Integrated wall with on-site pouring polyurethane sandwich thermal insulation structure

Abstract

The utility model belongs to the technical field of energy-saving plates of building structures, and particularly relates to an integrated wall with an on-site pouring polyurethane sandwich heat preservation structure. Comprising an outer wallboard body and an inner wallboard body, a heat preservation core material is poured into a cavity between the inner wallboard body and the outer wallboard body, the outer wallboard body is formed by mutually inserting a plurality of concrete outer protection plates, the inner wallboard body is formed by mutually inserting a plurality of concrete inner protection plates, and a plurality of pouring holes used for pouring the heat preservation core material are formed in the inner wallboard body. The multiple pouring holes are distributed in the whole inner wall plate, and after the heat preservation core material is poured and the pouring holes are blocked, the surface layer is painted on the surface of the inner protection plate to cover the pouring holes. The wall body is good in overall strength, high in safety, good in waterproof and heat insulation effect, short in construction period and easy to construct.

Description

Technical Field

[0001] The utility model belongs to the technical field of energy-saving panels for building structures, and in particular relates to an integrated wall body with a field-injected polyurethane sandwich thermal insulation structure. Background Art

[0002] my country's building energy conservation began in the 1980s, and now the country has fully achieved the 75% energy conservation standard, and the building energy conservation target has been raised year by year. Now some provinces and cities have gradually achieved the 85% energy conservation standard. In the future, the building energy conservation and insulation standards will be raised. Some provinces and cities have taken the lead in implementing ultra-low energy consumption buildings, zero energy consumption buildings, and even developing production capacity buildings. The country has also successively issued corresponding policies to strengthen the research and development and promotion of energy-saving and low-carbon technologies suitable for different climate zones and different building types, and promote the large-scale development of low-energy consumption buildings and low-carbon buildings. At present, prefabricated buildings or traditional structural exterior wall insulation cannot meet the increasingly stringent requirements for building energy conservation, insulation and safety. The main problems are as follows:

[0003] 1. Traditional structural insulation, or FS insulation system, the wall of the self-insulating block used in the filling wall has many cold and hot bridges and poor insulation effect; secondary structural masonry construction has many on-site operation procedures, requires maintenance, and has a long construction period; secondary masonry settlement is prone to cracks with the main structure, and has poor waterproof and vapor barrier performance;

[0004] 2. The thermal conductivity of the insulation materials used in traditional structural insulation is high. The insulation materials used for the same insulation performance are thick, which reduces the practical area of ​​the building; the density of the insulation materials is high, which increases the overall load of the building and has poor safety.

[0005] 3. The exterior wall enclosure structure of traditional prefabricated buildings uses lightweight concrete wall panels, ALC wall panels, or AAC wall panels, but the energy saving of the wall itself cannot meet the requirements, and secondary exterior wall insulation construction is required, which has a long construction period and complex processes.

[0006] 4. The finished panels used in traditional insulation sandwich walls and insulation materials cannot be effectively integrated with the internal and external walls or the main structure of the ALC. Some insulation substrates may even peel off or fall off from the protective layer or the main body, resulting in poor safety.

[0007] 5. The traditional exterior wall enclosure structure adopts lightweight concrete wall panels, ALC wall panels, or AAC wall panels, etc. The wall thickness is not less than 200mm, the wall is thick, and the connection points are weak. Utility Model Content

[0008] The utility model aims to solve the shortcomings of the existing building structure insulation filling wall insulation or prefabricated building exterior protective structure technology, and provide an on-site poured polyurethane sandwich insulation structure integrated wall, which can achieve a firm connection with the upper and lower side beams and floor slabs, has few cold and hot bridges, good insulation effect, and convenient construction.

[0009] The utility model discloses an integrated wall body with a cast-in-place polyurethane sandwich insulation structure, which is special in that it comprises an outer wall panel and an inner wall panel, and an insulation core material 2 is poured in the cavity between the inner and outer wall panels, wherein the outer wall panel is composed of a plurality of concrete outer protective panels 1 inserted into each other, and the inner wall panel is composed of a plurality of concrete inner protective panels 3 inserted into each other, and a plurality of pouring holes 4 for pouring the insulation core material 2 are opened on the inner wall panel, and the plurality of pouring holes 4 are arranged on the entire inner wall panel, and after the insulation core material 2 is poured through the pouring holes 4, the pouring holes are sealed and then a surface layer is painted on the surface of the concrete inner protective panel 3 to cover the pouring holes.

