Self-vibrating and magnetically-attracting quick-release forming mold and method for manufacturing prefabricated wall-hanging plate using the same

Abstract

The application discloses a self-vibrating and magnetically-attracting quick-release forming mold and a method for manufacturing a prefabricated wall-hanging plate by using the same. The self-vibrating and magnetically-attracting quick-release forming mold comprises a bottom plate, a mold upper plate and a connecting rod. The bottom plate and the mold upper plate are connected through the connecting rod. First and second L-shaped split frames are arranged on the mold upper plate to form a hollow frame. A micro vibration motor is arranged on one side surface of the mold upper plate close to the bottom plate. A magnetically-attracting device is arranged in the mold upper plate. A magnetically-attracting control switch is arranged on the side surface of the mold upper plate for controlling the magnetically-attracting device. A micro vibration motor switch is arranged on the bottom plate for controlling the micro vibration motor. The magnetically-attracting control switch is controllable. The magnetically-attracting device is attracted when power is on and is disconnected when power is off. The bolt connection is not needed in the whole process. The bolt connection is convenient to disassemble and assemble. One person can quickly complete the operation. The production efficiency is improved by more than 80%.

Description

Technical Field

[0001] This invention pertains to molds and their usage methods, specifically a self-vibrating magnetic quick-release molding mold and a method for preparing prefabricated wall panels. Background Technology

[0002] Highway subgrade slope protection is a key project to ensure road traffic safety and subgrade stability. Precast wall panels have become a core component of subgrade slope protection due to their advantages such as convenient construction and good protective effect. However, existing precast wall panels and molding molds used for highway subgrade slopes still have many problems with insufficient adaptability, which restricts the quality and construction efficiency of protection projects.

[0003] (1) Traditional molds are simple in form and have complicated production processes, resulting in poor sealing of the wall panels: The wall panels formed by existing molds are mostly flat-edged, which makes it easy for grout to leak during the assembly process, leading to defects in the forming quality of the components, affecting the integrity of the protection system, and seriously threatening the stability of the roadbed slope. Moreover, the molds are mostly integral or bolted, which are complicated to disassemble and assemble and have low positioning accuracy, making it difficult to meet the batch prefabrication requirements of highway roadbed slope protection components; The molds do not have built-in vibration devices and need to rely on external vibration tools. Uneven vibration can easily lead to defects such as honeycomb, pitting, and bubbles in the tongue and groove and the corners, reducing the anti-seepage and anti-erosion performance of the wall panels.

[0004] (2) Traditional release agents are not environmentally friendly and affect the molding quality of wall panels: Traditional release agents often contain oil components, which can easily form oil spots on the surface of wall panels, polluting the environment and affecting the bonding performance of subsequent splicing, thus reducing the stability of the slope protection system.

[0005] (3) The material’s low carbon content and good mechanical properties cannot be taken into account: Traditional roadbed slope protection wall panels are mostly made of ordinary cement-based cementitious materials, with low solid waste content and high carbon emissions, which do not meet the requirements of green transportation development; some wall panels with added solid waste admixtures have low early strength and poor durability due to insufficient activity of single solid waste and poor system synergy, making it difficult to resist the complex environmental impacts such as rainwater erosion and temperature changes on highway roadbed slopes.

[0006] In summary, the existing technology lacks a highway subgrade slope protection wall panel that takes into account low carbon performance, structural rationality and convenient production. The problems of its single form, complicated assembly and easy grout leakage urgently need to be solved. At the same time, there is a lack of molding molds that are suitable for its production and integrate self-vibration compaction, precise positioning, quick disassembly and environmental protection, which restricts the large-scale and efficient construction of highway subgrade slope protection projects. Summary of the Invention

[0007] Purpose of the invention: In order to overcome the shortcomings of the existing technology, the purpose of this invention is to provide a self-vibrating magnetic quick-release molding mold that is easy to assemble and disassemble and can be reused. Another purpose of this invention is to provide an environmentally friendly and efficient method for preparing prefabricated wall panels using a self-vibrating magnetic quick-release molding mold.

