Independent keel double-bin type ultra-low energy consumption building energy-saving enclosure wall

Abstract

This invention proposes an independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall. The wall frame includes two leaf wall templates that can be removed, and main and secondary keels vertically fixed to the inner sides of the two leaf wall templates. The leaf walls are attached to the outer side of the leaf wall templates. The main and secondary keels are channel-shaped keels with a gap in the width direction of the wall. A Class A fireproof and heat-insulating board is located between the main and secondary keels and covers and is fixed to the main keel. An insulating core is filled in the two compartments separated by the two leaf wall templates and the Class A fireproof and heat-insulating board. The space between the Class A fireproof and heat-insulating board and the secondary keel is filled with the insulating core to form a thermal break layer. This invention has excellent heat insulation and energy-saving performance, meeting the requirements of existing building energy consumption standards. The wall frame has high strength, and the inner and outer leaf walls independently transmit force to the main building structure, forming a double-curtain wall structure with independent force transmission paths, making the wall less prone to cracking and with a long service life.

Description

Technical Field

[0001] This utility model relates to the field of prefabricated building technology, and in particular to an independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall. Background Technology

[0002] The Energy Conservation Law, which came into effect on April 1, 2008, includes building energy conservation in national law. The Green Building Evaluation Standard (2024 Edition) changes green building from "optional" to "mandatory." With the implementation of the "dual carbon" goals (carbon peaking in 2030 and carbon neutrality in 2060), near-zero energy consumption (75% energy saving) has been incorporated into local mandatory standards in temperate southern regions and ultra-low energy consumption (85% energy saving) in cold northern regions. The Residential Project Standard, a building industry standard issued by the Ministry of Housing and Urban-Rural Development, proposes "safety," "comfort," "greenness," and "intelligence" as the "four good" construction standards. JG / T578, "Technical Requirements for Wall Panels for Prefabricated Buildings," has upgraded the combustion performance of wall materials from the original flame-retardant B1 level to the current non-combustible A level. The national standard for compressive strength of lightweight walls is 3.5 MPa. Traditional wall materials with such low standards can no longer meet the stringent requirements for non-combustible Class A fire resistance and ultra-low energy consumption (K-value of less than 0.15 for thermal transfer in walls). Low-strength walls are one of the important reasons why current building envelope structures cannot have the same lifespan as the main structure. These low-strength walls not only waste a lot of valuable resources, but also cause a lot of construction waste and secondary pollution to the environment, thus creating a demand for strengthening and upgrading existing building envelopes for energy conservation. Utility Model Content

[0003] To address the shortcomings of existing technologies, this utility model provides an independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall, which has high strength, good heat insulation and energy-saving performance, is not prone to cracking and has a long service life, and can meet existing building energy consumption standards.

[0004] To achieve the above objectives, the technical solution provided by this utility model is as follows: an independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall, comprising a wall frame, an insulation core, and leaf walls, and also including a Class A fireproof and heat-insulating board. The wall frame includes two leaf wall templates that can be removed, and main keels and secondary keels that are respectively vertically fixed to the inner sides of the two leaf wall templates. The leaf walls are attached to the outer side of the leaf wall templates. The main and secondary keels are channel-shaped keels and are spaced apart in the width direction of the wall. The Class A fireproof and heat-insulating board is located between the main and secondary keels and covers and is fixed to the main keel. The insulation core is a non-combustible Class A insulation material, which fills the two compartments separated by the two leaf wall templates and the Class A fireproof and heat-insulating board. The insulation core is filled in the gap between the Class A fireproof and heat-insulating board and the secondary keel to form a thermal break layer.

