Ultra-light fabricated wallboard based on multilayer composite strengthening method and preparation method therefor

Abstract

An ultra-light fabricated wallboard based on a multilayer composite strengthening method and a preparation method therefor. The wallboard comprises a frame, a wall core, and surface layers, wherein the frame comprises a right side frame, a left side frame, and a bottom frame having a groove, and a light three-dimensional fiber mesh is attached to the inner side of the frame; the surface layers are located on the front surface layer and the rear surface layer of the front and rear surfaces of a wall body, and a tightly pressed corner strengthening layer is formed at the lower part of the wall body; the whole light three-dimensional fiber mesh is attached to the inner sides of the front surface layer and the rear surface layer; the surface layers and the frame define an inner space for accommodating the wall core; the wall core is formed by filling an enclosure structure with a foam concrete core material to which ultra-light particles are fully mixed; and solidification maintenance is conducted to finally form the wallboard. In this way, according to the present invention, the wallboard has a light weight, the bearing performance is improved, sound insulation and noise reduction, waterproof and moisture-proof, fire-resistant and corrosion-resistant, and facing functions are achieved, the board body has a light weight and high strength, rapid assembly can be achieved, and the wallboard is wide and convenient to apply.

Description

Ultra-light assembled wall panel based on multi-layer composite reinforcement method and preparation method thereof Technical Field

[0001] The present invention relates to the field of construction engineering, and in particular to an ultra-light assembled wall panel based on a multi-layer composite reinforcement method and a preparation method thereof. The ultra-light assembled wall panel is suitable for the construction of assembled walls of buildings in various professional fields that have requirements for sound insulation and noise reduction, waterproofing and moisture-proofing, fire resistance, air pressure resistance and corrosion resistance, and at the same time require the panel to be light in weight, high in strength and can be quickly assembled. Background Art

[0002] Building walls are an important component of all types of construction projects. Traditional Chinese ground buildings mostly use block masonry to build walls. With the development of building structure and building material technology, various ground building technologies and building structure types based on concrete structures have continued to develop, and the construction methods of building walls have also changed accordingly. In addition to traditional masonry walls, various cast-in-place and prefabricated load-bearing walls based on concrete structures, non-load-bearing partition walls prefabricated in factories with lightweight building materials and then transported to the site for installation and construction, and partition walls constructed on-site using light steel keels and panel materials have all been used. Among them, the application of prefabricated walls has shown outstanding advantages over traditional masonry construction methods in terms of project quality, construction efficiency, and labor quantity.

[0003] A certain number of station equipment and management function rooms need to be set up inside urban rail transit stations. The equipment and management room area of ​​each station is about 3000~3500m 2 These rooms are generally single-story, with a total wall area of ​​approximately 11,000 to 15,000 m 2 Up to now, most of the walls of the equipment and management rooms inside the station are constructed using the traditional manual masonry method.

[0004] Due to the construction schedule, the large-scale wall construction required a large number of workers to construct the station's internal rooms. In addition, the traditional wall construction process was complicated, and the labor intensity per unit time was high, resulting in low actual wall construction quality and efficiency.

[0005] Another factor constrained by the construction period is that the internal station building construction process usually needs to be carried out simultaneously with the installation of some station building equipment, resulting in intensive multi-disciplinary cross-operations on site, difficult construction management, and further reduced construction efficiency; and the internal space of the subway station is closed, the construction environment is poor, the noise is loud, and there is a lot of construction dust. In addition to resulting in a relatively poor working environment, the equipment installed in advance is also seriously affected by the dust, and the failure rate increases.

[0006] To address these issues, ground-based prefabricated wall technology was introduced in subway station interior construction. Traditional representative prefabricated wall panels include ALC wall panels, foamed ceramic wall panels, and space panels. These wall panels can meet the construction requirements of subway station interiors to varying degrees. However, during implementation, the following issues arose and require improvement:

[0007] (1) Due to the use of a relatively single lightweight material, the strength of the wall panels is relatively weakened. In particular, the wall panels made of a single lightweight material are prone to local bumps and falls in the joint area during the splicing process, affecting the assembly accuracy and quality of the wall panels.