[0008] Technical Solution: The present invention discloses a self-vibrating magnetic quick-release molding mold, comprising a base plate, an upper base plate, and a connecting rod. The base plate and the upper base plate are connected by the connecting rod. The upper base plate is provided with a first L-shaped split frame and a second L-shaped split frame forming a hollow frame. Magnetic suction devices for the split frames are installed within the first and second L-shaped split frames. A micro-vibration motor is installed on the surface of the upper base plate near the base plate, and the upper base plate magnetic suction device is installed inside it. A magnetic suction control switch for controlling the split frame magnetic suction device and the upper base plate magnetic suction device is installed on the side. A micro-vibration motor switch for controlling the micro-vibration motor is installed on the base plate. This invention achieves self-vibrating molding, precise positioning via electro-controlled magnetic suction, pin-assisted fixing, and boltless quick release, making it suitable for the mass prefabrication of tongue-and-groove self-locking wall panels.

[0009] Furthermore, several pins are provided along the edge of the upper base plate of the mold, a first positioning hole matching the pins is provided on the first L-shaped split frame, and a second positioning hole matching the pins is provided on the second L-shaped split frame.

[0010] Furthermore, the pin is fitted with the first positioning hole and the second positioning hole with a clearance of ≤0.05mm, which not only assists in the quick positioning of the split frame, but also ensures that it is firmly fixed.

[0011] Furthermore, the top of the pin is rounded to facilitate insertion into the first and second positioning holes, ensuring that the first L-shaped split frame and the second L-shaped split frame are subjected to uniform force.

[0012] Furthermore, the inner sides of the first L-shaped split frame and the second L-shaped split frame are provided with tongue and groove forming surfaces with a surface roughness of ≤0.8μm. During demolding, they are separated along the diagonal to avoid the tongue and groove interlocking resistance and achieve non-destructive demolding.

[0013] Furthermore, the first L-shaped split frame and the second L-shaped split frame are made of glass fiber reinforced polycarbonate composite material, which combines transparency, rigidity and toughness, making it easy to observe the field pouring process. The tongue and groove forming positions on the inside are treated with high precision polishing to improve wear resistance and demolding smoothness, and to meet the needs of batch prefabrication.

[0014] Furthermore, a rubber damping sleeve is fitted over the miniature vibrating motor, and protruding buckles are provided on the outer side of the rubber damping sleeve. These protruding buckles engage and secure with pre-set grooves on the upper bottom plate of the mold. The miniature vibrating motor enables uniform vibration, ensuring dense filling of concrete in narrow areas such as tongue and groove, avoiding defects such as air bubbles, honeycomb, and pitting, and improving the impermeability and erosion resistance of the wall panel, making it suitable for the complex environment of roadbed slopes. The rubber damping sleeve effectively absorbs vibration energy, preventing vibration from being directly transmitted to the outer frame and causing mold displacement or deformation.

[0015] Furthermore, a removable maintenance cover is installed on the upper base plate of the mold corresponding to the position of the micro vibration motor. A waterproof sealing gasket is installed between the removable maintenance cover and the upper base plate of the mold to prevent concrete slurry from entering the installation cavity. A waterproof power interface is provided on the side of the base plate to power the magnetic attraction device of the upper base plate of the mold and the micro vibration motor, eliminating the need for additional power supply structures, simplifying mold design, and adapting to temporary power supply scenarios in the field. The waterproof sealing gasket is suitable for the humid environment of highway subgrade slope prefabrication yards.

[0016] The method for preparing prefabricated wall panels using a self-vibrating magnetic quick-release molding mold according to the present invention includes the following steps:

[0017] Step 1: Place the base plate flat, connect an external 10~12V low-voltage power supply, turn on the magnetic control switch, insert the first L-shaped split frame and the second L-shaped split frame into the upper base plate of the mold, automatically adsorb and align, and turn off the magnetic control switch after the pin is fully inserted.

[0018] Step 2: Spray a water-based, oil-free release agent onto the inner wall surface of the mold cavity formed by the first L-shaped split frame, the second L-shaped split frame, and the upper bottom plate of the mold, spreading it to a thickness of 0.05~0.1mm, and let it stand to form a uniform film.

[0019] Step 3: Pour the concrete mixture into the mold cavity in layers. During the pouring process, turn on the micro vibration motor to vibrate. After the vibration is completed, turn off the micro vibration motor and continue pouring to the designed height.

