Foamed ceramic wallboard reinforced load bearing structure
By setting UHPC reinforcing holes and surface reinforcing layers inside the foamed ceramic wall panel, combined with the reinforcing skeleton, a three-dimensional stress system is formed, which solves the problem of insufficient mechanical properties of foamed ceramic wall panels, improves the structure's compressive, bending and crack resistance, and maintains good thermal insulation and sound insulation performance, making it suitable for prefabricated buildings.
Patent Information
- Application Number
- CN202522143585.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-10
- Publication Date
- 2026-08-25
- Estimated Expiration
- 2035-10-10
AI Technical Summary
Foamed ceramic wall panels have weak mechanical properties and are prone to cracking, making them unsuitable for bearing large loads or impacts on their own. Existing reinforcement methods suffer from problems such as interface delamination, complex structure, and inconvenient construction.
Horizontal and vertical UHPC reinforcing holes are set inside the foamed ceramic wall panel, filled with high-strength and high-ductility concrete, and a reinforcing layer is set on the surface to form a three-dimensional synergistic stress system. Combined with the reinforcing skeleton, the material filled in the reinforcing holes is the same as the material of the surface reinforcing layer, forming an overall stress system.
It significantly improves the wall panel's resistance to compression, bending, and cracking, while retaining good thermal insulation, heat insulation, and sound insulation properties. It is suitable for interior and exterior partitions in prefabricated buildings, achieving the goals of lightweighting and green environmental protection.
Smart Images
Figure CN224679187U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of building wall technology, and in particular to a foamed ceramic wall panel reinforced load-bearing structure. Background Technology
[0002] With the promotion of prefabricated and green building concepts, lightweight, high-strength, and environmentally friendly building wall panels are gradually replacing traditional solid concrete or brick masonry wall panels. Foamed ceramic wall panels, as a new type of wall material with comprehensive properties such as lightweight, heat insulation, sound insulation, and fire resistance, are receiving increasing attention.
[0003] However, foamed ceramic materials have weak mechanical properties, are prone to brittleness, and are not suitable for bearing large loads or impacts alone. In practical engineering, they are mostly used for non-load-bearing partitions or external wall insulation layers. To improve their structural strength, composite reinforcement methods are often used, such as external steel mesh or reinforcement layers, but problems such as interface delamination, complex structure, and inconvenient construction still exist.
[0004] To expand its structural applications, a structural enhancement scheme needs to be developed that can significantly improve its overall mechanical properties and structural stability while retaining the advantages of foamed ceramics. Utility Model Content
[0005] In the prior art, foamed ceramic materials are not suitable for bearing large loads or impacts on their own, and methods to improve their structural strength have problems such as interface delamination, complex structure, and inconvenient construction. Therefore, this utility model provides a foamed ceramic wall panel reinforced load-bearing structure to solve the above problems.
[0006] This utility model provides a reinforced load-bearing structure for foamed ceramic wall panels, comprising: The wall panel body is a foamed ceramic wall panel. The reinforcing holes include multiple sets of transverse UHPC reinforcing holes and / or vertical UHPC reinforcing holes, which are uniformly or differentially distributed in three dimensions inside the wall panel body. The reinforcing holes are filled with reinforcing materials with a strength higher than that of the wall panel body. Reinforcing material is disposed inside the reinforcing hole; The surface reinforcement layer includes a first surface reinforcement layer and a second surface reinforcement layer, which are located on two pairs of opposite surfaces of the wall panel body, respectively.
[0007] In one implementation, the reinforcing material filling the reinforcing pores includes high-strength, high-ductility concrete, i.e., UHPC.
[0008] In one implementation, the surface reinforcement layer material is the same as the reinforcement material used to fill the reinforcement holes.
[0009] In one implementation, the transverse UHPC reinforcing holes are evenly arranged in the vertical cross-section of the wall panel body, and extend to both sides of the transverse UHPC reinforcing holes to the outer surface of the wall panel body, so that the reinforcing material filled in the transverse UHPC reinforcing holes is integrated with the first surface reinforcement layer or the second surface reinforcement layer to form a continuous reinforcement structure.
[0010] In one implementation, the vertical UHPC reinforcing holes are evenly arranged in the horizontal cross-section of the wall panel body, and the length of the vertical UHPC reinforcing holes is consistent with the height of the wall panel body.
[0011] In one implementation, the reinforcing hole is circular, elliptical, or other non-circular cross-sectional shape.
