Energy Saving House

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An energy-saving house, has a main frame, an enclosed wall, a floor cover plate, a top cover plate, a separation wall, a bathroom, and stairs. The enclosed wall is assembled from multiple integral composite prefabricated external wallboards and fixed on the main frame via an energy-dissipating connector. The bathroom and the stair are integrally prefabricated and directly installed. The energy-saving house features low power consumption, high construction efficiency, short construction time, low noise, low dust, light weight, good anti-seismic performance, and small thermal conductivity and is applicable to multi-floor houses and high rise buildings.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

Pursuant to 35 U.S.C.§119 and the Paris Convention Treaty, this application claims the benefit of Chinese Patent Application No. 200810142231.0 filed on Aug. 4, 2008, the contents of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a house, and more particularly to an energy-saving house.

2. Description of the Related Art

Conventionally, houses are constructed with various masonry materials via a wet construction method. However, there are some problems with the method: firstly, a great deal of wood resources are used as underside formworks and supporting materials, which causes large power consumption, low construction efficiency, long construction time, big noise and a great deal of dust; in addition, the masonry materials used in traditional reinforced concrete houses have large weight and poor ductility, and need a large number of reinforced materials so as to meet anti-seismic requirements; finally, enclosed bodies of the traditional reinforced concrete houses have large thermal conductivity and therefore consume energy.

SUMMARY OF THE INVENTION

In view of the above-described problem, it is one objective of the invention to provide an energy-saving house that features low power consumption, high construction efficiency, short construction time, low noise, little dust, light weight, good anti-seismic performance, and small thermal conductivity and is applicable for multi-storey houses and high houses.

It is another objective of the invention to provide a method for producing an energy-saving house that features low power consumption, high construction efficiency, short construction time, low noise, little dust, light weight, good anti-seismic performance, and small thermal conductivity and is applicable for multi-storey houses and high houses.

To achieve the above objectives, in accordance with one embodiment of the invention, provided is an energy-saving house, comprising a main frame, an enclosed wall, a floor cover plate, a top cover plate, a separation wall, a bathroom, and a stair, wherein the enclosed wall is assembled by multiple integral composite prefabricated external wallboards and fixed on the main frame via a seismic and energy-dissipation connector, and the bathroom and the stair are integrally prefabricated and directly installed.

In a class of this embodiment, the floor cover plate and the top cover plate are light-weight laminated slabs.

In a class of this embodiment, the light-weight laminated slab uses a hollow stripe board made of prefabricated and reinforced light aggregate concrete as a substrate, a reinforced skeleton tablet is disposed between the substrates, a reinforced net is disposed on an upper surface of the substrate, and high-strength and waterproof fine stone concrete is disposed between the substrates and on the upper surface of the substrate and operates to cover the reinforced skeleton tablet and the reinforced net.

In a class of this embodiment, the floor cover plate and the top cover plate are directly fixed on the main frame.

In a class of this embodiment, the frame is a steel frame formed by steel columns and steel beams connected to each other.

In a class of this embodiment, the frame is a steel frame.

In a class of this embodiment, a wallboard mount is pre-buried in the integral composite prefabricated external wallboard.

In a class of this embodiment, the wallboard mount cooperates with the seismic and energy-dissipation connector whereby fixing the integral composite prefabricated external wallboard on the main frame.

In a class of this embodiment, the seismic and energy-dissipation connector comprises a bolt, the wallboard mount comprises a bolt sleeve disposed in the integral composite prefabricated external wallboard, the bolt passes through a screw hole on the main frame and is connected to the bolt sleeve whereby fixing the integral composite prefabricated external wallboard on the main frame.

In a class of this embodiment, a damping pad is disposed at a connection of the bolt and between the integral composite prefabricated external wallboard and the main frame.

In a class of this embodiment, integral composite prefabricated external wallboards on the same storey are planarly connected.

In a class of this embodiment, integral composite prefabricated external wallboards on different stories are clutch connected, and the connection is caulk sealed.

In a class of this embodiment, a supporting plate is disposed on the main frame and operates to support the integral composite prefabricated external wallboard, multiple positioning pins are vertically disposed on the supporting plate, and multiple positioning holes are disposed on a top surface and a bottom surface of the integral composite prefabricated external wallboard and correspond to the positioning pins.