[0010] Preferably, the thickness of the concrete outer protective plate 1 and the concrete inner protective plate 3 are both greater than 45 mm, and the concrete outer protective plate 1 and the concrete inner protective plate 3 are any one of lightweight aggregate concrete panels, UHPC concrete curtain wall panels, ALC wall panels, ACC wall panels, AAC wall panels, GRC styling panels, and fine and dense concrete wall panels.

[0011] Preferably, the thickness of the thermal insulation core material 2 is 20 mm-500 mm, and the thermal insulation core material 2 is any one of PUR, PIR, and graphite-modified polyurethane.

[0012] Preferably, the diameter of the pouring hole 4 is 12-18 mm, the inclination angle of the pouring hole 4 is 45°, the height of the pouring hole 4 close to one end of the thermal insulation core material 2 is lower than the height of the other end of the pouring hole 4, and the pouring hole 4 runs through the entire concrete inner protective plate 3;

[0013] Preferably, the distance between adjacent injection holes 4 is no more than 300 mm.

[0014] Preferably, the concrete outer protective plate 1 and the concrete inner protective plate 3 have the same shape, a convex structure 6 is provided on the left side of the protective plate, and a groove structure 7 is provided on the right side. Adjacent protective plates are assembled together through the convex structure 6 and the groove structure 7 to form an outer wall panel or an inner wall panel.

[0015] Preferably, the top and bottom of the protective plate are respectively connected to the upper beam and the floor slab through two adapters 5. The adapter 5 is L-shaped, and mounting holes 8 are provided on the L-shaped vertical surface and horizontal surface of the adapter 5. The top and bottom of the protective plate are provided with adapter slots 9 used in conjunction with the adapter 5.

[0016] The advantages of the on-site poured polyurethane sandwich insulation structure integrated wall of the utility model are as follows:

[0017] 1. Good thermal insulation and energy saving effect, excellent waterproof and vapor barrier performance, and light weight. The thermal insulation core material is made of low thermal conductivity, low density polyurethane, which has good thermal insulation effect; there is no metal connection between the inner and outer protective plates, which are all connected to the main structure, reducing the cold and hot bridge effect of the inner and outer protective plates; the inner and outer protective plates are plugged into a whole by a single standard plate and a non-standard plate. The liquid polyurethane fills the gaps between the inner and outer protective plates, between the protective layer and the main body, and forms a complete closed layer with the main body, which is completely closed for thermal insulation, waterproofing and vapor barrier.

[0018] 2. The overall fireproof performance is good. Since the thickness of the structural protection plates on both sides of the insulation wall is greater than 45mm, and the protection plates on both sides are lightweight concrete, which is a non-combustible material, the overall fireproof performance of the wall insulation is improved.

[0019] 3. Liquid polyurethane solidifies with the inner and outer protective panels to form a whole. The two materials complement each other's advantages. Polyurethane makes up for the brittleness of lightweight concrete wall panels and enhances the waterproofness of lightweight concrete; lightweight concrete wall panels improve the overall fire resistance and wall stiffness of the wall.

[0020] 4. The connection is strengthened through the adapter, and the inner and outer protective plates are connected to the main structure, which enhances the integrity with the main structure.

[0021] 5. High strength and strong integrity. When the liquid polyurethane solidifies, it adheres the inner and outer protective panels to the main structure, forming a whole, which improves the internal and external protection strength. The insulation wall as a whole serves as the outer protective structure of the building, with a larger cross-section and enhanced overall stability and strength.

[0022] 6. High construction efficiency, easy construction, and reduced project cost; lightweight concrete wall panels are easy to connect and fast to construct. During the main construction process, the inner and outer protective panels of the lower construction enclosure structure can be inserted. The polyurethane pouring process only needs to be completed indoors, and can be constructed in parallel with the main structure construction without waiting for the main structure to be completed.

[0023] The on-site poured polyurethane sandwich insulation structure integrated wall of the utility model has a good application prospect in the application fields of ultra-low energy consumption buildings, zero-energy buildings or prefabricated buildings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a structural decomposition diagram of an on-site poured polyurethane sandwich insulation structure integrated wall of the utility model;

[0025] Figure 2 This is a position relationship diagram of an integrated wall protection plate, a thermal insulation core material, and a pouring hole of a field-injected polyurethane sandwich thermal insulation structure of the utility model;

[0026] Figure 3 It is the structural exploded view of the protective plate and the adapter;

[0027] Figure 4 It is a schematic diagram of the structure of pouring the thermal insulation core material through the pouring hole. DETAILED DESCRIPTION