[0012] In one implementation, the edge of the wall panel body is pre-set with grouting holes or connecting grooves.
[0013] In one implementation, the reinforcing material is one of steel bars, basalt reinforcement connectors, or thermal break connectors.
[0014] In one implementation, the surface reinforcement layer is formed by one of the following methods: integral molding, integral casting, or spray molding.
[0015] Beneficial effects: The foamed ceramic wall panel reinforced load-bearing structure provided in this utility model uses foamed ceramic wall panels as the main body of the wall structure. By uniformly filling the reinforcing holes inside the foamed ceramic wall panel with reinforcing material and setting a stiffening skeleton, a three-dimensional synergistic load-bearing system is formed in combination with the surface reinforcement layer set on the outside. This significantly improves the compressive, bending and crack resistance of the wall panel structure, while also having good thermal insulation, heat insulation and sound insulation performance, achieving the goals of lightweight and green environmental protection. It is suitable for the interior and exterior partition walls of prefabricated buildings. Attached Figure Description
[0016] Figure 1 This is a front view of the transverse perforated structure of the reinforced load-bearing structure of the foamed ceramic wall panel provided by this utility model; Figure 2 This is a front view of the vertical hole structure of the reinforced load-bearing structure of the foamed ceramic wall panel provided by this utility model; Figure 3 This is a cross-sectional view of the transverse holes in the reinforced load-bearing structure of the foamed ceramic wall panel provided by this utility model; Figure 4 This is a sectional view of the vertical holes in the reinforced load-bearing structure of the foamed ceramic wall panel provided by this utility model; Figure 5 This is a schematic diagram of the three-dimensional structure of the transverse holes in the reinforced load-bearing structure of the foamed ceramic wall panel provided by this utility model; Figure 6This is a schematic diagram of the vertical hole three-dimensional structure of the reinforced load-bearing structure of the foamed ceramic wall panel provided by this utility model; The labels in the diagram represent the following: 1. Foamed ceramic wall panel; 2. Horizontal UHPC reinforcing holes; 3. Vertical UHPC reinforcing holes; 4. First surface reinforcing layer; 5. Second surface reinforcing layer; 6. Reinforcing material.
[0017] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation
[0018] It should be understood that the specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention.
[0019] Those skilled in the art will understand that, unless specifically stated otherwise, the singular forms “a,” “an,” “the,” “the,” “the,” and “the” used herein may also include the plural forms. It should be further understood that the term “comprising” as used in this specification means the presence of the stated features, integers, steps, operations, elements, units, modules, and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, units, modules, components, and / or groups thereof. It should be understood that when we say an element is “connected” or “coupled” to another element, it can be directly connected or coupled to the other element, or there may be intermediate elements. Furthermore, “connected” or “coupled” as used herein can include wireless connection or wireless coupling. The term “and / or” as used herein includes all or any units and all combinations of one or more associated listed items.
[0020] It will be understood by those skilled in the art that, unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. It should also be understood that terms such as those defined in general dictionaries should be understood to have the same meaning as in the context of the prior art, and should not be interpreted in an idealized or overly formal sense unless specifically defined as herein.
[0021] See also Figures 1-6 , Figure 1 This is a front view of the transverse perforated structure of the reinforced load-bearing structure of the foamed ceramic wall panel provided by this utility model. Figure 2 This is a front view of the vertical perforation structure of the foamed ceramic wall panel reinforcement structure provided by this utility model. Figure 3 This is a cross-sectional view of the transverse holes in the reinforced load-bearing structure of the foamed ceramic wall panel provided by this utility model. Figure 4This is a sectional view of the vertical holes in the reinforced load-bearing structure of the foamed ceramic wall panel provided by this utility model. Figure 5 This is a schematic diagram of the three-dimensional structure of the transverse holes in the reinforced load-bearing structure of the foamed ceramic wall panel provided by this utility model. Figure 6 This is a three-dimensional structural diagram of the vertical holes in the reinforced load-bearing structure of the foamed ceramic wall panel provided by this utility model. In a specific embodiment, the horizontal holes refer to the horizontal UHPC reinforcing holes 2, and the vertical holes refer to the vertical UHPC reinforcing holes 3.