[0005] This utility model creatively proposes an independent main keel and secondary keel, and an independent thermal insulation double-compartment structure for the wall frame. The main keel and secondary keel are not connected, and are respectively close to the outer leaf wall and the inner leaf wall. A gap is left between the main keel and the secondary keel, and non-combustible Class A thermal insulation material is filled in this gap to form a thermal break layer. It not only has excellent thermal insulation function, but also the main keel and secondary keel are independently stressed and do not transmit or interfere with each other. Each of them independently transmits the stress to the main building structure, realizing the load distribution path and forming a double curtain wall structure. This avoids the mutual interference of stress between the inner and outer leaf walls, solves the cracking problem of traditional sandwich walls, and improves the life of the wall panels. Furthermore, the leaf wall formwork is separated into two insulated chambers by Class A fireproof and heat-insulating boards. Heat must pass through these two chambers to be transferred. The Class A fireproof and heat-insulating boards, together with the non-combustible Class A insulation materials in the two chambers, form a composite double-chamber insulation structure. Experimental testing has proven that this achieves a wall thermal transfer K-value ≤0.15, and the wall thickness is reduced by more than 100mm compared to traditional rock wool insulation structures. In addition, the double-keel, double-leaf wall formwork structure not only forms a double-curtain wall structure with independent force transmission paths, making the wall less prone to cracking, but also strengthens the wall skeleton, further improving the structural strength of the wall. The double-leaf wall formwork also serves as the formwork for the leaf walls.

[0006] To further enhance the strength of the wall panel frame, the leaf wall non-removable formwork includes non-removable steel formwork, steel mesh, and truss support components. Multiple truss support components connect the non-removable steel formwork and steel mesh into a sandwich integrated structure. The non-removable steel formwork is connected to the main keel or secondary keel, and the two sides of the non-removable steel formwork are connected to the non-removable steel formwork of the adjacent wall or the main structural column.

[0007] The leaf wall formwork is a three-dimensional double-layer structure. The bottom layer is a non-removable steel formwork, and the upper layer is a steel mesh. The two are supported and connected by multiple truss support components to form a three-dimensional structure. This three-dimensional non-removable steel formwork has a mezzanine space and a supporting skeleton. Its functions are: 1. High strength and rigidity, and also has thermal insulation and sound insulation effects; 2. It provides a concrete protective layer between the steel mesh and the non-removable steel formwork, and the steel mesh also serves as reinforcement and crack prevention for the wall; 3. It also serves as a leaf wall formwork that does not require formwork support or removal, ensuring the thickness and strength of the leaf wall.

[0008] Furthermore, if it is desired to further reduce the wall thickness, or if the wall's thermal heat transfer K-value cannot meet the condition of ≤0.15 due to material and other comprehensive reasons, an A1-grade thermal insulation coating layer can be applied to the surface of the non-removable steel formwork connected to the main and secondary keels to further enhance the thermal insulation effect of the thermal break.

[0009] Furthermore, as a better option, the upper and lower ends of the main keel are respectively connected to the main structural beams or slabs on the outdoor side, and the upper and lower ends of the secondary keel are respectively connected to the main structural beams or slabs on the indoor side.

[0010] Furthermore, to achieve better thermal insulation, the Class A fireproof insulation board is an inorganic Class A1 fireproof insulation board, and there is at least a gap of not less than 30mm between the inner side of the secondary keel and the Class A fireproof insulation board.

[0011] Furthermore, as a more optimized solution, the secondary keel is located closer to the interior side and its width is smaller than that of the main keel. The inner sides of each secondary keel are connected by keel tie rods. Since the secondary keel is closer to the interior side, the stress it experiences is not as great as that of the outer leaf wall. The main keel bears more stress from the outer leaf wall, so the width of the secondary keel can be designed to be smaller, while maintaining sufficient strength to save costs. The secondary keels are connected by keel tie rods to improve their strength.

[0012] Furthermore, the insulation core is a non-combustible inorganic A1 grade rock wool board to improve thermal insulation performance and facilitate installation.

[0013] Furthermore, in order to achieve flexible connection between the main and secondary keels to the main building structure, the upper and lower ends of the main and secondary keels are respectively assembled and connected to the main structure beams or plates through right-angle connectors.

[0014] Furthermore, the side of the right-angle connector that connects to the main and secondary keels is provided with a strip-shaped hole, which is parallel to the length direction of the main and secondary keels. The strip-shaped hole serves two purposes: firstly, it facilitates installation with screws; secondly, it allows for slight displacement and expansion when the wall is subjected to strong wind loads or thermal expansion and contraction, preventing wall cracking.