[0008] (2) Due to the poor splicing effect of the wall panels, the joints cannot be connected with high precision. Therefore, after the wall panels are spliced, a series of post-processing must be carried out on the wall panel joints (such as applying adhesive between the joints; or applying cast-in-place strips to improve the connection performance between the joints; or after the wall panels are spliced, the entire wall is subjected to integrated surface decoration treatment such as patching, meshing or hanging mesh to prevent the wall from cracking). Even if the above measures are taken, the reciprocating track wind pressure and train micro-vibration generated by the back-and-forth movement of trains in the closed environment of the subway station on the walls of the internal rooms can easily cause varying degrees of cracking in the wall panels and their joints, resulting in unsatisfactory actual construction results.

[0009] (3) In order to improve the strength and assembly accuracy of the wall panels, ribs are set on the wall and steel frames are set on the edges of the wall panels. This improves the strength of the wall panels, but it still causes deformation and corrosion of the frames during the assembly process. At the same time, the weight of the panels increases, and the construction difficulty increases;

[0010] (4) In addition, after the wall is assembled, multiple finishing processes will take up a lot of manpower and construction time resources. At the same time, the dust pollution generated will still have an adverse impact on the construction environment and high-precision equipment.

[0011] In summary, the main issues with prefabricated wall panels currently used in subway station interiors include a simple structure, low overall panel strength, difficulty controlling joint precision, and poor assembly quality. Furthermore, secondary construction leads to low construction efficiency and quality, and construction dust pollution that impacts the construction environment and equipment operation. To address these shortcomings, the designers of this invention, through dedicated research and design, and integrating years of experience and achievements in related industries, have developed an ultra-light prefabricated wall panel with a multi-layer composite reinforcement method and its preparation method to overcome these drawbacks.

[0012] Summary of the Invention

[0013] The purpose of the present invention is to provide an ultra-light assembled wall panel with a multi-layer composite reinforcement method and a preparation method thereof, which can effectively overcome many defects of the existing technology, meet the lightweight requirements of the wall panel, realize multi-layer reinforcement protection of the wall, and at the same time have the advantages of thermal insulation, sound insulation and noise reduction, waterproof and moisture-proof, fire resistance and corrosion resistance, and integrated finishing.

[0014] To achieve the above-mentioned purpose, the present invention discloses an ultra-light assembled wall panel based on a multi-layer composite reinforcement method, comprising three parts: a frame, a wall core, and a surface layer, characterized in that:

[0015] The frame is arranged at four surrounding positions, and includes a right side frame, a left side frame and a bottom frame with grooves, and the right side frame, the left side frame and the bottom frame are made of active powder concrete to form an outer frame load-bearing structure of the composite wall panel, wherein a lightweight three-dimensional fiber mesh is attached to the inner side of the frame, and the surface layer is located at the front layer and the back layer of the front and back surfaces of the wall, and a tightly stacked corner reinforcement layer is formed at the lower part of the wall, and the inner side of the front layer and the back layer is attached with a whole surface of lightweight three-dimensional fiber mesh, and the surface layer and the frame are enclosed to form an internal space for accommodating the wall core, and the wall core includes a lightweight three-dimensional mesh structure, which is reinforced with a lightweight three-dimensional fiber mesh and filled with foam concrete core material, and the lightweight three-dimensional fiber mesh structure is inserted into the space formed by the enclosed structure, and the foam concrete core material that has been fully mixed with ultra-light particles is filled into the enclosed structure, and solidified and cured to finally form a wall panel.

[0016] Among them: the ultra-light particles have microwave hot-melt properties. After microwave hot-melt treatment, the ultra-light particles melt into liquid. The liquid material formed by the hot-melt treatment of the ultra-light particles is coated on the hole wall of the internal cavity originally occupied by the ultra-light particles. After the liquid material solidifies again, it finally forms an ultra-light particle hot-melt reinforced bubble wall film inside the wall.