In a class of this embodiment, the integral composite prefabricated external wallboard comprises a structure layer, at least one light-weight filling block disposed on an inner side of the structure layer, and a heat insulation layer, the heat insulation layer is attached to an outer side of the light-weight filling block, the structure layer is disposed on a lateral outside of the integral composite prefabricated external wallboard, and the structure layer fills a gap between the heat insulation layer and the light-weight filling block and attaches the heat insulation layer to the light-weight filling block whereby forming the integral composite prefabricated external wallboard.

In a class of this embodiment, the bathroom comprises sanitary wares and accessories, and the bathroom is integrally or separately prefabricated from polyester composites.

In accordance with another embodiment of the invention, provided is a method for producing an energy-saving house, comprising performing foundation construction of the energy-saving house, installing a main frame, disposing an integral composite prefabricated external wallboard on the main frame, installing multiple floor cover plates and top cover plates on different stories, installing a pipeline system, a prefabricated bathroom, a stair and an enclosed wall, and installing a facing of an inner wall and other accessories.

Components of a main part of the house, such as the main frame, the floor cover plate, the top cover plate and the enclosed wall are prefabricated except for a basic part of the house, and thus industrial production is realized. Construction of the house is implemented by industrially produced components and products and processes such as field installation, connection, modification and so on. At the time a base of the house is constructed, factory production of various house component is performed. After the base is constructed, the main frame, the floor cover plate, the top cover plate and the enclosed wall are installed. The invention reduces a great deal of field work, and storey structure and external wall construction do not need a large amount of support frames and scaffolds, which saves energy consumption, water consumption, construction land and construction materials, and reduces construction noise and dust and construction time. Standardization and integration of house components and products are beneficial for application of new technology and materials and renewable energy such as solar energy. For example, solar devices are disposed on roofs, balconies and sunny sides of wall, or outside the structure layer, and the house is capable of improving residence comfort and increasing available use area, reducing consumption of energy and water, and thus facilitating a green house and green construction. Moreover, the invention is capable of implementing standardization, serialization and finalization, house drawing libraries, performing house design via digital management, and presenting architectural styles and aesthetic perception via design techniques such as difference of house layout, modeling of balconies, materials of decorative surface, color configuration and so on.

The main frame of the invention may employ a steel frame since steel is a renewable material that features good technical performance and ductility and capable of improving structural bearing capacity and seismic performance. Various steel components are easy for large-scale production, and feature high production efficiency and high product quality in manufacturing. With increasing demand for steel, to construct houses with steel is a development trend.

The floor cover plate and the top cover plate are light-weight laminated slabs. The light-weight laminated slab uses a hollow stripe board made of prefabricated and reinforced light aggregate concrete as a substrate to replace a traditional process of laying wooden formworks for a floor cover plate and a top cover plate made of cast-in-situ concrete. The substrate is disposed on a special tool-typed support frame to replace a support headframe. A reinforced skeleton tablet is disposed between the substrates, a reinforced net is disposed on an upper surface of the substrate, and the reinforced skeleton tablet and the reinforced net are casted via C30-grade fine-stone concrete to form the light-weight laminated slab. Since the hollow stripe board can be directly disposed on a main frame that is already constructed via the tool-typed support frame, the number of bottom formworks and supports is reduced, which improves production efficiency, reduces effect to surrounding environment, and overcomes limitation of storey-by-storey construction. After the main frame is constructed, construction can be performed from any storey upwardly or downwardly, or from multiple stories simultaneously whereby reducing construction time. After the light-weight laminated slab is formed, the only wet construction process - filed concrete casting is performed. After consolidation, the light-weight laminated slab is firmly combined with the main frame to form a combined structure interacted by a composite concrete floor cover or top cover and the main frame and bearing different acting force of the house. Construction of the light-weight laminated slab does not need to dismount a top bracing, a form spacer and a hoisting machine, and decreases some dominant processes. Moreover, the hollow stripe board, the reinforced skeleton tablet and the reinforced net can be directly processed in factories based on standards and transmitted to a construction field for installation, which greatly improves production efficiency, reduces construction time and helps to implement industrialization of manufacturing.

