A free-formwork sandwich shear wall for modular buildings

Abstract

The utility model relates to prefabricated building technical field especially relates to a kind of free formwork sandwich thermal insulation shear wall for modular building.Free formwork sandwich thermal insulation shear wall includes laminated thermal insulation outer layer, inner leaf layer and multiple pairs of pullers, and pouring cavity for pouring concrete is formed between laminated thermal insulation outer layer and inner leaf layer.Laminated thermal insulation outer layer includes outer leaf layer and thermal insulation layer fixedly connected in turn from outside to inside, one end of each pair of pullers is fixedly connected to outer leaf layer, and the other end is all inserted into pouring cavity and fixedly connected with reinforcing cage arranged in pouring cavity.Thermal insulation layer is arranged between inner leaf layer and outer leaf layer, to avoid direct exposure to external environment or stress, effectively prevent hollowing, shedding and damage, improve its impact resistance, puncture resistance and compression resistance during transportation, installation and use, can effectively prevent vacuum leakage problem.

Description

Technical Field

[0001] This utility model relates to the field of prefabricated building technology, and in particular to a formwork-free sandwich insulated shear wall for modular buildings. Background Technology

[0002] With the continuous improvement of building energy efficiency standards and fire safety requirements, the thermal performance and fire safety of building envelopes have become key considerations in engineering design and construction. Traditional organic insulation materials (such as polystyrene boards and extruded polystyrene boards) mostly have a fire performance rating of B or lower, which severely restricts their application in high-rise buildings, public buildings, and densely populated areas, posing significant fire safety hazards. To meet fire safety regulations, Class A non-combustible insulation materials are widely used in practical projects. However, while traditional Class A materials such as rock wool possess good fire resistance, they generally suffer from problems such as easy pulverization, high water absorption, and significant construction pollution.

[0003] In recent years, vacuum insulation panels, as a new type of Class A thermal insulation material, have become a potential material for high-performance building energy conservation due to their extremely low thermal conductivity, excellent thermal insulation performance, and relatively small thickness. Vacuum insulation panels consist of a core material, a gas-barrier membrane, and a getter; their excellent thermal insulation performance depends on the internal vacuum state. However, this material structure is relatively fragile. In practical engineering applications, especially during the transportation, hoisting, and on-site construction of modular integrated buildings, it is easily damaged by external forces such as tool scratches, nail punctures, and compression, leading to vacuum leakage. This results in a significant decrease in thermal insulation performance, affecting the thermal performance of the building envelope during its service life and creating potential quality hazards in the building's exterior walls.

[0004] At the same time, thermal insulation structures are developing towards high integration and factory prefabrication. Traditional on-site wet-applied thin-plaster external insulation systems have risks such as insufficient stability of materials and construction techniques, easy delamination and detachment, and poor durability. Utility Model Content

[0005] (a) Technical problems to be solved

[0006] In view of the above-mentioned shortcomings and deficiencies of the prior art, this utility model provides a formwork-free sandwich insulated shear wall for modular buildings, which solves the technical problems of vacuum insulation panels being easily damaged and delaminated during on-site construction, as well as being easily detached by external forces or environmental influences during transportation and operation.

[0007] (II) Technical Solution

[0008] To achieve the above objectives, the main technical solutions adopted by this utility model include:

[0009] This utility model provides a formwork-free sandwich insulated shear wall for modular buildings, including a composite insulation outer layer, an inner leaf layer, and multiple tie rods. A pouring cavity for pouring concrete is formed between the composite insulation outer layer and the inner leaf layer. The composite insulation outer layer includes an outer leaf layer and an insulation layer that are fixedly connected from the outside to the inside. One end of each tie rod is fixedly connected to the outer leaf layer, and the other end extends through the insulation layer and into the pouring cavity, where it is fixedly connected to a steel reinforcement skeleton set in the pouring cavity. The other end of the steel reinforcement skeleton is anchored inside the inner leaf layer.

[0010] Preferably, the tie member includes a tie bolt and a tie nut that is threadedly connected to the tie bolt; one end of the tie bolt is fixedly connected to the outer leaf layer, and the other end extends into the casting cavity, with external threads at the extended end; the tie nut is screwed onto the external threads of the tie bolt; one end of the reinforcing bar cage is anchored to the tie nut.

[0011] Preferably, the insulation layer includes multiple vacuum insulation panels arranged horizontally and vertically; gaps are left between two adjacent vacuum insulation panels, which are filled with insulation mortar to allow the tie rods to pass through; the vacuum insulation panels are fixed to the inner side of the outer leaf layer by adhesive.