[0028] In order to clearly understand the technical solution of the utility model, its detailed structure will be presented in the following description. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0029] The utility model is further described in detail below with reference to the accompanying drawings and embodiments. Example 1

[0030] The present embodiment is a polyurethane sandwich structure integrated wall poured on site, see the attached Figure 1-4 , including an outer wall panel and an inner wall panel, and a thermal insulation core material 2 is poured into the cavity between the inner and outer wall panels, wherein the outer wall panel is composed of a plurality of concrete outer protective panels 1 inserted into each other, and the inner wall panel is composed of a plurality of concrete inner protective panels 3 inserted into each other, and a plurality of pouring holes 4 for pouring the thermal insulation core material 2 are opened on the inner wall panel, and the plurality of pouring holes 4 are arranged on the entire inner wall panel. After the thermal insulation core material 2 is poured, the pouring holes 4 are sealed with gypsum and then a gypsum layer is painted on the surface of the inner protective panel 3.

[0031] The thickness of the concrete outer protective plate 1 and the concrete inner protective plate 3 of this embodiment are both greater than 45 mm. The concrete outer protective plate 1 and the concrete inner protective plate 3 are any one of lightweight aggregate concrete panels, UHPC concrete curtain wall panels, ALC wall panels, ACC wall panels, AAC wall panels, GRC shaped panels, and fine and dense concrete wall panels.

[0032] The thickness of the thermal insulation core material 2 of this embodiment is 20 mm-500 mm, and the thermal insulation core material 2 is any one of PUR, PIR, and graphite-modified polyurethane.

[0033] The diameter of the pouring hole 4 in this embodiment is 12-18 mm, the inclination angle of the pouring hole 4 is 45°, the height of the pouring hole 4 close to one end of the thermal insulation core material 2 is lower than the height of the other end of the pouring hole 4, and the pouring hole 4 runs through the entire concrete inner protective plate 3.

[0034] The distance between adjacent injection holes 4 in this embodiment is no more than 300 mm.

[0035] The concrete outer protective plate 1 and the concrete inner protective plate 3 of this embodiment have the same shape, with a convex structure 6 on the left side of the protective plate and a groove structure 7 on the right side. Adjacent protective plates are assembled together through the convex structure 6 and the groove structure 7 to form an outer wall panel or an inner wall panel.

[0036] The top and bottom of the protective plate of this embodiment are connected to the upper beam and the floor slab through two adapters 5 respectively. The adapter 5 is L-shaped, and mounting holes 8 are provided on the L-shaped vertical surface and horizontal surface of the adapter 5. The top and bottom of the protective plate are provided with adapter slots 9 used in conjunction with the adapter 5.

[0037] A construction process of an on-site poured polyurethane sandwich insulation structure integrated wall of this embodiment includes the following steps:

[0038] 1. Project Features

[0039] According to the characteristics of the thermal insulation construction of the project, the outer wall is a double-layer ALC wall panel with polyurethane poured into the cavity. The thickness of the polyurethane cavity in the wall cavity is 120mm, and the two sides are 100mm ALC wall panels. Before the pouring construction, the two sides of the cavity are blocked with polyurethane strips, and the inner side (outside of special parts) ALC board is drilled with a spacing of about 300mm according to the design requirements, and poured according to the hole arrangement. The polyurethane raw materials used are black and white materials in a ratio of 1.5:1 on the wall surface, and the polyurethane density is designed to be 22Kg / m³.

[0040] 2. Construction working environment requirements

[0041] Before construction, the base layer needs to be inspected and accepted to see if it is clean. Before polyurethane pouring, check whether the wall is fixed and installed, whether the joints of lightweight concrete wall panels are filled with cement mortar; check whether the dust, cement or gypsum residue on the ground are clean.

[0042] 3. Construction process:

[0043] Review and confirm the construction plan → prepare people, machines and materials → draw control lines → install lightweight concrete exterior wall panels → install lightweight concrete interior wall panels → seal both sides of lightweight concrete wall panels → check and seal the appearance gaps of lightweight concrete wall panels → fix limit protection on both sides of lightweight concrete wall panels → pour polyurethane → clean up the overflowed polyurethane → seal and clean the holes in lightweight concrete wall panels.

[0044] The details are as follows:

[0045] 1) Before the project is started, the construction plan shall be submitted for review, and construction can only be carried out after the construction plan is reviewed and signed for confirmation.