[0017] Wherein: the foam concrete core material satisfies the following formula (1):

[0018] V - total volume of wall core filling;

[0019] V1 – ultralight particle filling volume;

[0020] V2——the volume of original foam concrete before foaming;

[0021] δ0——original foaming rate of foam concrete;

[0022] β——Volume occupancy ratio of ultralight particles.

[0023] Also disclosed is a method for preparing an ultra-light assembled wall panel based on a multi-layer composite reinforcement method, which is characterized by comprising the following specific steps:

[0024] Step 1: Place the bottom frame template, left frame template and right frame template flat;

[0025] Step 2: injecting active powder concrete into the bottom frame formwork, the left frame formwork and the right frame formwork respectively to form an unsolidified bottom frame, a left frame and a right frame;

[0026] Step 3: Then press the multi-layer narrow lightweight three-dimensional fiber mesh into the unsolidified bottom frame, left frame and right frame respectively, and solidify them through curing;

[0027] Step 4: placing the bottom frame with the narrow strips of lightweight three-dimensional fiber mesh implanted into the surface layer preparation device;

[0028] Step 5: On the front layer template, the back layer template and the bottom frame surface of the surface layer preparation device, continuously spray the front layer and the back layer and keep them in an unsolidified state;

[0029] Step 6: Press multiple layers of wide and lightweight three-dimensional fiber mesh into the unsolidified front layer and back layer respectively;

[0030] Step 7: Under the set control time, that is, when the front layer and the back layer gradually change from liquid to solid but are not completely solidified, the front layer template and the back layer template in the surface layer template device are rotated 90 degrees around the connecting axis and then rotated from horizontal to vertical to form the corner reinforcement area at the bottom of the front and back layers of the wall panel;

[0031] Step 8: After the front and back layers are completely solidified, mold the left frame, right frame and bottom frame together with the front and back layers;

[0032] Step 9: Pour the foamed concrete containing ultra-light particles into the space formed by the mold;

[0033] Step 10: After the wall core reaches the age, demoulding and curing are carried out to gradually form the wallboard without microwave heat melting treatment;

[0034] Step 11: Send the wall panel into the microwave device to perform heat melting treatment on the ultralight particles in the wall panel, so that they soften into liquid when heated and adhere to the internal cavity wall formed by the ultralight particles. According to the strength requirements, the panel body is cyclically flipped and heated in a microwave hot melting manner, so that the ultralight particle melt softened by heat is fully coated on the internal cavity wall, thereby forming a layer of ultralight particle hot melt reinforced cavity membrane on the internal cavity wall, and finally forming an ultralight prefabricated wall panel based on the multi-layer reinforcement method.

[0035] Wherein: in the eighth step, the multi-layer wide lightweight three-dimensional mesh and the multi-layer narrow lightweight three-dimensional mesh are connected.

[0036] Among them: the wall is further reinforced, and multiple layers of additional wide and lightweight three-dimensional nets are added in the space formed by the mold closing.

[0037] Among them: in the tenth step, active powder concrete is used to cast the top frame.

[0038] From the above content, it can be seen that the ultra-light assembled wallboard of the multi-layer composite reinforcement method of the present invention and the preparation method thereof have the following effects:

[0039] 1. Ultra-light particles are used as lightweight aggregate for the main concrete of the wall panel. Microwave hot-melt technology is used to hot-melt the ultra-light particles in the formed wall panel. By flipping the panel, the ultra-light particles are hot-melted to form a strengthening membrane that is fully attached to the concrete pore wall, thereby improving the structural strength of the wall. These multiple strengthening measures include structural frame strengthening with reactive powder concrete as the wall frame, reinforcement of the entire wall with multi-layer lightweight three-dimensional mesh, strengthening of the wall corners formed by mechanical extrusion and accumulation, and internal strengthening of the wall by forming a strengthening membrane on the internal pore wall of the wall with microwave hot-melt ultra-light particles.

