Micro-expansion self-healing concrete decorative wallboard structure

Abstract

The utility model discloses a micro-expansion self-healing concrete decorative wallboard structure which comprises a wallboard body, and the wallboard body comprises a waterproof coating, a permeable crystallization layer, a self-healing concrete layer, a micro-expansion concrete layer, a board base layer and a decorative surface layer which are sequentially arranged. The permeable crystallization layer is sprayed on the self-healing concrete layer; a first bonding layer is arranged between the plate base layer and the micro-expansive concrete layer, a second bonding layer is arranged between the plate base layer and the decorative surface layer, a first reinforcing mesh is arranged in the self-healing concrete layer, and a second reinforcing mesh is arranged in the micro-expansive concrete layer. The utility model has the advantages of long service life and less maintenance workload.

Description

Technical Field

[0001] This utility model relates to the field of building wall panel structure technology, and in particular to a micro-expansion self-healing concrete decorative wall panel structure. Background Technology

[0002] Concrete is a brittle material with high compressive strength but low tensile strength, approximately one-tenth of its compressive strength. This makes it brittle and prone to cracking. Concrete exhibits defects such as thermal shrinkage cracks and confined cracks during use. Cracks are a direct cause of damage to concrete structures, opening pathways for water, chloride ions, carbon dioxide, and other substances; consequently reducing the durability of concrete and shortening its service life.

[0003] Prefabricated construction of underground projects first faces the challenge of poorly sealed joints between components. Secondly, after installation, the stress distribution of structural components changes, making them prone to defects such as micro-cracks. Often, problematic components cannot be replaced and can only be repaired, which in turn damages the existing decorative structure.

[0004] The changes in the stress field after the installation of underground engineering structures, the generation of micro-cracks, and the erosion of groundwater often cause major defects in underground structures. In addition, the existing prefabricated decoration is mainly suspended, which has many interfering factors on the concrete structure and is more likely to induce defects.

[0005] In on-site concrete construction, the quality of on-site curing directly affects the stability of concrete performance and its effectiveness. Secondly, the constraints of concrete construction conditions, the stress constraints of concrete structures, the hydration and thermal shrinkage of concrete, and the disturbances during concrete pouring all affect concrete structures, inducing cracks and structural damage, thereby reducing the durability and service life of concrete.

[0006] The proportion of prefabricated buildings in the construction field is increasing year by year, and the walls of underground engineering are also gradually developing into prefabricated components; however, conventional structures are simply a combination of ordinary silicate concrete and steel mesh structures, without considering the waterproof performance of the components and the repair of micro-cracks in the concrete after maintenance; at the same time, the decoration and finishing of the components are not considered, which is undoubtedly insufficient for prefabricated components.

[0007] The problem with existing technologies is that microcracks in underground concrete structures can easily lead to groundwater erosion, affecting the service life of the concrete structure; and the repair of cracks in concrete structures can damage the existing structure, making maintenance inconvenient. Summary of the Invention

[0008] The purpose of this invention is to address the problems existing in the prior art by providing a micro-expansion self-healing concrete decorative wall panel structure with a long service life and low maintenance workload.

[0009] To achieve the above objectives, the technical solution adopted by this utility model is: a micro-expansion self-healing concrete decorative wall panel structure, comprising a wall panel body, wherein the wall panel body comprises, in sequence, a waterproof coating, a penetrating crystallization layer, a self-healing concrete layer, a micro-expansion concrete layer, a panel base layer, and a decorative surface layer; the penetrating crystallization layer is sprayed onto the self-healing concrete layer; an adhesive layer one is provided between the panel base layer and the micro-expansion concrete layer, an adhesive layer two is provided between the panel base layer and the decorative surface layer, a steel mesh one is provided within the self-healing concrete layer, and a steel mesh two is provided within the micro-expansion concrete layer.

[0010] In the above scheme, the main body of the wall panel includes a waterproof coating and a penetrating crystallization layer to ensure the waterproof effect of the water-facing side of the wall panel structure. The self-healing concrete layer can fill and repair cracks when exposed to water. The micro-expansion concrete layer can slightly expand during the hydration and temperature shrinkage of concrete to compensate for concrete shrinkage and reduce concrete deformation. The base layer of the panel is the load-bearing foundation of the decorative surface layer. It is bonded to the micro-expansion concrete layer through adhesive layer one. The decorative surface layer is connected to the base layer of the panel through adhesive layer two, which serves to decorate and make the surface smooth. Reinforcing mesh one and reinforcing mesh two are set to strengthen the concrete structure of the main body of the wall panel and ensure its load-bearing performance.

