steel truss 15 adopt a wave-shaped design and are evenly arranged vertically, which not only improves the mechanical interlocking force between the steel bars and the concrete, but also facilitates the fluidity and compaction of the concrete during pouring. The second steel mesh 17 is fixed to the second steel truss 15, providing a reliable foundation for subsequent connections with beams, columns, or adjacent walls.

[0028] In this embodiment, specifically: a reserved concrete pouring cavity is provided between the concrete wall panel 11 and the thermal insulation wall panel 14, and all steel trusses are located in this cavity. During on-site construction, concrete is poured into the cavity so that the precast wall panel and the cast-in-place layer form an integral load-bearing structure. The cast-in-place concrete in the cavity is tightly bonded to the steel reinforcement, thereby improving the bending resistance, shear resistance and overall load-bearing capacity of the wall.

[0029] In this embodiment, specifically: the concrete wall panel 11 has no horizontal joints within the floor height range, but can have vertical joints, with horizontal reinforcing bars overlapping in the vertical joints; the insulation wall panel 14 can have tight joints as needed, with outward notches at the joints, and the second reinforcing mesh 17 can be connected or overlapped at the tight joints.

[0030] In this embodiment, specifically: a corner of the bottom of the concrete wall panel 11 near the side with the steel truss is cut at an angle to form an edge surface with a straight surface and an angled surface, and the first steel mesh bar extends out and bends on the angled surface.

[0031] In this embodiment, specifically: the first steel mesh 13 extends into the beam at the top and is anchored therein, and at the bottom it bends up and connects to the bottom of the second steel mesh 17 through the first lapped steel mesh 21 at the top of the beam structure 20. Since the beam structure 20 is mostly prefabricated, the first lapped steel mesh 21 is pre-embedded during prefabrication so that it can be combined with the prefabricated insulated composite wall structure to achieve continuous force transmission between the wall and the beam. The first lapped steel mesh 21 serves as a transition connector to ensure the stress reliability and seismic ductility of the node area, avoiding the problem of weak traditional node connections.

[0032] In this embodiment, specifically: the corrugated steel bars in the insulation wall panel 14 are cut off at the bottom of the beam, leaving one crest to be connected to the beam.

[0033] In this embodiment, specifically: the first steel mesh 13 and the second steel mesh 17 are anchored inside the wall and column structure 22 when they are connected to the concrete wall and column, and the steel bars are bent up and anchored inside the thermal insulation composite wall at the free end.

[0034] In this embodiment, specifically: after the insulation wall panel 14 is installed, the top elevation is higher than the floor beam elevation.

[0035] In this embodiment, specifically: adjacent insulated wall panels 14 are fixedly connected by a second steel mesh 17, and the horizontal steel reinforcement lap connection between adjacent insulated wall panels 14 is achieved through the second steel mesh 17, which solves the problem of weak stress at the joints of precast walls, forms a continuous steel reinforcement force transmission path, and improves the overall stability and seismic performance of the wall system.

[0036] When the present invention is in operation: the construction personnel first hoist and position the precast components, the insulation wall panel 14 is connected to the adjacent insulation wall panel 14 by the second steel mesh 17, and is reliably connected to the beam structure 20 by the first lapped steel mesh 21, so as to ensure that the size and relative position of the reserved concrete pouring cavity between the concrete wall panel 11 and the insulation wall panel 14 meet the design requirements.

[0037] Concrete is poured into the reserved concrete pouring cavity. During the pouring and vibration process, the wavy first steel truss 12 and the second steel truss 15 guide the flow of concrete, reduce aggregate accumulation, facilitate the insertion of the vibrator, and ensure that the concrete inside the cavity and at the joint surface of the precast components is fully compacted and free from defects such as honeycomb and voids.

[0038] After the cast-in-place concrete reaches its design strength, the wavy sections of the first steel truss 12 and the second steel truss 15 extending into the cavity are tightly wrapped by the cast-in-place concrete, forming an integral load-bearing structure. This allows the concrete wall panel 11 (load-bearing layer), the insulation wall panel 14 (insulation layer), and the cast-in-place concrete layer to work together, improving the wall's bending, shear, and seismic performance. The resulting wall has both excellent insulation performance and structural load-bearing capacity, making construction efficient and quality controllable.