The integral composite prefabricated external wallboard of the invention comprises a structure layer, a light-weight filling block, and a heat insulation layer. The structure layer is a reinforced (the reinforced skeleton tablet and the reinforced net) concrete layer in the shape of a rib, and disposed on an outer side and surrounding of a wall board, and in a gap of the light-weight filling block, which makes the structure layer capable of bearing external force, climate change and rain erosion.

In factories, materials with good heat insulation performance and light weight, and post-casting, high-strength, waterproof and fine-stone concrete of the reinforced net are casted with doors and windows to form an integral external wallboard. After inside and outside decoration, the integral external wallboard is transmitted to the field for installation, which replaces traditional processes such as installing scaffolds, house walls, decorating and so on. The integral composite prefabricated external wallboards can be installed sequentially and upwardly with the main frame or on different stories simultaneously after the main frame is constructed. A supporting plate is disposed on a supporting point of the main frame, multiple positioning holes are disposed on the external wallboard are aligned with positioning pins disposed on the supporting plate, which makes it easy for adjacent integral composite prefabricated external wallboards to be positioned. After positioning, high-strength bolts are used for tightening and fixing via optimized fastening force, and a damping pad is disposed in a gap between the integral composite prefabricated external wallboard and the main frame. Pressure is generated after the bolt is tightened, under the action of the pressure, the damping pad is worn and deformed, and therefore is capable of implementing a seismic and energy dissipation effect, reducing force applied by an earthquake to the house, and improving seismic performance of the house. Integral composite prefabricated external wallboards on different stories are clutch connected, which is beneficial for stabilization and firmness of installation of the external wallboard. Ends of integral composite prefabricated external wallboards on the same storey are parallel connected. Connection between integral composite prefabricated external wallboards on different stories and that on the same storey are caulk sealed to improve a sealing effect. A pair of vertical slots is disposed on both ends of the connection between integral composite prefabricated external wallboards on the same storey and form a cavity, which increases space of caulk sealing, guarantees tight connection between the integral composite prefabricated external wallboards, facilitates a rain-proof and anti-seepage effect, and keeps warm and prevents colds. A joint between the integral composite prefabricated external wallboards is disposed on the main frame, which helps to perform caulk sealing of the integral composite prefabricated external wallboards and ensures connecting quality.

The integral composite prefabricated external wallboard is an integral external wallboard made based on a dimension of one room, namely one integral composite prefabricated external wallboard is an external wall of one room. The reinforced concrete is C30-grade and has a seepage-resistant grade of P6. The light-weight filling block is light-weight-material prefabricated plate with a bulk density less or equal to 500 kg/m2 with certain strength. The light-weight filling block is dispose on an inner side of the integral composite prefabricated external wallboard whereby reducing an overall weight of the external wallboard and insulating (absorbing) sound. A squeezed foam board has a very low heat transfer coefficient, and is disposed on a middle portion of the integral composite prefabricated external wallboard as a heat insulation layer and operates as a heat insulation material for the wall. An external-wall door and a window frame are disposed in a mould before concrete is casted, so that the door and the window frame are firmly disposed in the wall, which improves weatherability of the door and the window frame. The invention can facilitate construction of the external wall of the house by transferring the integral composite prefabricated external wallboard to the field and perform installation one by one and caulk sealing, which decreases construction time, greatly reduces work amount of field construction, construction cost, and effect of construction land to the environment, increases the number of renewable materials, and facilitates real industrialization.

Except for industrialization of the main part of the house, standardization and industrialization of indoor bathrooms and stairs are also implemented. The bathrooms are configured to have several styles, sanitary wares are selected and molded in an integral or a combined form via polyester composites with pipe joints and connectors being reserved, and processes such as production of the wall, the sanitary wares and other accessories, decorative processing and so on are implemented in factories. Then, they are transmitted to the field for installation and connected to the reserved pipe joint, whereby facilitating convenient construction of the bathrooms, reliable quality and reduced construction cost.

The main frame employs a steel frame that is mature, safe and reliable, makes it convenient for industrialization, large-scale production and recycling use of resources, reduces weight of an upper portion of the house, features comparatively large ductility, a good seismic performance and convenient field installation and construction.