[0011] Furthermore, the bottom surface of the wall panel body is provided with several steel bar connection holes, and the wall panel body is provided with several grouting holes and grout outlet holes. The grouting holes are connected to the bottom of the steel bar connection holes, and the grout outlet holes are connected to the top of the steel bar connection holes.

[0012] By creating rebar connection holes, the decorative wall panel structure can be positioned in conjunction with the bottom positioning rebar of the building during installation. Grouting holes are used to inject grout into the rebar connection holes to achieve the connection between the bottom positioning rebar and the decorative wall panel structure. Grout outlet holes can be used to determine whether grouting is complete.

[0013] Furthermore, the bottom of the slurry outlet hole is provided with a fastening plane for installing a fastening nut, and the rebar connection hole penetrates the fastening plane.

[0014] A fastening plane is set up for fastening nuts on the reinforcing bars, and the positioning of the decorative wall panel structure is achieved by the nut engaging with the fastening plane.

[0015] Furthermore, the rebar connection hole is an irregularly shaped hole, used to form a gap between it and the fastening nut for the flow of grout.

[0016] After the fastening nut is installed, the grout flows through the gap between the irregular hole and the fastening nut.

[0017] Furthermore, the steel bar connection holes are arranged in several rows, and the grouting holes and grout outlet holes are connected to the corresponding rows of steel bar connection holes.

[0018] By setting several rows of steel bar connection holes, the positioning stability of the wall panel structure after the steel bar connection and fastening nuts are ensured, as well as the connection stability of the decorative wall panel structure after grouting. The grouting holes and grout outlet holes correspond to multiple rows of steel bar connection holes, which is simple in structure and convenient for grouting.

[0019] Furthermore, several transverse connecting stirrups are provided on the left and right sides of the wall panel body, and the two ends of the transverse connecting stirrups are respectively connected to steel mesh one and steel mesh two.

[0020] By setting horizontal connecting stirrups, it is convenient to coordinate the on-site pouring of decorative wall panel structure with the building steel reinforcement. The horizontal connecting stirrups are connected to steel mesh one and steel mesh two, so the structure is stable.

[0021] Furthermore, a plurality of vertical connecting bars are provided between the first and second steel meshes, and the two ends of the vertical connecting bars are fixed to the first and second steel meshes.

[0022] Vertical connecting bars are used to connect steel mesh one and steel mesh two, making the decorative wall panel structure stable under stress.

[0023] Furthermore, the substrate of the board includes UHPC board, calcium silicate board, or cement fiber board. It has a simple structure and is easy to use.

[0024] Compared with the prior art, the beneficial effects of this utility model are:

[0025] By setting a penetrating crystallization layer, a self-healing concrete layer, and a micro-expansion concrete layer inside the wall panel, it not only has micro-expansion properties but also self-healing properties that resist concrete cracks. This can reduce micro-cracks, extend the service life of the structure, and reduce maintenance workload.

[0026] By setting a fastening plane at the bottom of the grout outlet to cooperate with the fastening nut installation, the assembly and positioning of the decorative wall panel structure can be achieved. This is convenient to operate, reduces the amount of on-site support work, and has high construction efficiency.

[0027] By opening rebar connection holes and setting connecting stirrups, the on-site assembly and installation of the wall panel structure is facilitated. The prefabricated wall panel structure is produced in a centralized and standardized manner in the factory, ensuring the stability of component quality and improving overall quality. Attached Figure Description

[0028] Figure 1 This is a top view of a micro-expansion self-healing concrete decorative wall panel structure according to an embodiment of the present utility model;

[0029] Figure 2 This is a perspective view of a micro-expansion self-healing concrete decorative wall panel structure according to an embodiment of the present utility model;

[0030] Figure 3This is a front view of a micro-expansion self-healing concrete decorative wall panel structure according to an embodiment of the present utility model;

[0031] Figure 4 This is a cross-sectional view of a micro-expansion self-healing concrete decorative wall panel structure according to an embodiment of the present utility model;

