Manufacturing process of invisible steel bone inorganic slurry integrally formed nano-flexible ceramic wall mobile house

Abstract

The application discloses a kind of stealth steel bone inorganic slurry integrated forming nanometer soft porcelain ceramic wall mobile house manufacturing process, belong to integrated mobile house manufacturing technical field.The application breaks through the traditional "keel frame outer hanging wallboard" step-by-step assembly mode, realizes (wall) structure, heat preservation, moisture-proof, facing, (intelligent system decoration) integrated forming, material cost is reduced by more than 30%, construction period is shortened by 40%, thermal bridge problem is reduced by about 60%, moisture-proof performance is improved by about 50%, while supporting small-batch customized color drawing appearance, can adapt to multiple scene needs such as travel and tourism homestay, temporary residence, fill the green intelligent building and travel and tourism market new product blank.

Description

Technical Field

[0001] This invention belongs to the field of integrated mobile housing manufacturing technology, and specifically relates to a manufacturing process for a mobile house with an invisible steel frame and inorganic slurry integral molding nano-flexible ceramic wall. Background Technology

[0002] The current mainstream manufacturing technology for integrated mobile homes (such as Apple pods, modular travel cabins, etc.) is the traditional steel structure assembly process. Its core process involves: first, welding or bolting steel keels to form a frame; filling the spaces between the steel keels with insulation cotton; then installing prefabricated integrated wall panels on the inside and outside using hangers; and finally, sealing with adhesive and completing the exterior finishing work. This technology, after years of application, has revealed several limitations: 1. Material and structural defects: High steel consumption, with a single compartment typically using 180-250kg of steel, resulting in a high self-weight (the self-weight of a standard 6m×3m compartment is ≥2.8t), leading to high transportation and hoisting costs; the walls use a point / line connection method of "keel + hanging plate", and the joints are prone to becoming water leakage channels. After long-term use, the sealant ages and cracks, and the risk of leakage increases significantly with the increase of service life; the wall panels themselves have limited load-bearing capacity, making it impossible to directly hang heavy objects on the walls, which limits the flexibility of the internal space layout.

[0003] 2. Technological and cost deficiencies: Production requires a large-scale prefabrication production line, including wall panel pressing equipment, cutting equipment, and assembly lines. The initial equipment investment is ≥5 million yuan, making it difficult to adapt to small-batch, multi-batch customized orders. The entire process involves multiple steps such as keel processing, wall panel prefabrication, on-site assembly, and sealing construction. The production cycle for a single cabin is ≥7 days, and the labor input is ≥12 man-days. The overall cost is high, with a standard cabin market price of ≥80,000 yuan. Maintenance workload is large, and the annual maintenance cost is about 3%-5% of the initial cost.

[0004] 3. Performance and compatibility defects: Thermal bridges are easily formed between the insulation layer and the keel. In winter, indoor heat is quickly lost through the thermal bridge, and in summer, outdoor heat is transferred through the thermal bridge, resulting in energy consumption that is 15%-20% higher than that of traditional buildings; the moisture-proof layer is mostly made of inner polyethylene film, which is easily scratched by the keel during construction, and the probability of dampness and mold on the walls in humid southern regions is ≥40%; the appearance is limited by the fixed colors of prefabricated wall panels, which makes it difficult to meet the personalized and landscaped needs of cultural tourism projects and cannot support the creation of scenic area IP.

[0005] The aforementioned shortcomings make it difficult for existing integrated mobile homes to balance cost, performance, and customization needs, and they cannot fully match the current market trends of green building and cultural tourism upgrading. A new manufacturing process with more reliable structure, lower cost, and stronger adaptability is needed. Summary of the Invention

[0006] In view of this, the present invention provides a manufacturing process for a mobile house with an integrated invisible steel frame inorganic slurry nano-flexible ceramic wall, in order to solve or alleviate one of the technical problems existing in the prior art, and at least provide a beneficial alternative.