[0040] 2. Customizable to underground station construction requirements: The height can be set from the assembly floor to the ceiling, or even below. The width can be modularized based on transportation, lifting, weight, and installation difficulty. The wall panels are framed with reactive powder concrete, forming the load-bearing structure. The walls utilize a lightweight three-dimensional mesh (reinforced structure). The interior of the walls is filled with foam concrete mixed with ultra-light particles; the ultra-light particles are microwave-meltable.

[0041] The details of the present invention can be found in the following description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] FIG1 shows a schematic diagram of an ultra-light assembled wall panel using the multi-layer composite reinforcement method of the present invention.

[0043] FIG2A shows a partially enlarged schematic diagram of A in FIG1 .

[0044] FIG2B shows a partially enlarged schematic diagram of B in FIG2A .

[0045] FIG3 is a schematic diagram showing the relationship between the space occupancy ratio of ultralight particles and the thickness of the foam wall in the present invention.

[0046] FIG4 shows a schematic diagram of the wall corner reinforcement treatment according to the present invention. DETAILED DESCRIPTION

[0047] 1 to 4 , which show the ultra-light assembled wallboard with a multi-layer composite reinforcement method according to the present invention and the method for preparing the same.

[0048] Among them, as shown in Figure 1, the ultra-light prefabricated wall panel structure of the multi-layer composite reinforcement method of the present invention includes three major parts: a frame, a wall core and a surface layer; the frame is arranged at the four sides, and includes a right side frame 4 with concave and convex tongue and groove, a left side frame 5 and a bottom frame 6 with grooves, and a removable top frame 21 can also be provided as needed. The right side frame 4, the left side frame 5 and the bottom frame 6 are made of reactive powder concrete 23 (RPC concrete) to form the outer frame load-bearing structure of the composite wall panel, wherein the inner side of the frame (the side close to the wall core) can also be attached with a lightweight three-dimensional fiber mesh. Specifically, the right side frame 4, the left side frame 5 and the bottom frame 6 close to the wall core can be implanted with a lightweight three-dimensional fiber mesh when casting the right side frame 4, the left side frame 5 and the bottom frame 6.

[0049] The surface layer is located at the front layer 10 and the back layer 11 on the front and rear surfaces of the wall core, and a tightly stacked corner reinforcement layer 17 is formed at the lower part of the wall. The front layer 10 and the back layer 11 can use the same foam concrete material as the wall core (modified inorganic materials with high adhesion or other reinforcement materials with high adhesion can also be used). The inner side of the front layer 10 and the back layer 11 (the side close to the wall core) is attached with a lightweight three-dimensional fiber mesh on the entire surface. The lightweight three-dimensional fiber mesh is implanted when pouring the front layer 10 and the back layer 11 to form a composite board surface layer load-bearing structure.

[0050] The surface layer and the frame together form an internal space for accommodating the wall core, and the wall core includes a lightweight three-dimensional mesh structure 13, which is reinforced with a lightweight three-dimensional fiber mesh and filled with a foam concrete core material 2 (the lightweight three-dimensional fiber mesh structure 13 is placed in the space formed by the enclosing structure, and the foam concrete core material 2 that has been fully mixed with ultra-light particles 1 is filled into the enclosing structure), and finally solidifies and cures to form a wall panel.

[0051] As shown in Figures 2A and 2B, the ultralight particles 1 have microwave hot-melt properties. After microwave hot-melt treatment, the ultralight particles 1 melt into liquid. The liquid material formed by the hot-melt treatment of the ultralight particles is coated on the pore walls of the internal cavities 20 originally occupied by the ultralight particles 1. After the liquid material solidifies again, an ultralight particle hot-melt reinforced bubble wall membrane 19 is finally formed inside the wall. As shown in Figures 2A and 2B, a layer of ultralight particle hot-melt reinforced bubble wall membrane 19 is attached to the walls of the internal pores 20 of the foam concrete 2, thereby forming part of the internal load-bearing structure of the composite wall panel.