[0015] The beneficial effects of this utility model are: the thermal heat transfer K-value of the enclosure wall is low, which has excellent heat insulation and energy-saving performance and can meet the requirements of existing building energy consumption standards; the wall frame has high strength, and the inner and outer leaf walls independently transmit force to the main building structure, forming a double curtain wall structure with independent force transmission paths, making the wall less prone to cracking and with a long service life. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of Embodiment 1 of this utility model.

[0017] Figure 2 A schematic diagram of the installation structure of the main and secondary keels at their upper and lower ends and the main structure.

[0018] Figure 3 This is a structural diagram of the top and bottom ends of the wall.

[0019] Figure 4 A schematic diagram of the connection between the main keel or secondary keel and the keel tie rod.

[0020] Figure 5 This is a structural diagram of the leaf wall formwork that does not require dismantling.

[0021] Figure 6This is a structural schematic diagram of a truss support component.

[0022] Figure 7 This is a structural schematic diagram of Embodiment 2 of the present invention.

[0023] The present invention will now be described in further detail with reference to the accompanying drawings. Detailed Implementation

[0024] In the following example description, the direction "inside" refers to the interior of the wall, and the direction "outside" refers to the exterior of the wall. The "outer leaf wall" is closer to the exterior side, and the "inner leaf wall" is closer to the interior side. For example... Figures 1-4 As shown, an independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall includes a wall frame, an insulated inner core 7, a Class A fireproof and heat-insulating board 4, and leaf walls. The wall frame includes two leaf wall templates 3 that can be removed without dismantling, a main keel 1, and a secondary keel 2. Multiple parallel main keels 1 and secondary keels 2 are vertically fixed to the inner sides of the two leaf wall templates 3. The leaf walls are attached to the outer sides of the leaf wall templates 3. The main and secondary keels 1 and 2 are channel-shaped keels with two sides. The main keels 1 and secondary keels 2 are spaced apart in the width direction of the wall. The secondary keels 2 are closer to the indoor side and are narrower than the main keels 1. The inner sides of each secondary keel 2 are connected by horizontal keel tie members 9. Since the outer sides of each main and secondary keel 1 and 2 are fixed with leaf wall templates 3, it is equivalent to the outer sides of each main and secondary keel 1 and 2 being reinforced by tie connections through leaf wall templates 3. The secondary keel 2, being closer to the interior side, experiences less stress than the outer leaf wall 5. The main keel 1 bears more of the stress from the outer leaf wall. The width of the secondary keel 2 can be designed to be smaller, while maintaining sufficient strength to save costs. Each secondary keel 2 is connected by a keel tie 9, enhancing its strength. The Class A fireproof and heat-insulating board 4 is an inorganic Class A1 fireproof and heat-insulating board located between the main and secondary keels 1 and 2. The Class A fireproof and heat-insulating board 4 covers and is fixed to the main keel 1. The two leaf wall templates 3 are separated by the Class A fireproof and heat-insulating board 4, forming two heat-insulating compartments. The Class A fireproof and heat-insulating board 4 also serves as a horizontal tie for the inner side of the main keel 1. Alternatively, to further enhance the strength of the main keel 1, adjacent main keels 1 can also be connected by horizontal keel tie 9, with the tie 9 located close to the inner side of the main keel 1. There is a gap of at least 30mm between the inner side of the secondary keel 2 and the Class A fireproof and heat-insulating board 4. In this embodiment, the gap is 40-50mm.