[0007] The technical solution of this invention is implemented as follows: a manufacturing process for a mobile house with an integrated invisible steel frame inorganic slurry molding nano-flexible ceramic wall includes the following steps: S1 Mold Preparation: Customize steel molds according to the dimensions of the target mobile house, apply release agent to the inner wall of the mold, and reserve door and window openings and pipeline pre-embedded grooves; S2 Layered Laying: Lay the first layer of modified inorganic non-metallic cementitious polymer reinforced slurry flat (or vertically) at the bottom of the mold. The thickness of the slurry is 15%-20% of the total wall thickness. S3 Keel Embedding: Before the first layer of slurry sets, the concealed steel keel is vertically fixed in the mold at the designed spacing. The distance between the keel and the side wall of the mold is ≥50mm. The surface of the keel is treated with anti-rust. S4 Functional Layer Laying: Aluminum foil moisture-proof layer and rock wool insulation layer are laid sequentially in the gaps between the keels. The aluminum foil moisture-proof layer is tightly attached to the inside of the keel, and the rock wool insulation layer fills the remaining space between the keels, with no gaps between the layers. S5 Secondary Injection: Inject the second layer of modified inorganic non-metallic cementitious polymer reinforced slurry into the mold until the slurry completely covers the keel and functional layer. After vibration to compact, scrape the surface smooth. S6 Curing and Demolding: Allow to cure at room temperature for 48-72 hours. After the slurry has fully set, remove the mold to obtain an integral wall unit. S7 Finishing Construction: The outer surface of the wall unit is sanded smooth, and a custom landscape pattern is drawn using inorganic pigments. After the pigments dry, a nano-soft porcelain coating is sprayed on, with a coating thickness of 0.2-0.5mm. S8 Integrated Assembly: Multiple wall units are spliced ​​with prefabricated roofs and floors, and an intelligent central control network circuit system is embedded to complete the overall assembly of the mobile house; wherein the modified inorganic non-metallic cementitious polymer reinforced slurry is a magnesium oxychloride or magnesium sulfide slurry, and short fiber filaments, fiber mesh cloth or steel mesh can be added during preparation according to strength requirements.

[0008] Preferably, the raw materials for preparing the first layer of modified inorganic non-metallic cementitious polymer reinforced slurry in step S2 include, by weight: 55-65 parts of lightly calcined magnesium oxide, 25-35 parts of magnesium chloride / magnesium sulfate solution, 3-8 parts of modifier, and 5-12 parts of filler; wherein the modifier is composed of one or more of phosphoric acid, citric acid, and silica fume, and the filler is one or more of fly ash, slag powder, and quartz sand.

[0009] Preferably, the concealed steel structure keel in step S3 is made of cold-formed thin-walled steel (or aluminum alloy frame), with a cross-sectional shape of C or U, a thickness of 1.2-2.5mm, and a spacing of 400-600mm; overflow holes are pre-drilled on the contact surface between the keel and the slurry, with a hole diameter of 5-8mm and a hole spacing of 150-200mm, to ensure that the slurry and the keel form a mechanical interlock.

[0010] Preferably, the aluminum foil moisture-proof layer in step S4 is a polyethylene film with aluminum foil on both sides, with a thickness of 0.1-0.3 mm, an overlap width of ≥100 mm, and the overlap is sealed with aluminum foil tape; the rock wool insulation layer has a density of ≥120 kg / m³, a thermal conductivity of ≤0.040 W / (m·K), and a thickness of 50-120 mm according to the energy-saving requirements of the target area.

[0011] Preferably, in step S5, alkali-resistant glass fiber short filaments (or basalt fibers) with a fiber length of 6-12 mm are incorporated into the second layer of modified inorganic non-metallic cementitious polymer reinforced slurry, and the amount of filaments incorporated is 0.5%-1.2% of the total volume of the slurry. When the wall is used in high-load scenarios, steel mesh is tied and welded to the outside of the keel, with a steel diameter of 6-10 mm and a mesh spacing of 100-150 mm, and is poured and formed synchronously with the second layer of slurry.

[0012] Preferably, the inorganic pigment in step S7 is an iron oxide-based or titanium dioxide-based inorganic mineral pigment with a weather resistance of ≥800h; the nano-flexible ceramic coating is composed of nano-silica-modified acrylic resin, inorganic fillers, and additives, with a solid content of ≥45%, a pencil hardness of ≥2H, an adhesion of ≥1 grade, and self-cleaning and UV-resistant properties.