[0022] This utility model provides a reinforced load-bearing structure for foamed ceramic wall panels, comprising: The wall panel body is a foamed ceramic wall panel 1; The reinforcing holes, including multiple sets of transverse UHPC reinforcing holes 2 and / or vertical UHPC reinforcing holes 3, are three-dimensionally uniformly or differentially distributed inside the wall panel body. The reinforcing holes are filled with reinforcing materials with a strength higher than that of the wall panel body, which are used to enhance the structural integrity of the wall, improve its load-bearing capacity, improve its seismic performance, and ensure stability under various loads. Among them, the reinforcing material filling the reinforcing holes includes high-strength and high-ductility concrete. This material is known for its excellent mechanical properties and durability, and can effectively fill the reinforcing holes, work together with the wall panel body, and provide additional strength and toughness. Reinforcing member 6 is disposed inside the reinforcing hole to strengthen the skeleton; The surface reinforcement layer includes a first surface reinforcement layer 4 and a second surface reinforcement layer 5, which are respectively located on two pairs of opposite surfaces of the wall panel body. The surface reinforcement layer and the wall panel body together form an integral load-bearing system. The material of the surface reinforcement layer is the same as the material of the reinforcement material filling the reinforcement holes. This helps to achieve seamless bonding between materials, enhances interfacial adhesion, prevents delamination or cracking, and thus improves the durability and safety of the overall structure.
[0023] The wall panel body is selected as foamed ceramic wall panel 1, which ensures lightweight and thermal insulation functions. Furthermore, the edges of the wall panel body can be pre-set with grouting holes or connecting grooves, facilitating the assembly and connection of the foamed ceramic wall panel to reinforce the load-bearing structure. This allows for industrial prefabrication and rapid on-site installation, making it suitable for prefabricated building systems. The foamed ceramic wall panel 1 has excellent thermal insulation, heat insulation, and sound insulation properties. Its thermal insulation performance effectively blocks the transfer of indoor and outdoor temperatures, stabilizing the indoor temperature, reducing the use of air conditioning and heating, lowering energy consumption, and helping to reduce carbon emissions, aligning with green building principles. Its heat insulation performance prevents the intrusion of external heat or the loss of indoor cool air, improving living comfort, especially important under distinct seasons or extreme climate conditions. Its sound insulation performance reduces external noise interference, such as traffic and construction noise, creating a quiet living environment for residents and contributing to improved sleep quality and overall quality of life.
[0024] Furthermore, the reinforcing holes are circular, elliptical, or other non-circular cross-sectional shapes. The vertical UHPC reinforcing holes 3 are uniformly arranged in the horizontal cross-section of the wall panel body, and the length of the vertical UHPC reinforcing holes 3 is consistent with the height of the wall panel body, so that the reinforcing material filled in the vertical UHPC reinforcing holes 3 can provide full-height support, enhance the vertical stiffness and compressive strength of the wall panel, and effectively resist vertical loads. The horizontal UHPC reinforcing holes 2 are uniformly arranged in the vertical cross-section of the wall panel body; the horizontal UHPC reinforcing holes 2 extend to both sides to the outer surface of the wall panel body. In a specific embodiment, the length of the horizontal UHPC reinforcing holes 2 is consistent with the thickness of the wall panel body, so that the reinforcing material filled in the horizontal UHPC reinforcing holes 2 is integrated with the first surface reinforcement layer 4 or the second surface reinforcement layer 5 to form a continuous reinforcement structure, ensuring that the load can be evenly distributed. The reinforcing pores are filled with high-strength, high-ductility concrete, abbreviated as UHPC (Ultra-High Performance Concrete). As a new generation of building materials that emerged in the late 20th century, it possesses excellent properties such as ultra-high strength, high toughness, and high durability. In other embodiments, reactive powder concrete (RPC) can also be used. Compared with ordinary cement-based materials, UHPC exhibits better compressive strength, tensile strength, flexural strength, and impact resistance.