[0032] In the diagram: 1. Waterproof coating; 2. Penetrating crystallization layer; 3. Self-healing concrete layer; 4. Micro-expansion concrete layer; 5. Board base layer; 6. Decorative surface layer; 7. Reinforcing mesh one; 8. Reinforcing mesh two; 9. Reinforcing bar connection hole; 10. Grouting hole; 11. Grout outlet hole; 12. Fastening nut; 13. Fastening plane; 14. Horizontal connecting stirrup; 15. Vertical connecting bar; 16. Bottom positioning bar. Detailed Implementation

[0033] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this utility model, and not all of them. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0034] Self-healing concrete refers to experimental concrete that can repair cracks on its own. It contains dormant bacterial spores that can produce limestone and nutrients needed for bacterial growth. These spores are activated by corrosive rainwater seeping into the structure, aiming to locally fill the cracked areas. This new material has the potential to extend the service life of concrete and effectively reduce the maintenance costs of concrete structures.

[0035] Micro-expansion concrete refers to ordinary concrete with the addition of a certain amount of expansive agent. During hydration, the expansive agent causes the concrete to expand, compensating for shrinkage and thus preventing cracking and improving concrete performance.

[0036] like Figure 1-4 As shown, a micro-expansion self-healing concrete decorative wall panel structure includes a wall panel body, which comprises a waterproof coating 1, a penetrating crystallization layer 2, a self-healing concrete layer 3, a micro-expansion concrete layer 4, a substrate 5, and a decorative surface layer 6 arranged sequentially. The penetrating crystallization layer 2 is sprayed onto the self-healing concrete layer 3. An adhesive layer 1 is provided between the substrate 5 and the micro-expansion concrete layer 4, and an adhesive layer 2 is provided between the substrate 5 and the decorative surface layer 6. A steel mesh 1 7 is provided inside the self-healing concrete layer 3, and a steel mesh 2 8 is provided inside the micro-expansion concrete layer 4.

[0037] In the above scheme, the main body of the wall panel includes a waterproof coating 1 and a penetrating crystallization layer 2 to ensure the waterproof effect of the water-facing side of the wall panel structure. The self-healing concrete layer 3 can fill and repair cracks when exposed to water. The micro-expansion concrete layer 4 can slightly expand during the hydration and thermal shrinkage of concrete to compensate for concrete shrinkage and reduce concrete deformation. The base layer 5 of the panel is the load-bearing foundation of the decorative surface layer 6 and is bonded to the micro-expansion concrete layer 4 through an adhesive layer 1. The decorative surface layer 6 is connected to the base layer 5 of the panel through an adhesive layer 2, which serves to decorate and make the surface smooth. The concrete structure of the main body of the wall panel is reinforced by setting steel mesh 1 7 and steel mesh 2 8 to ensure the load-bearing performance.

[0038] Waterproof coating 1 is an organic or composite coating, or a waterproof adhesive layer with a fiber mesh, its purpose is waterproofing, serving as the water-facing surface; penetrating crystallization layer 2 is sprayed onto the self-healing concrete layer 3, serving a waterproof and dense function, blocking the entry channels of water; self-healing concrete layer, the self-healing concrete layer contains functional concrete with self-healing bacterial additives; micro-expansion concrete layer 4 is concrete with different expansion raw materials added internally; adhesive layer one is applied to the micro-expansion concrete layer 4, serving to bond the board base layer 5; the board base layer 5 is the load-bearing foundation of the decorative surface layer 6; adhesive layer two bonds the decorative surface layer 6 to the board base layer 5, the decorative surface layer 6 serves a decorative function, its surface layer can be inorganic, organic or metallic materials.

[0039] The thickness of the waterproof coating 1 is 1-3mm, the thickness of the penetrating crystallization layer 2 is no more than 2mm, the thickness of the self-healing concrete layer is 50-400mm, the thickness of the micro-expansion concrete layer 4 is 50-400mm, the thickness of the board base layer 5 is 8-12mm, and the thickness of the decorative surface layer 6 is no more than 2mm.

[0040] In this design, a micro-expansion structure is added based on the hydration and thermal shrinkage characteristics of concrete. Considering the principle that cracks form water molecule channels, self-healing bacteria, such as Bacillus pasteurellii, are added to the structural layer. These bacteria multiply within the channels, calcifying and healing the cracks, thus achieving self-repair. Simultaneously, a decorative layer is prepared on the outer surface according to design requirements, either by painting or pasting, shortening the construction period on-site.