[0020] Step four: After pouring, perform curing. After curing, turn on the magnetic control switch, pull out the first L-shaped split frame and the second L-shaped split frame upwards, turn off the magnetic control switch, separate the first L-shaped split frame and the second L-shaped split frame outwards along the diagonal direction, and take out the formed tongue-and-groove self-locking low-carbon concrete precast wall panel.

[0021] Furthermore, in step three, the concrete mixture comprises, by weight, 260-290 parts silicate cement, 40-80 parts fly ash, 30-50 parts red mud, 40-60 parts tailings powder, 40-60 parts slag powder, 750-800 parts sand, 1000-1080 parts crushed stone, 145-155 parts water, and 1.5-2.5 parts polycarboxylate superplasticizer.

[0022] The components of the quaternary composite cementitious system are not simply physically mixed, but rather work synergistically to form a triple-action mechanism of "alkali activation - pozzolanic reaction - particle filling," wherein:

[0023] Cement serves as the core starting component and early strength framework. After adding water, it rapidly hydrates to generate CSH gel and Ca(OH)2, forming an early strength framework. At the same time, it keeps the system pH ≥ 12.5, providing an alkaline environment for the activation of other solid waste admixtures. It can also regulate the system's setting time, suppress the effects of rapid red mud setting, ensure the early strength of the wall panel, and meet the needs of outdoor prefabrication and rapid construction.

[0024] Red mud acts as an alkaline activator and auxiliary active component, with its own pH reaching 13-14. It works synergistically with Ca(OH)2 generated during cement hydration to maintain the system pH at ≥13 and keep it stable. Its alkaline components disrupt the crystal structure of fly ash and tailings powder, activating their activity. At the same time, its own active mineral components hydrate and replenish cementitious products, enhancing interfacial adhesion and improving the erosion and impermeability of the wall panel.

[0025] Fly ash acts as a workability modifier and a later-stage strength compensator. The spherical and smooth particles exert a "ball effect" to optimize workability, while the glassy components delay cement hydration and reduce the risk of temperature cracks. In a highly alkaline environment, it gradually participates in secondary hydration, continuously generating CSH gel to compensate for later-stage strength and ensure the long-term stable service of the wall panel.

[0026] Tailings powder can be iron tailings powder, copper tailings powder, or limestone powder. It can be used as an ultrafine filler to fill multi-level pores, reduce porosity, and quickly participate in secondary hydration to replenish cementitious products, improve the interfacial transition zone, and requires no pretreatment, thus reducing preparation costs and carbon emissions, which meets the requirements of green transportation development.

[0027] The quaternary composite cementitious system achieves a 28-day compressive strength of C30~C50, significantly improving the utilization rate of solid waste. It is low-carbon, environmentally friendly, and has excellent mechanical properties, making it fully suitable for the complex environment and mechanical requirements of highway subgrade slope protection.

[0028] Furthermore, the prefabricated wall panels feature a tongue-and-groove self-locking structure around their perimeter, enabling self-locking during assembly and enhancing connection stability and leak-proof sealing, thus meeting the sloping assembly requirements of highway subgrade slopes. The tongue-and-groove self-locking structure of the wall panels features a staggered interlocking design, achieving self-locking during assembly through interlocking tongues and grooves, eliminating the need for additional bolts, simplifying the slope assembly process, and improving construction efficiency. With a joint width ≤0.5mm, the excellent sealing performance effectively prevents rainwater infiltration and mud leakage, ensuring the integrity and stability of the subgrade slope protection system.

[0029] Further, in step two, the water-based oil-free release agent is composed of the following components by weight: 25-35 parts of water-based polyurethane dispersion (PUD), 10-15 parts of water-based acrylic emulsion, 1.5-3 parts of hydrophobic nano-silica, 1.5-2.5 parts of composite molybdate-benzoate-polyaniline rust inhibitor, 0.5-1.2 parts of nonionic polyurethane, 0.1-0.3 parts of polyether modified defoamer, and 45-55 parts of deionized water. This release agent features a dual isolation structure of "continuous polymer film formation + nano-interface reinforcement." The water-based polyurethane dispersion and acrylic emulsion form a dense protective film, while hydrophobic nano-silica constructs a micro-nano hydrophobic interface, significantly reducing the release force. It integrates release, mold rust prevention, concrete self-curing, steam curing resistance, and long-term stability. A single spray application allows for 3-5 consecutive releases, and it can be diluted 10 times for use. It does not delaminate or settle after 90 days of standing. It has low production costs and is suitable for automated spraying and field storage. The completely oil-free system thoroughly solves the problems of oil stains, rebar contamination, and excessive VOCs, without affecting the bonding performance of subsequent wall panel splicing, ensuring the stability of the roadbed slope protection system.