[0039] Example 2 like Figure 5 As shown, this embodiment of the invention provides a prefabricated insulated composite wall structure, including a concrete wall panel 11 and an insulated wall panel 14. A first steel mesh 13 is embedded inside the concrete wall panel 11, and a plurality of first steel trusses 12 are uniformly embedded on one side of the concrete wall panel 11. The first steel trusses 12 are arranged vertically. A second steel mesh 17 is embedded inside the insulated wall panel 14, and a plurality of second steel trusses 15 are uniformly embedded on one side of the insulated wall panel 14. The second steel trusses 15 are arranged vertically. The first steel trusses 12 and the second steel trusses 15 are wavy, and the second steel mesh 17 is fixedly connected to the second steel trusses 15.

[0040] In this embodiment, specifically: one end of the first steel mesh 13 and the second steel mesh 17 is disposed inside the column structure 22.

[0041] This embodiment demonstrates the construction method between the prefabricated insulated composite wall structure and the column structure 22. Since the column structure 22 is mostly cast on-site, before the column structure 22 is cast, one end of the first steel mesh 13 and the second steel mesh 17 are inserted into the interior of the column structure 22 template. After the column structure 22 is cast, the column structure 22 and the prefabricated insulated composite wall structure form an integral whole.

[0042] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various variations or substitutions within the technical scope disclosed in the present invention, and these should all be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A prefabricated insulated composite wall structure, comprising a concrete wall panel (11) and an insulated wall panel (14), characterized in that: The concrete wall panel (11) has a first steel mesh (13) embedded inside. A number of first steel trusses (12) are evenly embedded on one side of the concrete wall panel (11). The first steel trusses (12) are vertically arranged. A number of second steel trusses (15) are evenly embedded on one side of the thermal insulation wall panel (14). The second steel trusses (15) are vertically arranged. The first steel trusses (12) and the second steel trusses (15) are wavy. A second steel mesh (17) is fixedly connected to the second steel truss (15).

2. The prefabricated insulated composite wall structure according to claim 1, characterized in that: A pre-reserved concrete pouring cavity is provided between the concrete wall panel (11) and the thermal insulation wall panel (14), and all steel trusses are located in this cavity.

3. The prefabricated insulated composite wall structure according to claim 1, characterized in that: The concrete wall panel (11) has no horizontal joints within the floor height range, but vertical joints can be set, and the horizontal steel bars are lapped in the vertical joints; the thermal insulation wall panel (14) can be set with tight joints as needed, and outward gaps are set at the joints, and the second steel mesh (17) is stretched or lapped at the tight joints.

4. The prefabricated insulated composite wall structure according to claim 1, characterized in that: The bottom of the concrete wall panel (11) is obliquely cut at one corner near the side with the steel truss to form an edge surface with a straight face and an oblique face, and the first steel mesh bar extends out and bends on the oblique face.

5. A prefabricated insulated composite wall structure according to claim 1, characterized in that: The end of the first steel mesh (13) extends to the outside of the concrete wall panel (11). The first steel mesh (13) is anchored inside the beam at the top and bent at the bottom to overlap with the bottom of the second steel mesh (17) through the first lapped steel mesh (21) and connected to the top of the beam structure (20).

6. A prefabricated insulated composite wall structure according to claim 1, characterized in that: The corrugated steel bars in the insulated wall panel (14) are cut off at the bottom of the beam, leaving one crest to be tied to the beam.

7. A prefabricated insulated composite wall structure according to claim 1, characterized in that: When the first steel mesh (13) and the second steel mesh (17) are connected to the concrete wall and column, they are anchored inside the wall and column structure (22). At the free end, the steel bars are bent up and anchored inside the thermal insulation composite wall.

8. A prefabricated insulated composite wall structure according to claim 1, characterized in that: After the insulation wall panel (14) is installed, the top elevation is higher than the floor beam elevation.

9. A prefabricated insulated composite wall structure according to claim 1, characterized in that: The wavelength of the corrugated steel bars in the thermal insulation wall panel (14) is the same as the spacing of the steel bars in the second steel mesh (17), and the finished steel mesh can be directly tied and fixed to the corrugated steel bars.

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