[0013] Preferably, the intelligent central control network circuit system mentioned in step S8 includes the Xiaomi Smart Home System and the Huasheng Air Purification Intelligent Ventilation System HS1.0. All lines, sensors, and ventilation ducts are pre-embedded inside the wall, with no exposed conduits. The system supports remote control of indoor temperature and humidity, air quality, lighting, and security equipment.

[0014] Preferably, the process is applicable to the manufacturing of all walls of mobile homes, including side walls, end walls, and partition walls; the walls of different functional areas can be customized by adjusting the mold size, keel specifications, and insulation layer thickness, without the need to replace the entire set of production equipment.

[0015] Preferably, an air-entraining agent can be added to the modified inorganic non-metallic cementitious polymer reinforced slurry during the stirring process to introduce tiny closed air bubbles with a diameter of 0.05-0.2 mm and an air content controlled at 8%-15%, thereby further improving the thermal insulation performance of the wall.

[0016] Preferably, the corners of the integral wall unit are chamfered with a chamfer radius of 10-20mm; the wall joints are sealed with a modified inorganic slurry of the same system and covered with a nano-soft ceramic coating of the same color as the wall to ensure consistent appearance and waterproof performance.

[0017] The embodiments of the present invention have the following advantages due to the adoption of the above technical solutions: (1) Overall improvement in structural performance: ① Integrity: The wall is a seamless, integral cast-in-place structure, which has a deformation resistance that is more than 60% higher than that of traditional steel-framed wall panels. It can withstand the impact of hoisting and transportation under winds of up to level 8, with no risk of structural loosening.

[0018] ② Load-bearing capacity: The mortar and keel work together to bear the load, and the wall surface load is ≥1.5kN / m². It can directly hang heavy objects of up to 50kg on the wall without additional reinforcement.

[0019] ③ Durability: The modified inorganic slurry itself has A1 fire resistance, freeze-thaw resistance (≥50 freeze-thaw cycles without cracking), and acid and alkali resistance. Combined with the built-in aluminum foil moisture-proof layer, the service life of the wall is ≥30 years, which is more than 50% longer than that of traditional mobile houses.

[0020] (2) Costs are significantly reduced: ① Material cost: The main raw materials of modified inorganic slurry are industrial by-product magnesium slag, fly ash, etc., and the cost is only 40%-50% of that of precast wall panels. The amount of steel used in a single compartment is reduced to 80-120kg, and the total material cost is reduced by 30%-40%.

[0021] ② Construction cost: No large prefabrication equipment is required, only simple mixing and pouring tools are needed, the production cycle of a single compartment is shortened to 3-4 days, the labor input is reduced to 5-6 man-days, and the construction cost is reduced by 40%-50%.

[0022] ③ Maintenance cost: With no exposed seams and sealant, the risk of leakage is reduced by 90%, and the average annual maintenance cost is only 0.5%-1% of the initial cost.

[0023] (3) Functional performance optimization: ① Thermal insulation and moisture protection: The continuous insulation layer reduces thermal bridging by about 60%, and the average heat transfer coefficient of the wall is ≤0.45W / (m²·K); the aluminum foil moisture-proof layer, combined with the water-repellent properties of the slurry itself, improves the moisture-proof performance by about 50%, and reduces the probability of dampness and mold in southern regions to below 5%.

[0024] ② Space utilization: The concealed keel does not occupy internal space, increasing the usable area by 3%-5% compared to traditional steel structure houses.

[0025] (4) It has strong customization and adaptability. Only by changing the mold can the cabin size and door and window positions be adjusted. It supports small order production of up to 5 units per batch. The painted patterns can be customized according to the theme of the scenic spot to meet the personalized needs of cultural tourism projects. The supporting intelligent system can be flexibly selected and adapted to different levels of use scenarios.

[0026] (5) Green and environmental benefits: Modified inorganic slurry can utilize industrial solid waste, and the production energy consumption is reduced by 50% compared with precast concrete wall panels; there is no cutting or welding waste on site, and the material utilization rate is ≥95%, which meets the requirements of green construction.

[0027] 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

[0028] 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.

[0029] Figure 1 This is the overall manufacturing process flow diagram of the present invention (S1-S8). Figure 2 This is a flowchart illustrating the preparation process of the modified inorganic non-metallic cementitious polymer-reinforced slurry of the present invention. Figure 3 This is a flowchart of the concealed steel structure keel processing of the present invention; Figure 4 This is a flowchart illustrating the functional layer layout of the present invention. Detailed Implementation

[0030] 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.