[0030] Working principle: When the magnetic control switch is turned on, it generates magnetic force to achieve automatic and precise pre-positioning between the first L-shaped split frame, the second L-shaped split frame and the upper base plate of the mold. The magnetic force of a single magnetic component is ≥80N, which meets the positioning and fastening requirements. When the switch is turned off, the magnetic force is lost and the magnetic attraction can be easily broken without applying separation force, achieving quick disassembly.

[0031] Beneficial effects: Compared with the prior art, the present invention has the following significant features:

[0032] 1. The mold adopts a diagonal split outer frame design, which separates along the diagonal line during demolding, avoiding the resistance of tongue and groove engagement, and realizing non-destructive demolding of the wall panel; it is equipped with an electric magnetic positioning component and a pin fixing component to achieve a dual fixing method of precise magnetic pre-positioning and pin-assisted fixing. The electric magnetic switch is controllable, and it is attracted when powered on and disconnected when powered off, without the need for manual force to separate. The gap between the pin and the positioning hole not only assists in quick positioning, but also ensures a reliable fixation. There are no bolts connected throughout the process, making disassembly and assembly convenient. A single person can quickly complete the process, increasing production efficiency by more than 80%.

[0033] 2. The upper base plate of the mold has a built-in micro vibration motor, which is arranged on both sides below the wall panel to achieve automatic and uniform vibration without the need for external vibration tools. This effectively solves the problems of uneven vibration and easy defects in the tongue and groove edges of traditional vibration methods. It has high molding accuracy and excellent anti-seepage and anti-erosion performance. The micro vibration motor adopts a snap-fit ​​fixing + waterproof quick-connect connector + detachable maintenance cover structure, which is convenient for disassembly, replacement and maintenance. The rubber shock-absorbing sleeve effectively avoids the transmission of vibration to the outer frame, prevents mold displacement and deformation, and is suitable for complex field construction environments.

[0034] 3. The mold is made of glass fiber reinforced polycarbonate composite material, which combines transparency, rigidity and toughness, making it easy to observe the pouring and vibration process. It also has good wear resistance and a mold reuse rate of ≥120 times. The sealing component is compacted by magnetic pre-pressure and pin limiting, with a sealing gap of ≤0.02mm, which completely prevents grout leakage. The outside of the electrically controlled magnetic positioning component is equipped with an anti-magnetic shielding layer to prevent magnetic powder from falling off and contaminating the concrete. The mold and the built-in vibration device share a 10~12V low-voltage power supply. The design is simple, it is compatible with generator power supply, and the operation is safe and convenient.

[0035] 4. The wall panel is equipped with a staggered interlocking tongue and groove self-locking structure around its perimeter, which can achieve self-locking positioning during splicing, eliminating the need for a large number of bolts, simplifying the slope assembly process, improving construction efficiency, and ensuring that the splice joint width is ≤0.5mm. It has excellent sealing and leak-proof performance, effectively preventing rainwater infiltration and mud leakage, and ensuring the stability of the roadbed slope.

[0036] 5. The wall panel forming method is simple to operate, with high forming accuracy and fast production efficiency. The mold can be reused. After curing, the wall panel has a complete tongue and groove self-locking structure, a smooth surface, and no defects. It is suitable for the slope assembly construction of highway subgrade slopes, which can realize the large-scale and efficient construction of protection projects, significantly improve the quality of projects and construction safety, and has good economic, social and environmental benefits.