[0041] The decorative wall panel structure is prefabricated and assembled on-site. Integrated factory production and standardized curing are beneficial for improving the uniformity of concrete quality. Furthermore, the self-repair and healing of micro-cracks in the concrete allows for non-invasive self-healing, preventing minor issues from causing structural damage. Utilizing a micro-expansion structural layer, the internal design incorporates self-healing materials, termed self-healing concrete layer 3. The outer layer is the panel base layer 5, and beyond that is the decorative surface layer 6.

[0042] In summary, this invention presents a micro-expansion self-healing concrete decorative wall panel structure. Through its internal self-healing structural design, the panel heals cracks after they appear using internal self-healing agents, thereby blocking corrosion pathways and protecting the stability and durability of the concrete structure. Furthermore, considering the hydration and thermal shrinkage stages of concrete, the invention employs a micro-expansion source structure and utilizes factory prefabrication to ensure structural performance stability and improve quality. This invention plays a significant role in the application and promotion of this technology in civil buildings, particularly in underground engineering.

[0043] Furthermore, the bottom surface of the wall panel body is provided with a plurality of steel bar connection holes 9, and the wall panel body is provided with a plurality of grouting holes 10 and grout outlet holes 11. The grouting holes 10 are connected to the bottom of the steel bar connection holes 9, and the grout outlet holes 11 are connected to the top of the steel bar connection holes 9.

[0044] The steel bar connection hole 9 is opened to be used for positioning with the bottom positioning steel bar 16 of the building during the installation of the decorative wall panel structure. The grouting hole 10 is used to grout into the steel bar connection hole 9 to realize the connection between the bottom positioning steel bar 16 and the decorative wall panel structure. The grout outlet hole 11 can be used to determine whether the grouting is completed.

[0045] Furthermore, the bottom of the slurry outlet hole 11 is provided with a fastening plane 13 for installing the fastening nut 12, and the reinforcing bar connection hole 9 penetrates the fastening plane 13.

[0046] A fastening plane 13 is provided for connecting the fastening nuts 12 on the reinforcing bars. The positioning of the decorative wall panel structure is achieved by the cooperation of the nuts with the fastening plane 13.

[0047] The fastening nut 12 is screwed onto the top of the bottom positioning steel bar 16.

[0048] Furthermore, the steel bar connection hole 9 is an irregularly shaped hole, used to form a gap with the fastening nut 12 for the flow of grout.

[0049] After the fastening nut 12 is installed, the grouting material flows through the gap between the irregular hole and the fastening nut 12.

[0050] Irregular holes refer to holes other than circles, such as polygonal holes and elliptical holes.

[0051] Furthermore, the steel bar connection holes 9 are provided in several rows, and the grouting holes 10 and grout outlet holes 11 are connected to the several rows of steel bar connection holes 9 respectively.

[0052] By setting several rows of steel bar connection holes 9, the positioning stability of the wall panel structure after the steel bar connection and fastening nuts 12 are ensured, as well as the connection stability of the decorative wall panel structure after grouting. The grouting holes 10 and grout outlet holes 11 correspond to multiple rows of steel bar connection holes 9. The structure is simple and grouting is convenient.

[0053] Furthermore, several transverse connecting stirrups 14 are provided on the left and right sides of the wall panel body, and the two ends of the transverse connecting stirrups 14 are respectively connected to the steel mesh 7 and the steel mesh 8.

[0054] By setting the transverse connecting stirrups 14, it is convenient to coordinate the on-site pouring of the decorative wall panel structure with the building steel reinforcement. The transverse connecting stirrups 14 are connected with steel mesh 1 7 and steel mesh 2 8, so the structure is stable.

[0055] Furthermore, a plurality of vertical connecting bars 15 are provided between the first steel mesh 7 and the second steel mesh 8, and the two ends of the vertical connecting bars 15 are fixed to the first steel mesh 7 and the second steel mesh 8.

[0056] Vertical connecting bars 15 are used to connect steel mesh 7 and steel mesh 8, so that the decorative wall panel structure is stable under stress.

[0057] The horizontal connecting stirrups 14 and the vertical connecting bars 15 can be connected to the steel mesh 7 and steel mesh 8 by welding or binding.

[0058] Furthermore, the substrate 5 of the board comprises a UHPC board, a calcium silicate board, or a cement fiber board. The structure is simple and easy to use.