[0012] Preferably, the insulation layer further includes an insulation mortar layer; the insulation mortar layer is made of insulation mortar, and the inner surface of the vacuum insulation panel is covered with insulation mortar.

[0013] Preferably, the thermal insulation mortar is a mortar made of granulated polystyrene adhesive.

[0014] Preferably, it also includes multiple anchoring components; the anchoring components include anchoring bolts, fixing nuts, fastening nuts and washers; the fixing nuts are fixedly connected to the outer leaf layer, one end of the anchoring bolt is connected to the fixing nut, and the other end of the anchoring bolt passes through the gap between two adjacent vacuum insulation panels and the insulation grout layer in sequence and is threadedly connected to the fastening nut, and the washers are disposed between the fastening nut and the inner surface of the insulation grout layer.

[0015] Preferably, the gap width between two longitudinally adjacent vacuum insulation panels is less than 30 mm, and the gap width between two transversely adjacent vacuum insulation panels is less than 5 mm.

[0016] Preferably, the outer blade layer includes an outer blade plate and a plurality of connecting steel plates fixedly connected to its inner side; the outer blade plate has through holes for the tie rods to pass through, and connecting steel plates are arranged laterally at the through holes, with the plurality of connecting steel plates arranged at intervals along the longitudinal direction of the outer blade plate.

[0017] Preferably, the casting cavity is further provided with multiple longitudinal steel bars and multiple annular stirrups; the multiple longitudinal steel bars are respectively set at both ends of the casting cavity; the multiple annular stirrups are arranged at intervals along the length direction of the longitudinal steel bars, and are sleeved on the outside of the longitudinal steel bars and fixedly connected to the longitudinal steel bars.

[0018] Preferably, the composite insulation outer layer further includes a crack-resistant layer; the crack-resistant layer is disposed on the outer surface of the outer leaf layer.

[0019] (III) Beneficial Effects

[0020] The beneficial effects of this utility model are:

[0021] This invention relates to a formwork-free sandwich insulated shear wall for modular buildings. By prefabricating the vacuum insulation layer and the outer leaf layer of the modular integrated building box-formwork system in a factory, the composite insulation outer layer functions as both the outer formwork for concrete pouring and the insulation base layer. The inner leaf layer is prefabricated in the factory and, together with the composite insulation outer layer, is quickly assembled on-site using tie rods to directly form a stable pouring cavity. This design avoids the cumbersome procedures of erecting and dismantling inner and outer formwork in traditional construction, significantly reducing on-site work and labor costs, achieving formwork-free construction, and significantly improving construction efficiency and the degree of building assembly.

[0022] The insulation layer is positioned between the inner and outer blades, preventing direct exposure to the external environment or stress, effectively preventing bulging, detachment, and damage. The insulation layer is fixedly connected to the outer blades, significantly improving its resistance to impact, puncture, and pressure loss during transportation, installation, and use. This effectively prevents vacuum leakage, ensuring long-term stable and reliable insulation performance, and thus significantly enhancing the durability and reliability of the vacuum insulation layer. Attached Figure Description

[0023] Figure 1 This is a breakdown diagram of a formwork-free sandwich insulated shear wall for modular buildings according to the present invention.

[0024] Figure 2 This is a cross-sectional schematic diagram of a formwork-free sandwich insulated shear wall for modular buildings according to the present invention.

[0025] Figure 3 for Figure 2 Enlarged view of point A in the middle;

[0026] Figure 4 This is a longitudinal sectional view of a formwork-free sandwich insulated shear wall for modular buildings according to the present invention.

[0027] Figure 5 This is a schematic diagram of the outer leaf layer.

[0028] [Explanation of Labels in the Attached Image]

[0029] 1: Composite outer insulation layer; 11: Crack-resistant layer; 12: Outer blade layer; 121: Outer blade plate; 122: Connecting steel plate; 13: Insulation layer; 131: Vacuum insulation board; 14: Insulation mortar layer;

[0030] 2: Inner leaf layer;

[0031] 3: Tie rod; 31: Tie bolt; 32: Tie nut;

[0032] 4: Anchoring assembly; 41: Anchor bolt; 42: Fixing nut; 43: Fastening nut; 44: Washer;

[0033] 5: Longitudinal reinforcement;

[0034] 6: Circular stirrups;

[0035] 7: Cast the cavity;

[0036] 8: Reinforcing steel frame. Detailed Implementation

[0037] To better explain and facilitate understanding of this utility model, the present utility model will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0038] To better understand the above technical solutions, exemplary embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present invention are shown in the drawings, it should be understood that the present invention can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the present invention can be understood more clearly and thoroughly, and that the scope of the present invention can be fully conveyed to those skilled in the art.