[0037] 6. The resulting tongue-and-groove self-locking low-carbon concrete precast wall panel is specially adapted for highway subgrade slope protection. It is prepared using a quaternary composite cementitious system of cement-fly ash-red mud-tailings powder. Through the synergistic construction of the quaternary components, a triple action mechanism of "alkali activation-volcanic ash reaction-particle filling" is formed. The 28-day compressive strength reaches C30~C50 grade, with excellent mechanical properties and durability. It can withstand complex environments such as slope rainwater erosion and temperature changes. The solid waste utilization rate is greatly improved, and there is no need to pre-treat solid waste such as tailings powder, which reduces the preparation cost and carbon emissions, and meets the requirements of green transportation development.

[0038] 7. The molding process uses a special water-based oil-free release agent, which is completely free of oil components, environmentally friendly and pollution-free. It solves the problems of oil stains, steel bar contamination, and excessive VOCs caused by traditional release agents, and does not affect the bonding performance of subsequent splicing of wall panels. This release agent has a double isolation structure, low demolding force, and integrates multiple functions such as demolding, rust prevention, and self-curing. One spray can be used for continuous demolding 3 to 5 times. It can be diluted for use, has low production cost, and is suitable for automated spraying and field storage. It has good compatibility with the glass fiber reinforced polycarbonate surface of the mold and the concrete surface of the wall panel, ensuring the surface quality of the component. Attached Figure Description

[0039] Figure 1 This is a schematic diagram of the structure of the present invention;

[0040] Figure 2This is a connection diagram of the miniature vibration motor 7 of the present invention;

[0041] Figure 3 This is a schematic diagram of the structure of the upper base plate 2 of the mold of the present invention;

[0042] Figure 4 This is a cross-sectional view of the upper base plate 2 of the mold of the present invention;

[0043] Figure 5 This is a schematic diagram of the structure of the first L-shaped split frame 4 and the second L-shaped split frame 5 of the present invention;

[0044] Figure 6 This is a connection diagram of the split-frame magnetic suction device 6 of the present invention;

[0045] Figure 7 This is a schematic diagram showing the connection between the upper base plate 2 of the mold of the present invention and the first L-shaped split frame 4 and the second L-shaped split frame 5;

[0046] Figure 8 This is a schematic diagram of the precast wall panel cast by the mold of the present invention;

[0047] Figure 9 This is a schematic diagram of the assembly of the prefabricated wall panels cast by the mold of this invention;

[0048] Figure 10 This is a partial enlarged view of point A in the present invention;

[0049] Figure 11 This is a schematic diagram of the prefabricated wall panel assembly formed by the mold of this invention. Detailed Implementation

[0050] like Figures 1-7A self-vibrating magnetic quick-release molding mold for preparing tongue-and-groove self-locking low-carbon concrete precast wall panels has a base plate 1 and an upper base plate 2 fixedly connected by a connecting rod 3. Eight stainless steel pins 11 are evenly distributed along the edge of the upper surface of the upper base plate 2. The upper surface of the upper base plate 2 encloses a hollow frame, consisting of a first L-shaped split frame 4 and a second L-shaped split frame 5. The first L-shaped split frame 4 and the second L-shaped split frame 5 have four first positioning holes 12 and four second positioning holes 13 corresponding to the pins 11, respectively. The pins 11 are clearance-fitted with the first positioning holes 12 and the second positioning holes 13, with a clearance of 0.05 mm. Tongue-and-groove forming surfaces 14 are provided on the inner sides of the first L-shaped split frame 4 and the second L-shaped split frame 5. The L-shaped split frames are made of glass fiber reinforced polycarbonate composite material. The tongue-and-groove forming surfaces 14 are high-precision polished, with a surface roughness Ra≤0.8μm, preferably Ra=0.6μm. The top of pin 11 is rounded. The diameter of the first positioning hole 12 and the second positioning hole 13 are 8.05mm and the depth is 15mm. The upper base plate 2 of the mold is 12mm thick, the base plate 1 is 8mm thick, and the mounting cavity is 10mm high.

[0051] The first L-shaped split frame 4 and the second L-shaped split frame 5 are made of glass fiber reinforced polycarbonate composite material. Magnetic suction devices 6 are evenly spaced along the inner edges of the first L-shaped split frame 4 and the second L-shaped split frame 5, compatible with 10~12V low-voltage power supply. An independent magnetic control switch 9 (waterproof push-button control switch) is installed on the upper base plate 2 of the mold. When the switch is turned on, power is supplied to generate magnetic force for pre-positioning. The magnetic force of a single magnetic component is ≥80N. When the switch is turned off, power is cut off and the magnetic force is lost. The magnetic suction device 6 is an N35 type electromagnetic chuck with a single-piece suction force of 80N.