[0025] In this embodiment, to achieve better thermal insulation, the insulation core 7 is a non-combustible inorganic A1-grade rock wool board. Various thicknesses of rock wool boards are available on the market. The thickness of the rock wool board is approximately equal to the width of the main and secondary keels 1 and 2, and the distance between the inner side of the secondary keel 2 and the A-grade fireproof insulation board 4, to facilitate filling. The insulation core 7 is filled in the two compartments separated by the two leaf wall templates 3 (removable) and the A-grade fireproof insulation board 4. The insulation core 7 forms a thermal break layer by filling the gap between the A-grade fireproof insulation board 4 and the secondary keel 2. This utility model creatively proposes an independent main keel 1 and secondary keel 2, and an independent thermal insulation double-compartment structure for the wall frame. The main keel 1 and secondary keel 2 are not connected and are located close to the outer leaf wall 5 and inner leaf wall 6, respectively. A gap is left between the main keel 1 and secondary keel 2, and non-combustible Class A thermal insulation material is filled in this gap to form a thermal break layer. This not only has excellent thermal insulation function, but also allows the main keel 1 and secondary keel 2 to bear the load independently without mutual transmission and interference. Each of them independently transmits the load to the main building structure, realizing load distribution along different paths and forming a double curtain wall structure. This avoids mutual stress interference between the inner and outer leaf walls 6 and 5, solves the cracking problem of traditional sandwich walls, and improves the lifespan of the wall panels. Furthermore, the leaf wall formwork 3 is separated into two insulated chambers by Class A fireproof and heat-insulating boards 4. Heat needs to pass through these two chambers to be transferred. The Class A fireproof and heat-insulating boards 4, together with the non-combustible Class A insulation materials in the two chambers, form a composite double-chamber insulation structure. Experimental testing has proven that the wall's thermal transfer K-value is ≤0.15, and the wall thickness is reduced by more than 100mm compared to traditional rock wool insulation structures. In addition, the double-keel, double-leaf wall formwork structure not only forms a double curtain wall structure with independent force transmission paths, making the wall less prone to cracking, but also strengthens the wall skeleton, further improving the structural strength of the wall. The double-leaf wall formwork also serves as the formwork for the leaf walls.

[0026] like Figure 2 , Figure 3 As shown, the upper and lower ends of the main keel 1 are connected to the main structural beams or slabs 10 on the exterior side, respectively, and the upper and lower ends of the secondary keel 2 are connected to the main structural beams or slabs 10 on the interior side, respectively. To achieve a flexible connection between the main and secondary keels 1 and 2 to the main building structure, the upper and lower ends of the main keel 1 and secondary keel 2 are respectively assembled and connected to the main structural beams or slabs 10 via right-angle connectors 8. Figure 2 The right-angle connector 8 shown has a slotted hole 81 on the side that connects to the main and secondary keels 1 and 2. The slotted hole 81 is parallel to the length direction of the main and secondary keels 1 and 2. The slotted hole 81 serves two purposes: first, it facilitates installation with screws; second, it allows for slight displacement and expansion when the wall is subjected to strong wind loads or thermal expansion and contraction, preventing the wall from cracking.

[0027] like Figure 5 and Figure 6As shown, to further enhance the strength of the wall panel frame, the leaf wall non-removable formwork 3 includes a non-removable steel formwork 31, a steel mesh 32, and truss support members 33. Multiple truss support members 33 connect the non-removable steel formwork 31 and the steel mesh 32 into a sandwich integrated structure. The non-removable steel formwork 31 is connected to the main keel 1 or the secondary keel 2, and both sides of the non-removable steel formwork 31 are connected to the non-removable steel formwork 31 of the adjacent wall or the main structural column. The truss support members 33 can be as follows: Figure 4 The fixed points are distributed on the non-removable steel formwork 31, or as follows: Figure 5 As shown, the truss support member 33 is formed by multiple trapezoidal protrusions from a single steel bar. The bottom of the groove between adjacent trapezoidal protrusions is welded to the reinforcing ribs of the protrusions on the non-removable steel formwork 31, and the top of the trapezoidal protrusions is welded to the steel mesh 32. Using a single steel bar to form multiple support points makes the processing simpler, easier to implement, lower in processing cost, and more manufacturable. The formed strip truss support members 33 can be roughly evenly distributed on the non-removable steel formwork 31.