[0025] Each reinforcing hole is equipped with a reinforcing bar 6, which can be one of the following: steel reinforcement, basalt fiber reinforcement connector, or thermal break connector. These connectors have high tensile strength and corrosion resistance, and can bond well with concrete, further improving the ductility and overall stability of the structure. In other words, the reinforcing bar 6 is used to enhance ductility and integrity. Steel reinforcement, as a widely used reinforcing material, is known for its high tensile strength, good toughness, and excellent bonding performance with concrete. It can effectively bear and transfer loads, enhance the bending, shear, and crack resistance of components, and improve the overall durability and seismic performance of the structure. Basalt fiber reinforcement connectors are made of basalt fiber composite materials, which are lightweight, high-strength, corrosion-resistant, and fatigue-resistant. They are suitable for corrosive environments or situations requiring weight reduction, significantly improving the dynamic response and long-term stability of the structure and reducing maintenance needs. Thermal break connectors are designed with thermal insulation materials to interrupt the thermal bridge effect, reduce energy loss, and provide reliable mechanical connections, enhancing the thermal insulation performance and thermal efficiency of the wall. They are suitable for energy-efficient buildings and can improve overall comfort and sustainability. Furthermore, the length direction of the reinforcing member 6 is aligned with the direction of the reinforcing hole. In this embodiment, the reinforcing member 6 within the reinforcing hole forms a truss structure to improve the ductility, bending resistance, and crack resistance of the wall panel. The UHPC reinforcing hole and the reinforcing member 6 together form a reinforcing skeleton, significantly improving the compressive, bending, and impact resistance.
[0026] In other embodiments, the reinforcing holes may also include obliquely arranged UHPC reinforcing holes, which together with the transverse and vertical UHPC reinforcing holes form a three-dimensional cross-distributed spatial reinforcement network structure to improve the shear resistance and seismic performance of the wall panel.
[0027] Specifically, a surface reinforcement layer is provided on the surface of the wall panel body. This surface reinforcement layer is made of UHPC material, i.e., high-strength, high-ductility concrete, to improve the compressive strength, impact resistance, and vertical stability of the wall panel. Further, a first surface reinforcement layer 4 is provided on both sides of the wall panel body along its length to increase compressive strength and impact resistance; a second surface reinforcement layer 5 is provided on both sides of the wall panel body along its width to increase the vertical stability of the wall panel structure. The surface reinforcement layer is formed using one of the following methods: integral molding, integral casting, or spray molding, making it integrally formed with the wall panel body, eliminating secondary construction steps, improving interface bonding strength and construction efficiency, and reducing construction difficulty and cost. In other embodiments, the surface reinforcement layer and the wall panel body can also be bonded together with mortar. Furthermore, the material of the surface reinforcement layer is consistent with the material used to fill the reinforcing holes, forming an integrated load-bearing system and avoiding interface weakening problems. This utility model combines foamed ceramics to ensure lightweight and thermal insulation functions, and UHPC reinforcement to achieve structural load-bearing function, balancing functionality and safety.
[0028] The method for preparing the reinforced load-bearing structure of the foamed ceramic wall panel of this utility model includes the following specific steps: Step S1: Based on the dimensions and reinforcement hole layout of the foamed ceramic wall panel 1, a wall panel mold is made, and a positioning component for forming the horizontal UHPC reinforcement hole 2 and / or vertical UHPC reinforcement hole 3 is set in the mold; Step S2: Embed the reinforcing material 6 in the hole position of the pre-set reinforcing hole in the mold to form a three-dimensional mesh-like reinforcing structure; Step S3: Pour foamed ceramic slurry into the mold, and after curing, form the wall panel body with the reinforcing holes; Step S4: Inject high-strength, high-ductility concrete, i.e., UHPC material, into the reinforcing holes to complete the internal reinforcement system; Step S5: Spray, mold, or continue to pour high-strength, high-ductility concrete, i.e., UHPC material, onto two pairs of opposite surfaces of the wall panel body to form a surface reinforcement layer integrated with the internal reinforcement structure. Step S6: After the overall structure has been cured to the required standard, the wall panel is demolded, and the wall panel preparation is completed.
[0029] The positioning components used to form the transverse UHPC reinforcing holes 2 and / or the vertical UHPC reinforcing holes 3 can be detachable metal or plastic mandrels, embedded sleeves, etc. These structures maintain the shape and positional accuracy of the holes during the pouring of the foamed ceramic slurry and are removed after the slurry has initially cured, thus leaving precise reinforcing hole channels in the wall panel body. This method ensures that the three-dimensional distribution of the reinforcing holes meets design requirements, provides accurate cavities for subsequent high-performance concrete pouring and reinforcement arrangement, and guarantees the integrity and mechanical reliability of the final composite structure.
[0030] Example 1 Prepare an exterior wall panel with dimensions of 3000mm × 600mm × 120mm: The wall panel body has a dry density of 600 kg / m³. 3 Foamed ceramic materials; The reinforcing holes are circular holes with a diameter of 25mm, arranged in a grid pattern with 5 rows horizontally and 8 rows vertically. Insert an 8mm threaded steel bar into each hole; The reinforced pore-filled UHPC has a compressive strength greater than 120MPa. A 10mm thick UHPC layer is sprayed onto the outer surface of the wall panel body as a surface reinforcement layer to obtain the required foamed ceramic wall panel reinforcement structure.