[0052] Two miniature vibration motors 7, each with a power of 50W and a vibration frequency of 4000r / min, are installed on the lower surface of the upper base plate 2 near the base plate 1. These motors correspond to the lower sides of the wall panel to be prepared. A magnetic suction device 8 is installed inside the upper base plate 2, and a magnetic control switch 9 for controlling the magnetic suction device 6 of the split frame and the magnetic suction device 8 is located on the side. A miniature vibration motor switch 10 for controlling the miniature vibration motors 7 is located on the base plate 1.

[0053] The miniature vibration motor 7 is covered with a 3mm thick rubber shock-absorbing sleeve. The outer side of the rubber shock-absorbing sleeve is provided with a protruding buckle, which engages and is fixed with a pre-set slot on the upper base plate 2 of the mold. A removable maintenance cover plate 15 is provided on the upper base plate 2 of the mold at the position corresponding to the miniature vibration motor 7. A waterproof sealing gasket 16 is provided between the removable maintenance cover plate and the upper base plate 2 of the mold.

[0054] The self-vibrating magnetic quick-release molding mold of this embodiment is used to prepare prefabricated wall panels, and specifically includes the following steps:

[0055] S1. Mold Assembly: Place the base plate 1 on a flat prefabrication yard workbench, connect an external 10~12V low-voltage power supply (compatible with outdoor generator power supply), and press the waterproof press-type magnetic control switch 9 to activate the magnetic force; gently insert the stainless steel pin 11 on the upper base plate 2 of the mold, aligning it with the first positioning hole 12 on the first L-shaped split frame 4 and the second positioning hole 13 on the second L-shaped split frame 5. The split frame magnetic device 6 will automatically adsorb and align the pins, with a positioning accuracy of ≤±0.1mm, ensuring precise matching between the tongue and groove forming surface 14 and the self-locking structure of the wall panel tongue and groove. After the pin 11 is fully inserted into the first positioning hole 12 and the second positioning hole 13, turn off the magnetic control switch 9 to complete the mold assembly. At this point, the pin 11, in conjunction with the first positioning hole 12 and the second positioning hole 13, achieves a firm fixation, preventing displacement due to uneven ground or slight vibrations during pouring.

[0056] S2. Mold release agent spraying: Apply a special water-based oil-free mold release agent evenly to the inner wall of the mold cavity and the tongue and groove forming surface 14 using a spraying method. The spreading thickness is controlled at 0.05~0.1mm. After spraying, let it stand for 5 minutes to allow the mold release agent to form a uniform and dense film on the mold surface.

[0057] This specialized water-based, oil-free mold release agent contains no oil components and is composed of the following components by weight: water-based polyurethane dispersion (PUD): 25-35 parts; water-based acrylic emulsion: 10-15 parts; hydrophobic nano-silica: 1.5-3 parts; composite rust and corrosion inhibitor: 1.5-2.5 parts; nonionic polyurethane (thixotropic stabilizer): 0.5-1.2 parts; polyether-modified defoamer: 0.1-0.3 parts; and deionized water: 45-55 parts. The preparation method of the mold release agent is as follows:

[0058] (a) Add deionized water to the reactor, adjust the stirring speed to 300-500 r / min, and control the temperature at 40±5℃.

[0059] (b) Add the aqueous polyurethane dispersion and aqueous acrylic emulsion to the reactor in sequence, and stir continuously for 30 minutes until the system is uniform and stable.

[0060] (c) Add hydrophobic nano-silica and non-ionic polyurethane, adjust the stirring speed to 1200-1500 r / min, disperse at high speed for 20 min to ensure uniform dispersion of nanoparticles.

[0061] (d) Add composite rust inhibitor and corrosion inhibitor and polyether modified defoamer, stir at low speed for 15 minutes to avoid generating bubbles, and finally filter and discharge to obtain the finished release agent.