[0052] Among them, the ultra-light assembled wall panel structure of the multi-layer composite reinforcement method of the present invention adopts four types of reinforcement methods: wall core reinforcement, wall connection surface reinforcement, surface layer reinforcement and wall corner reinforcement.

[0053] The wall core strengthening methods include:

[0054] (1) A lightweight three-dimensional fiber mesh is implanted in the wall core to reinforce the entire wall. The structure of the lightweight three-dimensional fiber mesh can be a single piece, double layer, or an integral three-dimensional mesh structure that runs through the wall core. The material of the lightweight three-dimensional fiber mesh can be glass fiber, basalt fiber mesh, steel fiber mesh, etc. The structure and material of the lightweight three-dimensional fiber mesh can be designed according to the target strength of the wall panel.

[0055] (2) In the process of preparing foam concrete for the core material of the wall, in order to form a relatively thick bubble wall of the foam concrete, a method of increasing the bubble wall thickness of the foam concrete by filling a placeholder material is proposed under the condition that the mass of the filled foam concrete remains unchanged (which also means that the volume of the concrete before foaming remains unchanged): that is, under the condition that the pre-filled amount (and volume) of the concrete before foaming remains unchanged, a certain amount of ultra-light particles are mixed according to the strength requirements of the wall panel for placeholder filling, and the concrete mixed with ultra-light particles is foamed under the condition that the total filling volume remains unchanged; this will compress the foaming volume that can be produced by the concrete under the condition that the total filling volume and the total amount (and volume) of the concrete before foaming remain unchanged, thereby increasing the average thickness of the foamed bubble wall, while maintaining the lightweight of the wall, and improving the structural strength of the wall core. In order to increase the bubble wall thickness of the foam concrete, the following formula (1) needs to be satisfied:

[0056] V - total volume of wall core filling (known);

[0057] V1 – ultralight particle filling volume;

[0058] V2——the volume of the original foam concrete before foaming (known);

[0059] δ0——original foaming rate of foam concrete;

[0060] β——Volume occupation ratio of ultralight particles (related to the thickness of the foam wall t: Under unit volume, the thickness of the foam wall t produced by a certain grade of foam concrete is proportional to the volume occupation ratio of ultralight particles (that is, the thickness of the foam wall t increases with the increase of the occupation ratio). In principle, the maximum value of the foam wall t should be taken. extre However, considering that the cost of ultra-light granular materials is higher than that of concrete materials, it is advisable to choose a more cost-effective solution on the premise of meeting the strength requirements of the wall panels. Therefore, based on the comprehensive consideration of the wall panel strength requirements and economic indicators, the foam wall thickness is selected as t opt , and the corresponding optimal occupancy ratio of ultralight particles is β opt ; A schematic diagram of the relationship between the ultralight particle occupancy ratio and the foam wall thickness is shown in Figure 3.

[0061] Since the relationship between the occupation ratio of ultra-light particles in foam concrete of different grades and the corresponding foam wall thickness is slightly different, the specific curve distribution law needs to be determined through specific material tests. At the same time, combined with the design strength requirements of the wall panel and the cost analysis, the optimal occupation ratio of ultra-light particles is comprehensively determined to be β opt , and finally determine the ultra-light particle dosage V1.

[0062] (3) Ultralight particles are mixed into the concrete of the wall core filling material. The ultralight particles have the property of being heat-fusible. After the wall panels are formed, they are transformed from solid to liquid through microwave heat-melting technology (only from solid to liquid; other physical and chemical properties remain unchanged). By adjusting the wall panel posture, the liquid ultralight particles are coated on the pore walls of the pores formed by the original ultralight particles. After solidification, they form a strengthening membrane on the inner pores. In this way, the structural strength of the wall is improved from the perspective of microscopic pores while maintaining the wall's lightness.