[0039] Example

[0040] like Figure 1 and Figure 4As shown, this embodiment provides a formwork-free sandwich insulated shear wall for modular buildings. The formwork-free sandwich insulated shear wall includes a composite insulation outer layer 1, an inner leaf layer 2, and multiple tie rods 3, wherein a pouring cavity 7 for pouring concrete is formed between the composite insulation outer layer 1 and the inner leaf layer 2. Specifically, the composite insulation outer layer 1 includes an outer leaf layer 12 and an insulation layer 13 that are fixedly connected from the outside to the inside. One end of each tie rod 3 is fixedly connected to the outer leaf layer 12, and the other end extends through the insulation layer 13 and into the pouring cavity 7, where it is fixedly connected to a steel reinforcement skeleton 8 disposed in the pouring cavity 7. The other end of the steel reinforcement skeleton 8 is anchored inside the inner leaf layer 2. By prefabricating the insulation layer 13 and the outer leaf layer 12 in the modular integrated building box formwork system in the factory, the composite insulation outer layer 1 functions as both an outer formwork for concrete pouring and an insulation base layer. The inner leaf layer 2 is prefabricated in the factory and quickly assembled on-site with the overlapping outer insulation layer 1 via tie rods 3 to directly form a stable cast-in-place cavity 7. This design avoids the cumbersome process of setting up and dismantling inner and outer formwork in traditional construction, significantly reducing on-site work and labor costs, achieving formwork-free construction, and significantly improving construction efficiency and the degree of building assembly. The insulation layer 13 is set between the inner leaf layer 2 and the outer leaf layer 12, avoiding direct exposure to the external environment or stress, effectively preventing hollowing, detachment, and damage. The insulation layer 13 is fixedly connected to the outer leaf layer 12, greatly improving its impact resistance, puncture resistance, and pressure loss resistance during transportation, installation, and use, effectively preventing vacuum leakage problems, ensuring long-term stable and reliable insulation performance, and thus significantly enhancing the durability and reliability of the vacuum insulation panel 13.

[0041] Preferably, in order to enhance the overall strength of the outer leaf layer 12, such as Figure 5 As shown, the outer leaf layer 12 includes an outer leaf plate 121 and multiple connecting steel plates 122 fixedly connected to its inner side. The outer leaf plate 121 has through holes for the tie rods 3 to pass through, and the connecting steel plates 122 are arranged laterally at the through holes. The multiple connecting steel plates 122 are arranged at intervals along the longitudinal direction of the outer leaf plate 121. The connecting steel plates 122 prevent deformation and cracking of the outer leaf plate 121, ensuring the accuracy of the wall dimensions and the flatness of the appearance. The outer leaf plate 121 can be used as a fair-faced concrete exterior finish. If required by the project, other finishing layers can be added on top of it to meet the customized needs of different projects.

[0042] like Figure 1 As shown, the insulation layer 13 includes multiple vacuum insulation panels 131 arranged horizontally and vertically. Gaps are left between adjacent vacuum insulation panels 131, which are filled with insulation mortar to allow the tie rods 3 to pass through. The vacuum insulation panels 131 are fixed to the inner side of the outer leaf layer 12 by adhesive.

[0043] It should be noted that in other embodiments, the vacuum insulation panel 131 can also be replaced with other conventional insulation materials, such as rock wool board, glass wool board or foam concrete board, to suit different cost and performance requirements.

[0044] Preferably, the gap width between two longitudinally adjacent vacuum insulation panels 131 is less than 30mm, which provides ample and precise operating space for the arrangement of the tie rods 3. The gap width between two laterally adjacent vacuum insulation panels 131 is less than 5mm, minimizing the thermal bridging effect and ensuring the continuity of the overall thermal insulation performance of the wall.

[0045] Preferably, the insulation layer 13 further includes an insulation slurry layer 14, which is made of insulation slurry, and the inner surface of the vacuum insulation panel 131 is covered with insulation slurry.

[0046] Preferably, the thermal insulation mortar is a granulated polystyrene mortar, and the thickness of the thermal insulation mortar covering the inner surface of the vacuum insulation board 131 is 5mm, which can enhance the protection of the vacuum insulation board 131.