[0062] S3. Concrete Pouring and Self-Vibration: The concrete mixture prepared from the quaternary composite cementitious system of cement-fly ash-red mud-tailings powder is poured into the mold cavity in layers. During the pouring process, the micro-vibration motor 7 is turned on by the micro-vibration motor switch 10 on the side of the base plate 1, and the vibration frequency is adjusted to 4000 r / min. The vibration time is controlled at 10~30 seconds to promote the upward release of air bubbles inside the concrete and ensure that narrow parts such as tongue and groove are densely filled. After vibration is completed, the micro-vibration motor 7 is turned off, and the concrete mixture is poured to the designed height of the mold, and the surface is leveled.

[0063] The cement-fly ash-red mud-tailings powder quaternary composite cementitious system comprises, by weight, 260 parts of silicate cement (P・O42.5), 60 parts of fly ash, 40 parts of red mud, 40 parts of iron tailings powder, 40 parts of slag powder, 780 parts of medium sand, 1050 parts of crushed stone, 150 parts of water, and 2.0 parts of polycarboxylate high-performance water-reducing agent; its 28-day compressive strength reaches C30 grade, meeting the mechanical requirements of highway subgrade slope protection; the tongue-and-groove self-locking structure of the wall panel features a staggered interlocking design with a splice width of 0.4mm.

[0064] S4. Curing and Demolding: After the concrete is poured, cure it according to the specifications. After curing, connect an external 10~12V low-voltage power supply again, press the magnetic control switch 9 to activate the magnetic force, assisting in separating the pin 11 from the first positioning hole 12 and the second positioning hole 13, preventing the pin 11 from getting stuck due to concrete pressure. Pull the first L-shaped split frame 4 and the second L-shaped split frame 5 upwards by hand, so that the pin 11 is completely separated from the first positioning hole 12 and the second positioning hole 13. Turn off the magnetic control switch 9, and slowly separate the first L-shaped split frame 4 and the second L-shaped split frame 5 outwards along the diagonal direction, avoiding the tongue and groove interlocking resistance, and easily remove the formed tongue and groove self-locking low-carbon concrete precast wall panel, achieving non-destructive demolding.

[0065] S5. Mold Cleaning: Clean the residual release agent and concrete debris from the inner wall of the mold. Check whether the magnetic suction device 8 on the upper bottom plate of the mold, the magnetic suction device 6 on the split frame, and the micro vibration motor 7 are normal. The mold can be reused directly without additional maintenance and is suitable for the batch prefabrication of highway subgrade slope protection components.

[0066] like Figures 8-11 .

[0067] like Figure 8 The image shows the finished wall panel obtained after demolding according to this embodiment. The panel is rectangular and flat, with a staggered interlocking tongue-and-groove self-locking structure integrally formed around its four edges. That is, the adjacent two sides have raised tongues and grooves, and the other two sides have corresponding grooves. The panel surface is flat and smooth, without appearance defects such as honeycomb, pitting, or bubbles, and the tongue and groove edges are complete and clear.

[0068] like Figure 9The diagram shows adjacent wall panels interlocking via a tongue-and-groove mechanism at their adjacent edges. During assembly, the protruding tongue of one panel slides axially into the groove of the other panel, achieving self-locking through a staggered interlocking design, without the need for any bolts or external connectors. Figure 9 The overall assembly effect is visible. The two boards are flat and coplanar after assembly, with minimal gaps between them. Furthermore, due to the staggered interlocking path of the tongue and groove joints, mechanical locking is achieved along both the normal direction of the board surface and the direction of the joint after assembly, effectively preventing the joints from opening due to minor displacement during use.

[0069] like Figure 10 As shown in the magnified details, the protrusions and grooves of the tongue and groove are designed with asymmetry and misalignment. After interlocking, they form a tortuous sealing path. This tortuous sealing structure can effectively reduce grout leakage. This structure is the key technical feature of the present invention that solves the problem of grout leakage in the assembly of traditional flat-mouth wall panels.

[0070] like Figure 11 The image shown is a schematic diagram of the overall assembly of some wall panels.