[0046] 2) Preparation of personnel, machines and materials: After the construction plan is confirmed, the corresponding personnel, machines and materials shall be organized according to the construction plan to ensure that the construction progress is not affected.

[0047] Processing of lightweight concrete wall panels: First, produce the outer protective panel 1 and the inner protective panel 3 in the factory. Design the specifications and dimensions of the lightweight concrete wall panels according to the dimensions of the structural drawings. The thickness of the inner and outer protective panels is 100mm, the width is not less than 600mm, and the height is based on the net height of the structural beam 3000mm. Drill the injection hole 4 in the inner protective panel 3. The diameter of the injection hole 4 is 15mm. When opening the hole, the downward inclination angle is 45° (see the attached for the inclination angle). Figure 4 ), and penetrates the inner protective plate 3, with a hole spacing of no more than 300mm.

[0048] After the construction materials are prepared, they are transported to the construction site, stacked neatly in the specified locations, and appropriate protection and precautionary measures are taken.

[0049] 3) Draw control lines according to the layout drawing, draw vertical lines at the columns, draw parallel straight lines at the beams, and draw the installation position lines of the inner and outer walls and the edge lines of the door and window openings on the ground. The lines should be clear and the positions should be accurate.

[0050] 4) Install lightweight concrete interior and exterior wall panels

[0051] (1) Install the connecting parts: The adapter 5 should be installed along the upper and lower side beams and floor slabs. The number and position of the adapter 5 should be strictly in accordance with the layout drawing.

[0052] (2) Installation sequence: Install the outer protective plate 1 first, then install the inner protective plate 3. The inner (outer) protective plate can be installed sequentially from one end of the main structure (wall, column) to the other end. When there is a door opening, it is advisable to install it from the opening to both sides. A whole piece of plate should be used on both sides of the opening. When there is less than one piece, the width of the supplementary plate should not be less than 200 mm.

[0053] (3) Before connecting and fixing the lightweight concrete wall panels to the main structure, first calibrate the verticality and flatness of the protective panels to ensure that the wall panels are arranged in an orderly manner, the panel joints are uniform, and the upper and lower exterior walls are straight without misalignment. During the installation process, the flatness and verticality of the wall panels after installation should be checked at any time with a ruler.

[0054] 5) Blocking on both sides of lightweight concrete wall panels

[0055] According to the characteristics of the project, the polyurethane poured into the cavity is guaranteed to foam normally and prevent overflow. The finished polyurethane slats with a width equal to the width of the cavity and a splicing length according to the actual height are prepared in advance. The thickness of the polyurethane slats is not less than 20mm. After the wall is poured with polyurethane, the overall appearance is coordinated and beautiful. At the same time, the consistent materials used also ensure the effect of thermal insulation and energy saving.

[0056] 6) Check and seal the appearance gaps of ALC wall panels:

[0057] After completing the side sealing of the ALC wallboard, check for large gaps in appearance and seal them to prevent a large amount of polyurethane from overflowing from the gaps during the injection process. The sealing material should be a single-component polyurethane smeared gap, and the next process should be carried out after the sealing material is cured.

[0058] 7) Fixed limit protection on both sides of lightweight concrete wall panels

[0059] The outer sides of the sealing polyurethane slats on both sides of the lightweight concrete wall panel are close to each other with thick wooden boards and fixed to the lightweight concrete wall panel with stainless steel screw clips or similar structural facilities, which can effectively prevent the deformation of the polyurethane slats caused by expansion and extrusion during the polyurethane injection process.

[0060] 8) Pouring polyurethane: After completing the above process, start pouring polyurethane into the lightweight concrete cavity, using a ratio of 1.5:1 between black and white polyurethane. The polyurethane is poured from bottom to top, from the holes of the wall panels in sequence, or from the sealed parts on the side of the lightweight concrete wall panels. Combine the two, observe the foaming of polyurethane in the lightweight concrete wall panels while pouring, and fine-tune the pouring time in time according to the foaming speed and density;

[0061] Before pouring polyurethane, pre-spray it in a waste bucket for 5 to 10 seconds to observe whether the polyurethane foaming meets the design requirements;

[0062] The pouring time of the pouring hole 4 is 3-5 seconds, the pouring interval between the holes in the same row is controlled at 1-3 seconds, and the pouring interval between the holes in the rows is 25-30 seconds. The foaming of the polyurethane in the lightweight concrete wallboard is closely monitored through the pouring hole 4 located on the side.