[0063] The wall connection surface strengthening methods include:

[0064] Setting up a frame made of reactive powder concrete (RPC) can form a high-precision and high-strength frame on the wall connection surface, achieve accurate and straight frame connection surface, and facilitate high-precision dry docking of wall panel connection surfaces when splicing wall panels; at the same time, when prestressing is carried out between wall panels, it can effectively distribute and transmit the tension load; avoid the problems of easy bumps and cracks on the wall edges and indirect gluing of wall panel joints during the assembly process of traditional lightweight wall panels; in addition, a lightweight three-dimensional fiber mesh is implanted on the inside of the frame, which can maintain the integrity of the connection between the frame and the wall, avoiding the problem of frame and wall separation that is prone to occur in traditional framed wall panels.

[0065] The surface reinforcement method involves spraying the surface material on the formwork and then pressing in a three-dimensional fiber mesh to form a reinforced surface layer, which improves the surface strength and crack resistance of the wall panels under the wind pressure near the track and the micro-vibration environment of the train.

[0066] The wall corner strengthening method includes using a mold to achieve surface spray strengthening while adjusting the mold posture so that the spray slurry accumulates in the bottom area of ​​the mold, forming a wall corner accumulation area with a thickness and volume far greater than the thickness of the spray surface layer, thereby achieving corner strengthening of the wall panel.

[0067] As shown in FIG1 to FIG4 , the method for preparing the multi-layer reinforced ultra-light composite wallboard of the present invention comprises the following specific steps:

[0068] Step 1: Lay the bottom frame template 9, the left frame template 7 and the right frame template 8 flat;

[0069] Step 2: Reactive powder concrete 23 is injected into the bottom frame template 9, the left frame template 7 and the right frame template 8 respectively to form an unsolidified bottom frame 6, a left frame 5 and a right frame 4;

[0070] Step 3: Then, the multi-layer narrow lightweight three-dimensional fiber mesh 3 is pressed into the unsolidified bottom frame 6, the left side frame 5 and the right side frame 4 respectively, and the solidified bottom frame 6, the left side frame 5 and the right side frame 4 are formed through curing;

[0071] Step 4: Place the bottom frame 6 with the narrow strips of lightweight three-dimensional fiber mesh 3 embedded in it into the surface layer preparation device 22;

[0072] Step 5: Continuously spray the front layer 10 and the back layer 11 on the front layer template 15, the back layer template 16 and the bottom frame 6 of the surface layer preparation device 22 and keep them in an unsolidified state;

[0073] Step 6: Press multiple layers of wide and lightweight three-dimensional fiber web 12 into the unsolidified front layer 10 and the back layer 11 respectively;

[0074] Step 7: At the set control time, that is, when the front layer 10 and the rear layer 11 gradually change from liquid to solid but are not completely solidified, the front layer template 15 and the rear layer template 16 in the surface layer template device 22 are rotated 90 degrees around the connecting shaft 18 and rotated from the horizontal state shown in Figure 4 to the vertical state. Since the front layer 10 and the rear layer 11 are not completely solidified during the rotation process, the sprayed material of the front layer 10 and the rear layer 11 is grouting and accumulated at the corners to form the corner reinforcement area 17 at the bottom of the front and rear layers of the wallboard;

[0075] Step 8: Before the front layer 10 and the back layer 11 are solidified, the left frame 5, the right frame 4 and the bottom frame 6 are molded with the front layer 10 and the back layer 11, and the multi-layer wide lightweight three-dimensional fiber mesh 12 and the multi-layer narrow lightweight three-dimensional fiber mesh 3 can be connected (the connection can be carried out by heat welding, physical binding or hooking, etc.). Preferably, the wall core can be further reinforced, and a multi-layer wall core lightweight three-dimensional fiber mesh 13 is added to the space formed by the mold; after the front layer 10 and the back layer 11 are completely solidified,

[0076] Step 9: As shown in FIG2A , foamed concrete 2 containing ultralight particles 1 (which have microwave-meltable properties (i.e., the particles can be converted into liquid under microwave heating, but the physical properties remain unchanged)) is injected into the space formed by the mold;

[0077] Step 10: After the wall core reaches the age of 2, demoulding and curing are carried out to gradually form the wall panels that have not been treated with microwave heat melting. Active powder concrete can also be used to cast the top frame in this step;