[0031] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0032] Example 1: Manufacturing a 3m×6m standard apple-shaped cabin for cultural tourism and homestays

[0033] This embodiment is designed for a scenic homestay scenario. The target cabin dimensions are 6m long, 3m wide, and 2.8m high. It is required to have A1 fire resistance, thermal insulation performance suitable for winter temperatures (-10℃) in the Qinling Mountains, and a forest-themed painted exterior.

[0034] 1. Raw material preparation

[0035] 2. Process Implementation Steps

[0036] 3. Performance test results

[0037] Example 2: Construction of a 4m×8m mobile home for scenic views in a southern coastal area

[0038] This embodiment is designed for high-temperature and high-humidity coastal scenarios. The target cabin dimensions are 8m long, 4m wide, and 3m high. It requires high moisture resistance and salt spray resistance, and the exterior is decorated with marine-themed paint, making it suitable for long-term outdoor use.

[0039] 1. Raw material preparation

[0040] 2. Process Implementation Steps

[0041] 3. Performance test results

[0042] Example 3: Manufacturing of 2.4m×6m modular mobile homes for temporary urban offices

[0043] This embodiment is designed for temporary office scenarios in cities. The target cabin dimensions are 6m long, 2.4m wide, and 2.6m high. It requires high cost-effectiveness, rapid deployment, and an exterior painted with corporate VI colors. It can be repeatedly hoisted and used.

[0044] 1. Raw material preparation

[0045] 2. Process Implementation Steps

[0046] 3. Performance test results

[0047] 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 manufacturing process for a mobile house with an integrated invisible steel frame inorganic slurry molding nano-flexible ceramic wall, characterized in that... Includes the following steps: S1 Mold Preparation: Customize steel molds according to the dimensions of the target mobile house, apply release agent to the inner wall of the mold, and reserve door and window openings and pipeline pre-embedded grooves; S2 Layered Laying: The first layer of modified inorganic non-metallic cementitious polymer reinforced slurry is laid flat at the bottom of the mold, with a slurry thickness of 15%-20% of the total wall thickness; S3 keel (framework) pre-embedding: Before the first layer of slurry sets, the hidden steel keel (invisible frame) is vertically fixed in the mold at the designed spacing. The distance between the keel (framework) and the side wall of the mold is ≥50mm. The surface of the keel (framework) is treated with anti-rust. S4 Functional Layer Laying: Aluminum foil moisture-proof layer and rock wool insulation layer are laid sequentially in the gaps between the (skeleton) keel. The aluminum foil moisture-proof layer is tightly attached to the inner side of the keel, and the rock wool insulation layer fills the remaining space between the keels. There are no gaps between the layers. S5 Secondary Injection: Inject the second layer of modified inorganic non-metallic cementitious polymer reinforced slurry into the mold until the slurry completely covers the keel and functional layer. After vibration to compact, scrape the surface smooth. S6 Curing and Demolding: Let it cure at room temperature for 48-72 hours. After the slurry has set, remove the mold to obtain an integral wall unit. S7 Finishing Construction: The outer surface of the wall unit is sanded smooth, and a custom landscape pattern is drawn using inorganic pigments. After the pigments dry, a nano-soft porcelain coating (topcoat) is sprayed on, with a coating thickness of 0.2-0.5mm. S8 Integrated Assembly: Multiple wall units are spliced ​​with prefabricated roofs and (chassis) floors, and an intelligent central control network circuit system is pre-embedded to complete the overall assembly of the mobile house; wherein the modified inorganic non-metallic cementitious polymer reinforced slurry is a magnesium oxychloride or magnesium sulfide slurry, and short fiber filaments, fiber mesh cloth or steel mesh can be added during preparation according to strength requirements.

2. The manufacturing process for a mobile house with an integrated invisible steel frame inorganic slurry molding nano-flexible ceramic wall as described in claim 1, characterized in that, The raw materials for preparing the first layer of modified inorganic non-metallic cementitious polymer reinforced slurry in step S2 include, by weight: 55-65 parts of lightly calcined magnesium oxide, 25-35 parts of magnesium chloride / magnesium sulfate solution, 3-8 parts of modifier, and 5-12 parts of filler; wherein the modifier is composed of one or more of phosphoric acid, citric acid, and silica fume, and the filler is one or more of fly ash, slag powder, and quartz sand.