[0063] When pouring polyurethane, the pouring time of each pouring hole 4 near the ground is 4 to 6 seconds. When pouring polyurethane to the highest row of pouring holes 4, pour from the outer pouring holes 4 first, and pour from the outside to the inside in sequence. Each hole position is extended by 1 to 2 seconds to ensure that the polyurethane foam can fully fill the top cavity.

[0064] When pouring polyurethane into the side sealing part, one side of the lightweight concrete wall panel is sealed with polyurethane strips as a whole, and the other side is poured while being sealed. This is convenient for observing the foaming of the lower layer of polyurethane in the lightweight concrete wall panel, and can also release the lateral tension generated by the expansion of polyurethane foam, ensuring that the polyurethane foam fills the entire cavity of the lightweight concrete wall panel.

[0065] During the polyurethane pouring process, the pouring order is controlled and the holes at the same height are poured one by one. After completing the polyurethane pouring of one row of holes, the polyurethane pouring of the second row of holes is started after the time interval requirements for the pouring of the second row of holes are met, and the same pouring order should be maintained.

[0066] 9) Cleaning up spilled polyurethane

[0067] During the process of pouring polyurethane, a small amount of polyurethane will overflow due to the drilling of lightweight concrete wall panels, the tiny gaps between the wall panels and the main structure, and the side sealing. After the pouring operation of the entire wall is completed, it will solidify within 72 hours, all fixed protective measures will be removed, and the overflowed polyurethane will be cleaned up in time.

[0068] 10) Sealing and cleaning of holes in ALC wall panels

[0069] After the polyurethane pouring operation is completed, the holes on the lightweight concrete wall panels need to be sealed with plaster. If polyurethane overflows from the holes, use a drill bit with a diameter of about φ10mm to drill the holes to a depth of 5~10mm (or other effective methods), and then paint the plaster. After all the operations of pouring polyurethane into the wall are completed, clean up the garbage generated by the operation in time to avoid affecting the construction work on the ground.

Claims

1. A site-cast polyurethane sandwich insulation structure integrated wall, characterized in that It includes exterior wall panels and interior wall panels, and the cavity between the interior and exterior wall panels is poured with thermal insulation core material, wherein the exterior wall panels are composed of multiple concrete exterior protective panels inserted into each other, and the interior wall panels are composed of multiple concrete interior protective panels inserted into each other, and multiple pouring holes for pouring thermal insulation core material are opened on the interior wall panels, and the multiple pouring holes are arranged on the entire interior wall panels. After the thermal insulation core material is poured through the pouring holes, the pouring holes are sealed and then the surface of the concrete interior protective panels is painted to cover the pouring holes.

2. A site-cast polyurethane sandwich insulation structure integrated wall according to claim 1, characterized in that The thickness of the concrete outer protective plate and the concrete inner protective plate are both greater than 45 mm, and the concrete outer protective plate and the concrete inner protective plate are any one of lightweight aggregate concrete panels, UHPC concrete curtain wall panels, ALC wall panels, ACC wall panels, AAC wall panels, GRC styling panels, and fine and dense concrete wall panels.

3. The on-site poured polyurethane sandwich insulation structure integrated wall according to claim 1, characterized in that The thickness of the thermal insulation core material is 20 mm-500 mm, and the thermal insulation core material is any one of PUR, PIR, and graphite-modified polyurethane.

4. The on-site poured polyurethane sandwich insulation structure integrated wall according to claim 1, characterized in that The diameter of the pouring hole is 12-18 mm, the inclination angle of the pouring hole is 45°, the height of the pouring hole close to one end of the thermal insulation core material is lower than the height of the other end of the pouring hole, and the pouring hole runs through the entire concrete inner protective plate.

5. The on-site poured polyurethane sandwich insulation structure integrated wall according to claim 4, characterized in that The distance between adjacent injection holes is no more than 300 mm.

6. The on-site poured polyurethane sandwich insulation structure integrated wall according to claim 1, characterized in that The concrete outer protective plate and the concrete inner protective plate have the same shape, a convex structure is provided on the left side of the protective plate, and a groove structure is provided on the right side. Adjacent protective plates are assembled together through the convex structure and the groove structure to form an outer wall panel or an inner wall panel.

7. The on-site poured polyurethane sandwich insulation structure integrated wall according to claim 1, characterized in that The top and bottom of the protective plate are connected to the upper beam and the floor slab through two adapters respectively. The adapter is L-shaped, and mounting holes are provided on the L-shaped vertical surface and horizontal surface of the adapter. The top and bottom of the protective plate are provided with adapter slots for use with the adapter.

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