[0028] The leaf wall formwork 3 is a three-dimensional double-layer structure. The inner layer is a non-removable steel formwork 31, and the outer layer is a steel mesh 32. The two are supported and connected by multiple truss support members 33 to form a three-dimensional structure. This three-dimensional non-removable steel formwork 31 has a mezzanine space and a supporting skeleton. Its functions are: 1. High strength and rigidity, and has the functions of heat insulation and sound insulation; 2. It provides a concrete protective layer between the steel mesh 32 and the non-removable steel formwork 31. The steel mesh 32 also serves as reinforcement and crack prevention for the wall; 3. It also serves as a leaf wall formwork that does not require formwork support or removal, ensuring the thickness and strength of the leaf wall.

[0029] The main and secondary keels 1 and 2 are flexibly connected to the main structure. The main and secondary keels 1 and 2 respectively transmit the stress borne by the outer and inner leaf walls 5 and 6 to the main structure through the main and secondary keels 1 and 2, forming a combination of "external curtain wall structure" and "inner curtain wall structure". A thermal insulation layer is also formed between the two curtain walls. This double curtain wall structure is an "ultra-low energy consumption building energy-saving enclosure wall" that conforms to the "four new technologies, new processes, new materials and new equipment" of building and the industrialization development direction of prefabricated buildings.

[0030] Manufacturing the energy-saving enclosure wall of this embodiment 1 includes the following steps: (1) Fixing multiple truss support members 33 to the non-removable steel template 31 by welding or riveting according to the design position, and then placing the steel mesh 32 on the truss support members 33 and welding the two together, thereby making the leaf wall non-removable template 3 for later use; (2) Assembling and connecting the upper and lower ends of the main keel 1 to the main structural beam or plate 10 respectively through right angle connectors 8 and fixing them with screws, and then installing the Class A fireproof heat insulation board 4 on the side of the main keel 1 facing the interior, thereby connecting the adjacent main keels 1. In this step, according to the wall strength design requirements, the inner sides of the adjacent main keels 1 can also be connected with keel tie members 9; (3) Filling the heat insulation core 7 between the adjacent main keels 1 and the Class A fireproof heat insulation board 4, and connecting the leaf wall of the outer leaf wall 5. (3) Install and fix the template 3 without disassembly to the main keel 1; (4) Assemble and connect the upper and lower ends of the secondary keel 2 to the main structural beam or plate 10 through right-angle connectors 8 and fix them with screws. The inner side of the secondary keel 2 and the Class A fireproof heat insulation board 4 are at least 30mm apart; (5) The inner side of the secondary keel 2 is connected through the keel tie 9. The insulation core 7 is filled and inserted between the Class A fireproof heat insulation board 4 and the keel tie 9, and between two adjacent secondary keels 2. Install and fix the template 3 of the inner leaf wall 6 without disassembly to the secondary keel 2; (6) After inspecting and correcting the template 3 of the inner and outer leaf walls 5 without disassembly, spray the leaf wall material and carry out the water hardening material construction of the leaf wall so that the concrete of the leaf wall covers the steel mesh 32 of the template 3 without disassembly. After leveling and compacting, the inner leaf wall 6 and the outer leaf wall 5 are formed. In addition, according to the wall design, pipes, wires, and boxes can be pre-embedded in step (6) before the construction of the leaf wall water hardening material is carried out. In this embodiment, the leaf wall is made of solid waste recycled concrete with a compressive strength ≥10Mpa wrapped with steel mesh. When the leaf wall hardening material is saturated, cement coarse sand mortar is added to level it and compacted and smoothed. After the inner and outer leaf wall water hardening materials have hardened, water is poured for reasonable curing for several days.

[0031] The independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall obtained in Example 1 solves the technical problems of high strength, good thermal insulation and energy-saving performance, and long service life that are not prone to cracking, thus meeting the existing building energy consumption standards. Tests have proven that the thermal transfer K-value of a wall with a total thickness of approximately 350mm can be controlled within 0.15.