[0078] Step 11: Send the wall panel into a microwave device to perform heat melting treatment on the ultralight particles 1 in the wall panel, so that they soften into liquid when heated and adhere to the internal cavity wall 20 formed by the ultralight particles. According to the strength requirements, the panel body is cyclically flipped and heated in a microwave hot melting manner, so that the melt of the ultralight particles 1 softened by heat is fully coated on the internal cavity wall 20, thereby forming a layer of ultralight particle hot melt reinforced cavity membrane 19 on the internal cavity wall 20, and finally forming an ultralight assembled wall panel based on a multi-layer reinforcement method.

[0079] Therefore, the core filling layer of the composite board of the present invention uses ultra-light particles as lightweight aggregate for the main concrete of the wall panel, and adopts microwave hot melting technology to perform hot melting treatment on the ultra-light particles in the formed wall panel body, and by flipping the panel body, the ultra-light particles are hot melted to form a strengthening membrane that is fully attached to the concrete pore wall, thereby improving the structural strength of the wall. The multiple strengthening measures of the present invention include structural frame strengthening with active powder concrete as the wall frame, reinforcement strengthening of the entire wall with multi-layer lightweight three-dimensional mesh, reinforcement of the wall corners formed by mechanical extrusion and accumulation, and internal wall strengthening by forming a strengthening membrane of the internal pore wall of the wall with microwave hot melting ultra-light particles.

[0080] The panel body of the present invention can be customized according to the requirements of underground station construction: the height can be arbitrarily set from the assembled ground to the top surface or less than the top surface. The width can be determined modularly according to transportation, lifting, weight, and installation difficulty. The wall panel frame uses active powder concrete to form the outer frame load-bearing structure of the wall panel; the wall body uses a lightweight three-dimensional mesh (reinforced structure); the interior of the wall body is filled with foam concrete mixed with ultra-light particles; the ultra-light particles have microwave hot-melt properties. The overall principle of the wall panel construction process is to first establish a connection between a narrow strip of lightweight three-dimensional mesh (reinforced structure) and the active powder concrete frame layer; at the same time, establish a connection between the entire lightweight three-dimensional mesh (reinforced structure) and the surface layer, and when the surface layer is molded, the corners of the surface layer are strengthened; then the surface layer and the frame are assembled, and the intersection of the narrow strip and the entire lightweight three-dimensional mesh (reinforced structure) is connected; the external structure of the wall is formed; and then the foam concrete mixed with ultra-light particles is injected into it and cast to form a composite wall. The lightweighting of the wall panels relies on: the wall body adopts a lightweight three-dimensional mesh (reinforced structure) and the interior of the wall is filled with foam concrete mixed with ultra-light particles; the lightweight three-dimensional mesh (reinforced structure) and ultra-light particles belong to material weight reduction, while the foam concrete belongs to pore structure weight reduction.

[0081] It is obvious that the above description and description are only examples and are not intended to limit the disclosure, application or use of the present invention. Although the embodiments have been described in the embodiments and the embodiments are described in the drawings, the present invention is not limited to the specific examples illustrated in the drawings and described in the embodiments as the best mode currently believed to implement the teachings of the present invention. The scope of the present invention will include any embodiment falling within the above description and the appended claims.