[0059] The production process of decorative wall panel structures is as follows:

[0060] Step 1: Install the steel mesh structure according to the design drawings. First, lay the template layer of the design dimensions, apply a release agent, and lay the steel mesh 1 and 2 in the template. Fix the hoisting rods to the steel mesh. First, pour the micro-expansion concrete structural layer in the horizontal mold. If conditions permit, the self-healing concrete layer 3 can be poured directly on the micro-expansion concrete structural layer. If conditions do not permit, wait until the curing conditions are met before pouring again.

[0061] Step 2: Remove the formwork from the concrete structure that has been cured in Step 1, and spray the penetrating crystallization layer 2 on the water-facing side of the structural layer.

[0062] Step 3: After the penetrating crystallization layer 2 has cured, apply or stick the waterproof coating 1 onto the penetrating crystallization layer 2.

[0063] Step 4: Apply adhesive layer 2 to the substrate 5 of the board and then attach the decorative surface layer 6 to the substrate 5 of the board.

[0064] Step 5: Attach the bonded substrate 5 to the structural components. After the bonding has cured and the curing is complete, the substrate will be packaged after passing quality inspection and then sent to the construction site for installation.

[0065] Its operation is simple and convenient, which is conducive to large-scale engineering production; at the same time, it provides better assurance of the quality of concrete materials, saves construction links on site, and improves construction efficiency.

[0066] During the production process, the micro-expansion concrete layer 4 and the self-healing concrete layer are respectively poured into the steel mesh in the mold to form the main body of the prefabricated frame. Then, the water-facing surface is sprayed with the penetrating crystallization layer 2 and the waterproof coating 1 is bonded. Then, the decorative structural layer board base 5 is bonded together with the decorative surface layer 6 by the second adhesive layer. After curing, the decorative board base 5 is then bonded to the back water surface of the main body by the first adhesive layer. Finally, the prefabricated micro-expansion self-healing concrete decorative wall panel structure is formed.

[0067] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A micro-expansion self-healing concrete decorative wall panel structure, characterized in that, The wall panel includes a main body comprising, in sequence, a waterproof coating, a penetrating crystalline layer, a self-healing concrete layer, a micro-expansion concrete layer, a substrate, and a decorative surface layer; the penetrating crystalline layer is sprayed onto the self-healing concrete layer; an adhesive layer one is provided between the substrate and the micro-expansion concrete layer, an adhesive layer two is provided between the substrate and the decorative surface layer, a steel mesh one is provided within the self-healing concrete layer, and a steel mesh two is provided within the micro-expansion concrete layer.

2. The micro-expansion self-healing concrete decorative wall panel structure according to claim 1, characterized in that: The bottom surface of the wall panel body is provided with several steel bar connection holes, and the wall panel body is provided with several grouting holes and grout outlet holes. The bottom of the grouting holes is connected to the bottom of the steel bar connection holes, and the grout outlet holes are connected to the top of the steel bar connection holes.

3. The micro-expansion self-healing concrete decorative wall panel structure according to claim 2, characterized in that: The bottom of the grout outlet is provided with a fastening plane for installing a fastening nut, and the rebar connection hole penetrates the fastening plane.

4. The micro-expansion self-healing concrete decorative wall panel structure according to claim 2, characterized in that: The rebar connection hole is an irregularly shaped hole, used to form a gap between it and the fastening nut for the flow of grout.

5. The micro-expansion self-healing concrete decorative wall panel structure according to claim 2, characterized in that: The steel bar connection holes are arranged in several rows, and the grouting holes and grout outlet holes are connected to the corresponding rows of steel bar connection holes.

6. The micro-expansion self-healing concrete decorative wall panel structure according to claim 1, characterized in that: Several transverse connecting stirrups are provided on the left and right sides of the wall panel body, and the two ends of the transverse connecting stirrups are respectively connected to steel mesh one and steel mesh two.

7. The micro-expansion self-healing concrete decorative wall panel structure according to claim 1, characterized in that: Several vertical connecting bars are provided between the first steel mesh and the second steel mesh, and the two ends of the vertical connecting bars are fixed to the first steel mesh and the second steel mesh.

8. The micro-expansion self-healing concrete decorative wall panel structure according to claim 1, characterized in that: The substrate of the board includes UHPC board, calcium silicate board or cement fiber board.

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