[0047] Preferably, such as Figure 3 As shown, it also includes multiple anchoring components 4. Anchoring components 4 include anchoring bolts 41, fixing nuts 42, fastening nuts 43, and washers 44. The fixing nuts 42 are fixedly connected to the outer leaf layer 12. One end of the anchoring bolt 41 is connected to the fixing nuts 42, and the other end of the anchoring bolt 41 passes sequentially through the gap between two adjacent vacuum insulation panels 131 and the insulation mortar layer 14, and is threadedly connected to the fastening nuts 43. The washers 44 are disposed between the fastening nuts 43 and the inner surfaces of the insulation mortar layer 14. The anchoring components 4 provide secondary fixation for the vacuum insulation panels 131, effectively preventing misalignment, displacement, or detachment of the insulation mortar layer 14 and the vacuum insulation panels 131 between the inner and outer wall layers. The pre-tightening force applied by the fastening nuts 43 and washers 44 compresses each layer of material into a whole, effectively suppressing relative displacement between layers and ensuring the integrity and stability of the insulation system under long-term use. The design of the gasket 44 protects the inner surface of the insulation layer. The gasket 44 increases the contact area between the fastening nut 43 and the relatively soft inner surface of the insulation mortar layer 14, preventing the fastening nut 43 from embedding into the insulation mortar layer 14 and causing local crushing when tightened, thus ensuring the effective application of preload and the long-lasting reliability of the connection.

[0048] like Figure 2 and Figure 3As shown, the tie rod 3 includes a tie bolt 31 and a tie nut 32 threadedly connected to the tie bolt 31. One end of the tie bolt 31 is fixedly connected to the outer leaf plate 121 of the outer leaf layer 12, and the other end extends into the casting cavity 7. The extended end has an external thread, and the tie nut 32 is screwed onto the external thread of the tie bolt 31. One end of the reinforcing steel skeleton 8 is anchored to the tie nut 32. Traditional single-sided composite shear walls require on-site erection of external formwork, making it difficult to integrate the insulation and decorative structures in advance in the factory, resulting in a large amount of on-site work. The tie rod 3 in this solution provides precise formwork positioning and control functions, realizing formwork-free construction. Before concrete pouring, by tightening the tie nut 32, the distance between the composite insulation outer layer 1 and the internal reinforcing steel skeleton 8 can be precisely controlled, that is, the thickness of the casting cavity 7 can be precisely controlled. This allows the prefabricated composite insulation outer layer 1 to act as a high-quality, non-removable outer formwork, eliminating the cumbersome process of setting up and dismantling the outer formwork in traditional construction. It integrates the wall insulation and formwork functions into the factory production stage in advance, significantly improving the factory completion rate and overall assembly rate, reducing the construction cycle and labor input, greatly improving construction efficiency and reducing costs.

[0049] like Figure 2 As shown, the casting cavity 7 also contains multiple longitudinal reinforcing bars 5 and multiple annular stirrups 6. The longitudinal reinforcing bars 5 are respectively positioned at both ends of the casting cavity 7, and the annular stirrups 6 are spaced apart along the length of the longitudinal reinforcing bars 5, fitted onto the outside of the longitudinal reinforcing bars 5 and fixedly connected to them. Concentrating multiple longitudinal reinforcing bars 5 at both ends of the casting cavity 7 forms a strong edge restraint member. This structure effectively restrains the core concrete, greatly improving the compressive and bending resistance of the wall ends, giving the shear wall better ductility and energy dissipation capacity when subjected to horizontal loads such as wind loads and seismic actions, preventing brittle failure. By arranging the annular stirrups 6 at intervals along the longitudinal direction and tightening the longitudinal reinforcing bars 5, a rigid spatial grid skeleton is formed. This skeleton is not easily displaced or deformed during concrete pouring, ensuring a uniform thickness of the reinforcing bar protective layer, thereby guaranteeing the compactness of the poured concrete and the final forming quality, ensuring that the wall strength meets design requirements.

[0050] Preferably, this is to prevent surface cracking of the outer leaf layer 12 and improve the durability of the wall. For example... Figure 1 As shown, the composite insulation outer layer 1 also includes a crack-resistant layer 11, which is disposed on the outer surface of the outer leaf layer 12. Completing the construction of the crack-resistant layer 11 during the factory prefabrication stage results in significantly higher quality than on-site work, achieving optimal crack resistance. This ensures that the modular building possesses a high-performance external envelope system upon delivery, reducing the need and cost of later maintenance and improving building quality.

[0051] In the description of this utility model, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0052] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.