[0031] In summary, this invention forms an integrated load-bearing system by incorporating horizontally or vertically uniformly distributed reinforcing holes within a lightweight foamed ceramic wall panel 1, with the holes filled with UHPC material of the same composition as the surface reinforcement layer. The foamed ceramic acts as a lightweight core material, providing thermal insulation, fire resistance, and weight reduction. The UHPC filling the reinforcing holes constitutes a three-dimensional spatial skeleton, significantly improving the wall's compressive, shear, and bending resistance. Embedded reinforcing materials 6 further enhance tensile and seismic resistance. The surface reinforcement layer, made of the same material as the reinforcing holes, forms a shell-core synergistic structure with the wall body, jointly bearing external loads and inhibiting crack propagation. The foamed ceramic panel undergoes surface reinforcement via UPHC, altering its surface brittleness and increasing its surface compressive strength. The reinforcing material filling the reinforcing holes and the surface reinforcement layer use high-strength, high-ductility concrete (UHPC) of the same composition, avoiding interface stress concentration, improving overall integrity, and creating a uniform load-bearing path with excellent load-bearing capacity, ductility, and crack resistance. The foamed ceramic wall panel provided by this utility model has a reinforced load-bearing structure that significantly improves the compressive, bending and crack resistance of the wall panel structure. At the same time, it has good thermal insulation, heat insulation and sound insulation properties, achieving the goals of lightweight and green environmental protection. It is suitable for interior and exterior partition walls of prefabricated buildings.
[0032] The above description is only a preferred embodiment of the present utility model and does not limit the patent scope of the present utility model. Any equivalent structural or procedural transformations made based on the content of the present utility model specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present utility model.
Claims
1. A reinforced load-bearing structure for foamed ceramic wall panels, characterized in that, include: The wall panel body is a foamed ceramic wall panel (1). The reinforcing holes include multiple sets of transverse UHPC reinforcing holes (2) and / or vertical UHPC reinforcing holes (3), which are uniformly or differentially distributed in three dimensions inside the wall panel body. The reinforcing holes are filled with reinforcing materials with a strength higher than that of the wall panel body. The reinforcing bar (6) is disposed inside the reinforcing hole; The surface reinforcement layer includes a first surface reinforcement layer (4) and a second surface reinforcement layer (5), which are located on two pairs of opposite surfaces of the wall panel body, respectively.
2. The foamed ceramic wall panel reinforced load-bearing structure according to claim 1, characterized in that, The reinforcing material filling the reinforcing holes includes high-strength, high-ductility concrete.
3. The foamed ceramic wall panel reinforced load-bearing structure according to claim 1, characterized in that, The surface reinforcement layer is made of the same material as the reinforcement material used to fill the reinforcement holes.
4. The foamed ceramic wall panel reinforced load-bearing structure according to claim 1, characterized in that, The transverse UHPC reinforcing holes (2) are evenly arranged in the vertical section of the wall panel body. The transverse UHPC reinforcing holes (2) extend to both sides to the outer surface of the wall panel body, so that the reinforcing material filled in the transverse UHPC reinforcing holes (2) is integrated with the first surface reinforcement layer (4) or the second surface reinforcement layer (5) to form a continuous reinforcement structure.
5. The foamed ceramic wall panel reinforced load-bearing structure according to claim 1, characterized in that, The vertical UHPC reinforcing holes (3) are evenly arranged in the horizontal section of the wall panel body, and the length of the vertical UHPC reinforcing holes (3) is consistent with the height of the wall panel body.
6. The reinforced load-bearing structure of the foamed ceramic wall panel according to claim 1, characterized in that, The reinforcing holes are circular, elliptical, or other non-circular cross-sectional shapes.
7. The foamed ceramic wall panel reinforced load-bearing structure according to claim 1, characterized in that, The edge of the wall panel body is pre-set with grouting holes or connecting grooves.
8. The reinforced load-bearing structure of the foamed ceramic wall panel according to claim 1, characterized in that, The reinforcing material (6) is one of the following: steel bar, basalt reinforcement connector, or thermal break connector.
9. The foamed ceramic wall panel reinforced load-bearing structure according to claim 1, characterized in that, The surface reinforcement layer is formed by one of the following methods: integral molding, integral casting, or spray molding.