3. The manufacturing process for a mobile house with an integrated invisible steel frame inorganic slurry molding nano-flexible ceramic wall as described in claim 1, characterized in that... The concealed steel keel (invisible skeleton) mentioned in step S3 is made of cold-formed thin-walled steel (or aluminum alloy skeleton), with a cross-section of C or U, a thickness of 1.2-2.5mm, and a spacing of 400-600mm; overflow holes are pre-drilled on the contact surface between the keel and the grout, with a hole diameter of 5-8mm and a hole spacing of 150-200mm, to ensure that the grout and the keel form a mechanical interlock.

4. The manufacturing process for a mobile house with an integrated invisible steel frame inorganic slurry molding nano-flexible ceramic wall as described in claim 1, characterized in that... The aluminum foil moisture-proof layer mentioned in step S4 is a polyethylene film with aluminum foil on both sides, with a thickness of 0.1-0.3mm and an overlap width of ≥100mm. The overlap is sealed with aluminum foil tape. The rock wool insulation layer has a density of ≥120kg / m³, a thermal conductivity of ≤0.040W / (m·K), and a thickness of 50-120mm according to the energy-saving requirements of the target area.

5. The manufacturing process for a mobile house with an integrated invisible steel frame inorganic slurry molding nano-flexible ceramic wall as described in claim 1, characterized in that... In step S5, alkali-resistant glass fiber short filaments with a fiber length of 6-12mm are incorporated into the second layer of modified inorganic non-metallic cementitious polymer reinforced slurry, and the dosage is 0.5%-1.2% of the total volume of the slurry. When the wall is used in high-load scenarios, steel mesh is tied and welded to the outside of the keel, with a steel diameter of 6-10mm and a mesh spacing of 100-150mm, and is poured and formed synchronously with the second layer of slurry.

6. The manufacturing process for a mobile house with an integrated invisible steel frame inorganic slurry molding nano-flexible ceramic wall as described in claim 1, characterized in that, The inorganic pigments mentioned in step S7 are iron oxide-based and titanium dioxide-based inorganic mineral pigments with a weather resistance of ≥800h; the nano-flexible ceramic coating is composed of nano-silica-modified acrylic resin, inorganic fillers, and additives, with a solid content of ≥45%, a pencil hardness of ≥2H, an adhesion of ≥1 grade, and self-cleaning and UV-resistant properties.

7. The manufacturing process for a mobile house with an integrated invisible steel frame inorganic slurry molding nano-flexible ceramic wall as described in claim 1, characterized in that, The intelligent central control network circuit system mentioned in step S8 includes the Xiaomi Technology Smart Home System and the Huasheng Air Purification Intelligent Ventilation System HS1.

0. All lines, sensors, and ventilation ducts are pre-embedded inside the wall, with no exposed conduits. The system supports remote control of indoor temperature and humidity, air quality, lighting, and security equipment.

8. The manufacturing process for a mobile house with an integrated invisible steel frame inorganic slurry molding nano-flexible ceramic wall as described in claim 1, characterized in that, The process is applicable to the manufacturing of all walls of mobile homes, including side walls, end walls, and partition walls; the walls of different functional areas can be customized by adjusting the mold size, keel specifications, and insulation layer thickness, without the need to replace the entire set of production equipment.

9. The manufacturing process for a mobile house with an integrated invisible steel frame inorganic slurry molding nano-flexible ceramic wall as described in claim 1, characterized in that... During the mixing process, an air-entraining agent can be added to the modified inorganic non-metallic cementitious polymer reinforced slurry to introduce tiny closed air bubbles with a diameter of 0.05-0.2 mm and an air content controlled at 8%-15%, thereby further improving the thermal insulation performance of the wall.

10. The manufacturing process for a mobile house with an integrated invisible steel frame inorganic slurry molding nano-flexible ceramic wall as described in claim 1, characterized in that, The edges and corners of the integral wall unit are chamfered with a chamfer radius of 10-20mm; the wall joints are sealed with a modified inorganic slurry of the same system and covered with a nano-soft ceramic coating of the same color as the wall to ensure consistent appearance and waterproof performance.

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