[0053] In this utility model, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "beneath" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0054] In the description of this specification, the terms "one embodiment," "some embodiments," "embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0055] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make modifications, alterations, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A formwork-free sandwich insulated shear wall for modular buildings, characterized in that, It includes a composite insulation outer layer (1), an inner leaf layer (2) and multiple tie rods (3), and a pouring cavity (7) for pouring concrete is formed between the composite insulation outer layer (1) and the inner leaf layer (2). The composite insulation outer layer (1) includes an outer leaf layer (12) and an insulation layer (13) that are fixedly connected from the outside to the inside. One end of each of the tie rods (3) is fixedly connected to the outer leaf layer (12), and the other end extends through the insulation layer (13) and into the casting cavity (7), and is fixedly connected to the steel reinforcement skeleton (8) provided in the casting cavity (7). The other end of the steel reinforcement skeleton (8) is anchored inside the inner leaf layer (2).

2. The formwork-free sandwich insulated shear wall for modular buildings as described in claim 1, characterized in that: The tie rod (3) includes a tie bolt (31) and a tie nut (32) threadedly connected to the tie bolt (31); One end of the tie bolt (31) is fixedly connected to the outer leaf layer (12), and the other end extends into the casting cavity (7), with external threads at the end of the extension. The pull nut (32) is screwed onto the external thread of the pull bolt (31); One end of the steel reinforcement cage (8) is anchored to the tie nut (32).

3. The formwork-free sandwich insulated shear wall for modular buildings as described in claim 1, characterized in that: The insulation layer (13) includes multiple horizontally and vertically arranged vacuum insulation panels (131). A gap is left between two adjacent vacuum insulation panels (131), which is filled with thermal insulation mortar for the tie rod (3) to pass through; The vacuum insulation panel (131) is fixed to the inner side of the outer leaf layer (12) by adhesive.

4. The formwork-free sandwich insulated shear wall for modular buildings as described in claim 3, characterized in that: The insulation layer (13) also includes an insulation slurry layer (14); The insulation slurry layer (14) is made of insulation slurry, and the inner surface of the vacuum insulation panel (131) is covered with the insulation slurry.

5. The formwork-free sandwich insulated shear wall for modular buildings as described in claim 4, characterized in that: The thermal insulation mortar is a polystyrene granule thermal insulation mortar.

6. The formwork-free sandwich insulated shear wall for modular buildings as described in claim 4, characterized in that: It also includes multiple anchoring components (4); The anchoring assembly (4) includes an anchoring bolt (41), a fixing nut (42), a fastening nut (43), and a washer (44). The fixing nut (42) is fixedly connected to the outer leaf layer (12), one end of the anchoring screw (41) is connected to the fixing nut (42), and the other end of the anchoring screw (41) passes through the gap between two adjacent vacuum insulation panels (131) and the insulation grout layer (14) and is threadedly connected to the fastening nut (43). The gasket (44) is disposed between the fastening nut (43) and the inner surface of the insulation grout layer (14).

7. The formwork-free sandwich insulated shear wall for modular buildings as described in claim 3, characterized in that: The gap width between two longitudinally adjacent vacuum insulation panels (131) is less than 30 mm, and the gap width between two transversely adjacent vacuum insulation panels (131) is less than 5 mm.

8. The formwork-free sandwich insulated shear wall for modular buildings as described in claim 1, characterized in that: The outer blade layer (12) includes an outer blade plate (121) and a plurality of connecting steel plates (122) fixedly connected to its inner side; The outer leaf plate (121) has a through hole for the tie member (3) to pass through, and the connecting steel plate (122) is arranged laterally at the through hole. Multiple connecting steel plates (122) are arranged at intervals along the longitudinal direction of the outer leaf plate (121).

9. The formwork-free sandwich insulated shear wall for modular buildings as described in claim 1, characterized in that: The casting cavity (7) is also provided with multiple longitudinal steel bars (5) and multiple annular stirrups (6). Multiple longitudinal reinforcing bars (5) are respectively disposed at both ends of the cast-in-place cavity (7); Multiple annular stirrups (6) are arranged at intervals along the length direction of the longitudinal steel bar (5), and are sleeved on the outside of the longitudinal steel bar (5) and fixedly connected to the longitudinal steel bar (5).

10. The formwork-free sandwich insulated shear wall for modular buildings as described in claim 1, characterized in that: The composite insulation outer layer (1) also includes a crack-resistant layer (11); The crack-resistant layer (11) is disposed on the outer surface of the outer leaf layer (12).

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