[0032] Example 2: Figure 7As shown, in this embodiment, the structure of each component and the connection relationship between them are basically the same as in embodiment 1. The difference is that an A1-grade heat insulation coating layer is set on the surface of the non-removable steel formwork 31 connected to the main and secondary keels 1 and 2 to further enhance the thermal break effect. In this embodiment, the bottom of the main and secondary keels 1 and 2 is wavy to further strengthen the keel. In this embodiment, the main keel compartment near the outer leaf wall 5 is filled with two stacked non-combustible inorganic A1-grade rock wool boards according to the width of the keel, and the secondary keel compartment near the inner leaf wall 6 is also filled with two non-combustible inorganic A1-grade rock wool boards. One of them is located between the inner side of the secondary keel 2 and the A-grade fireproof heat insulation board 4 to form a thermal break layer, and the other is located inside the secondary keel 2 with the same width as the secondary keel 2.

[0033] This utility model has a low thermal heat transfer K-value, excellent heat insulation and energy-saving performance, and can meet the requirements of existing building energy consumption standards; the wall frame has high strength, and the inner and outer leaf walls independently transmit force to the main building structure, forming a double curtain wall structure with independent force transmission paths, making the wall less prone to cracking and with a long service life.

[0034] The above embodiments are only used to illustrate the technical solutions of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this utility model without departing from the spirit and scope of the technical solutions of this utility model, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. An independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall, comprising a wall frame, an insulated inner core, and leaf walls, characterized in that: It also includes a Class A fireproof and heat-insulating board. The wall frame includes two leaf wall templates that can be removed and a main keel and a secondary keel that are respectively vertically fixed to the inner side of the two leaf wall templates. The leaf wall is attached to the outer side of the leaf wall templates. The main and secondary keels are channel-shaped keels and are spaced apart in the width direction of the wall. The Class A fireproof and heat-insulating board is located between the main and secondary keels and is fixed to the main keel. The heat-insulating core is a non-combustible Class A heat-insulating material. The heat-insulating core is filled in the two compartments separated by the two leaf wall templates and the Class A fireproof and heat-insulating board. The heat-insulating core is filled in the gap between the Class A fireproof and heat-insulating board and the secondary keel to form a thermal break layer.

2. The independent keel double-bin ultra-low energy consumption building energy-saving envelope wall according to claim 1, characterized in that: The leaf wall non-removable formwork includes non-removable steel formwork, steel mesh and truss support components. Multiple truss support components connect the non-removable steel formwork and steel mesh into a sandwich structure. The non-removable steel formwork is connected to the main keel or secondary keel.

3. The independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall according to claim 2, characterized in that: The two sides of the non-removable steel formwork are connected to the non-removable steel formwork of the adjacent wall or the main structural column.

4. The independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall according to claim 2, characterized in that: The surface of the non-removable steel formwork connected to the main and secondary keels is provided with an A1 grade heat insulation coating layer.

5. The independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall according to claim 1, characterized in that: The upper and lower ends of the main keel are respectively connected to the main structural beams or slabs on the outdoor side, and the upper and lower ends of the secondary keel are respectively connected to the main structural beams or slabs on the indoor side.

6. The independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall according to claim 1, characterized in that: The Class A fireproof and heat-insulating board is an inorganic Class A1 fireproof and heat-insulating board, and there is a gap of at least 30mm between the inner side of the secondary keel and the Class A fireproof and heat-insulating board.

7. The independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall according to claim 1, characterized in that: The secondary keel is located near the interior side and its width is smaller than that of the main keel. The inner sides of each secondary keel are connected by keel tie members.

8. The independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall according to claim 1, characterized in that: The thermal insulation core is a non-combustible inorganic A1 grade rock wool board.

9. The independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall according to claim 1, characterized in that: The upper and lower ends of the main keel and the secondary keel are respectively assembled and connected to the main structural beams or plates through right-angle connectors.

10. The independent keel double-compartment ultra-low energy consumption building energy-saving enclosure wall according to claim 9, characterized in that: The right-angle connector has a strip-shaped hole on the side that connects to the main and secondary keels, and the strip-shaped hole is parallel to the length direction of the main and secondary keels.

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