Claims

1. An ultra-light assembled wall panel based on a multi-layer composite reinforcement method, comprising a frame, a wall core, and a surface layer, characterized by: The frame is arranged at four surrounding positions, and includes a right side frame, a left side frame and a bottom frame with grooves, and the right side frame, the left side frame and the bottom frame are made of active powder concrete to form an outer frame load-bearing structure of the composite wall panel, wherein a lightweight three-dimensional fiber mesh is attached to the inner side of the frame, and the surface layer is the front layer and the back layer located on the front and back surfaces of the wall, and a tightly stacked corner reinforcement layer is formed at the lower part of the wall, and the inner side of the front layer and the back layer is attached with a whole surface of lightweight three-dimensional fiber mesh, and the surface layer and the frame are enclosed to form an internal space for accommodating the wall core, and the wall core includes a lightweight three-dimensional mesh structure, which is reinforced with a lightweight three-dimensional fiber mesh and filled with foam concrete core material, and the lightweight three-dimensional fiber mesh structure is inserted into the space formed by the enclosed structure, and the foam concrete core material that has been fully mixed with ultra-light particles is filled into the enclosed structure, and solidified and cured to finally form a wall panel. The ultralight particles have microwave hot-melt properties. After microwave hot-melt treatment, the ultralight particles melt into liquid. The liquid material formed by the hot-melt treatment of the ultralight particles is coated on the hole wall of the internal cavity originally occupied by the ultralight particles. After the liquid material solidifies again, an ultralight particle hot-melt reinforced bubble wall film is finally formed inside the wall.

2. The ultra-light assembled wall panel based on the multi-layer composite reinforcement method according to claim 1, characterized in that: The foam concrete core material satisfies the following formula (1): V - total volume of wall core filling; V1 – ultralight particle filling volume; V2——the volume of original foam concrete before foaming; δ0——original foaming rate of foam concrete; β——Volume occupancy ratio of ultralight particles.

3. A method for preparing an ultra-light assembled wall panel based on a multi-layer composite reinforcement method, characterized in that The following specific steps are included: Step 1: Place the bottom frame template, left frame template and right frame template flat; Step 2: injecting active powder concrete into the bottom frame formwork, the left frame formwork and the right frame formwork respectively to form an unsolidified bottom frame, a left frame and a right frame; Step 3: Then press the multi-layer narrow lightweight three-dimensional fiber mesh into the unsolidified bottom frame, left frame and right frame respectively, and solidify them through curing; Step 4: placing the bottom frame with the narrow strips of lightweight three-dimensional fiber mesh implanted into the surface layer preparation device; Step 5: On the front layer template, the back layer template and the bottom frame surface of the surface layer preparation device, continuously spray the front layer and the back layer and keep them in an unsolidified state; Step 6: Press multiple layers of wide and lightweight three-dimensional fiber mesh into the unsolidified front layer and back layer respectively; Step 7: Under the set control time, that is, when the front layer and the back layer gradually change from liquid to solid but are not completely solidified, the front layer template and the back layer template in the surface layer template device are rotated 90 degrees around the connecting axis and then rotated from horizontal to vertical to form the corner reinforcement area at the bottom of the front and back layers of the wall panel; Step 8: After the front and back layers are completely solidified, mold the left frame, right frame and bottom frame together with the front and back layers; Step 9: Pour the foamed concrete containing ultra-light particles into the space formed by the mold; Step 10: After the wall core reaches the age, demoulding and curing are carried out to gradually form the wallboard without microwave heat melting treatment; Step 11: Send the wall panel into the microwave device to perform heat melting treatment on the ultralight particles in the wall panel, so that they soften into liquid when heated and adhere to the internal cavity wall formed by the ultralight particles. According to the strength requirements, the panel body is cyclically flipped and heated in a microwave hot melting manner, so that the ultralight particle melt softened by heat is fully coated on the internal cavity wall, thereby forming a layer of ultralight particle hot melt reinforced cavity membrane on the internal cavity wall, and finally forming an ultralight prefabricated wall panel based on the multi-layer reinforcement method.

4. The method for preparing an ultra-light assembled wall panel using a multi-layer composite reinforcement method according to claim 3, wherein: In the eighth step, the multiple layers of wide lightweight three-dimensional fiber webs and the multiple layers of narrow lightweight three-dimensional fiber webs are connected.

5. The method for preparing an ultra-light assembled wall panel using a multi-layer composite reinforcement method according to claim 4, wherein: The wall is further reinforced by adding multiple layers of additional wide and lightweight three-dimensional fiber mesh in the space formed by the mold.

6. The method for preparing an ultra-light assembled wall panel using a multi-layer composite reinforcement method according to claim 3, wherein: In the tenth step, the top frame is cast using reactive powder concrete.

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