Claims

1. A self-vibrating magnetic quick-release molding die, characterized in that: The mold includes a base plate (1), an upper base plate (2) of the mold, and a connecting rod (3). The base plate (1) and the upper base plate (2) of the mold are connected by the connecting rod (3). The upper base plate (2) of the mold is provided with a first L-shaped split frame (4) and a second L-shaped split frame (5) that form a hollow frame. The first L-shaped split frame (4) and the second L-shaped split frame (5) are provided with a split frame magnetic suction device (6). The upper base plate (2) of the mold is provided with a micro vibration motor (7) on the side surface near the base plate (1), and the upper base plate magnetic suction device (8) of the mold is provided inside. The side is provided with a magnetic suction control switch (9) for controlling the split frame magnetic suction device (6) and the upper base plate magnetic suction device (8). The base plate (1) is provided with a micro vibration motor switch (10) for controlling the micro vibration motor (7).

2. The self-vibrating magnetic quick-release molding die according to claim 1, characterized in that: The upper bottom plate (2) of the mold is provided with several pins (11) along the edge. The first L-shaped split frame (4) is provided with a first positioning hole (12) that matches the pins (11). The second L-shaped split frame (5) is provided with a second positioning hole (13) that matches the pins (11).

3. The self-vibrating magnetic quick-release molding die according to claim 2, characterized in that: The pin (11) is clearance-fitted with the first positioning hole (12) and the second positioning hole (13), with a clearance ≤ 0.05 mm.

4. The self-vibrating magnetic quick-release molding die according to claim 2, characterized in that: The top of the pin (11) is rounded.

5. The self-vibrating magnetic quick-release molding die according to claim 1, characterized in that: The inner sides of the first L-shaped split frame (4) and the second L-shaped split frame (5) are provided with tongue and groove forming surfaces (14) with a surface roughness ≤0.8μm.

6. The self-vibrating magnetic quick-release molding die according to claim 1, characterized in that: The first L-shaped split frame (4) and the second L-shaped split frame (5) are made of glass fiber reinforced polycarbonate composite material.

7. The self-vibrating magnetic quick-release molding die according to claim 1, characterized in that: The micro vibration motor (7) is covered with a rubber shock-absorbing sleeve. The rubber shock-absorbing sleeve has a protruding buckle on the outside. The protruding buckle engages and is fixed with the pre-set slot of the upper bottom plate (2) of the mold.

8. The self-vibrating magnetic quick-release molding die according to claim 1, characterized in that: The base plate (1) is provided with a micro vibration motor switch (10) on the side to supply power to the micro vibration motor (7).

9. A method for preparing prefabricated wall panels using the self-vibrating magnetic quick-release molding mold as described in claim 1, characterized in that, Includes the following steps: Step 1: Place the base plate (1) flat, connect an external 10~12V low voltage power supply, turn on the magnetic control switch (9), insert the first L-shaped split frame (4) and the second L-shaped split frame (5) into the upper base plate (2) of the mold, automatically adsorb and align, and turn off the magnetic control switch (9) after the pin is fully inserted. Step 2: Spray water-based oil-free release agent onto the inner wall surface of the mold cavity formed by the first L-shaped split frame (4), the second L-shaped split frame (5), and the upper bottom plate (2) of the mold, spreading it to a thickness of 0.05~0.1mm, and let it stand to form a uniform film. Step 3: Pour the concrete mixture into the mold cavity in layers. During the pouring process, turn on the micro vibration motor (7) to vibrate. After the vibration is completed, turn off the micro vibration motor switch (10) and continue pouring to the designed height. Step 4: After the pouring is completed, perform curing. After curing, turn on the magnetic control switch (9), pull out the first L-shaped split frame (4) and the second L-shaped split frame (5) upwards, turn off the magnetic control switch (9), separate the first L-shaped split frame (4) and the second L-shaped split frame (5) outwards along the diagonal direction, and take out the formed tongue-and-groove self-locking low-carbon concrete precast wall panel.

10. The method for preparing prefabricated wall panels according to claim 9, characterized in that: In step three, the concrete mixture comprises, by weight, 260-290 parts silicate cement, 40-80 parts fly ash, 30-50 parts red mud, 40-60 parts tailings powder, 40-60 parts slag powder, 750-800 parts sand, 1000-1080 parts crushed stone, 145-155 parts water, and 1.5-2.5 parts polycarboxylate superplasticizer.

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