BRIEF DESCRIPTION OF THE DRAWINGS

Detailed description will be given below in conjunction with accompanying drawings, in which

FIG. 1a is a schematic view of an energy-saving house of an exemplary embodiment of the invention;

FIG. 1b is a front view of an energy-saving house of an exemplary embodiment of the invention;

FIG. 2 is a partial enlarged view of an F joint in FIG. 1b of an exemplary embodiment of the invention;

FIG. 3 is a partial enlarged view of an F joint in FIG. 1b of another exemplary embodiment of the invention;

FIG. 4 is a partial enlarged view of a G joint in FIG. 1b of an exemplary embodiment of the invention;

FIG. 5 is a partial enlarged view of a P Joint in FIG. 1b of an exemplary embodiment of the invention;

FIG. 6 is a partial enlarged view of an I joint in FIG. 1b of an exemplary embodiment of the invention;

FIG. 7 illustrates connection between integral composite prefabricated external wallboards on different stories;

FIG. 8 is a partial enlarged view of a G position in FIG. 2;

FIG. 9 is a partial enlarged view of an R position in FIG. 7;

FIG. 10 is a schematic view of an integral composite prefabricated external wallboard of a first exemplary embodiment of the invention;

FIG. 11 is a cross-sectional view of FIG. 10 along a line A-A;

FIG. 12 is a top view of FIG. 10;

FIG. 13 is a schematic view of an integral composite prefabricated external wallboard of a second exemplary embodiment of the invention;

FIG. 14 is a cross-sectional view of FIG. 13 along a line B-B;

FIG. 15 is a top view of FIG. 13;

FIG. 16 is a schematic view of an integral composite prefabricated external wallboard of a third exemplary embodiment of the invention;

FIG. 17 is a cross-sectional view of FIG. 16 along a line C-C;

FIG. 18 is a top view of FIG. 16;

FIG. 19 illustrates a wallboard mount disposed in an integral composite prefabricated external wallboard;

FIG. 20 is a top view of a wallboard mount in FIG. 19;

FIG. 21 is a schematic view of a light-weight laminated slab of an exemplary embodiment of the invention;

FIG. 22 is a cross-sectional view of a light-weight laminated slab in FIG. 21;

FIG. 23 illustrates connection between a light-weight laminated slab and a main frame;

FIG. 24 illustrates connection between an integral composite prefabricated external wallboard and supporting plate of a main frame; and

FIG. 25 is a schematic view of FIG. 24 along a K direction.

 DETAILED DESCRIPTION OF THE EMBODIMENTS

As shown in FIGS. 1a and 1b, an energy-saving house of the invention comprises a main frame 101, an enclosed wall, a top cover plate 103, a floor cover plate 104, a separation wall 106, a stair 107, a bathroom 108, and a balcony 109. The enclosed wall is assembled by multiple integral composite prefabricated external wallboards. The bathroom 108, the balcony 109, and the stair 107 are respectively an integral prefabricated bathroom, an integral prefabricated balcony, and an integral prefabricated stair which are hoisted to a designed position for installation. The main frame 101 is a steel frame, and comprises steel columns and steel beams connected to each other via welding or high-strength bolts. The main frame 101 can also be a steel frame.

The integral composite prefabricated external wallboards and the stair 107 are fixed on the main frame 101. The bathroom 108 is disposed on the floor cover plate 104, and comprises sanitary wares and accessories. The bathroom 108 is configured to have several styles, and sanitary wares are selected, and are molded in an integral or a combined form via polyester composites with pipe joints and connectors being reserved. Processes such as production of the wall, the sanitary wares and other accessories, decorative processing and so on are implemented in factories. Then, they are transmitted to the field for installation and connected to the reserved pipe joint. Kitchen stoves can be directly installed for approved products. The top cover plate 103 and the floor cover plate 104 are light-weight laminated slabs. Field casted concrete is fixedly connected to the main frame 101. The separation walls 106 are transmitted to field and installed one-by-one on the floor cover plate 104 after being prefabricated, and an upper end and a lower end thereof are fixed on the floor cover plate 104 via a buckle.

As shown in FIGS. 10-12, a schematic view of the integral composite prefabricated external wallboard. The integral composite prefabricated external wallboard is an external wallboard formed by a structure layer 1 operating as a support framework, 12 light-weight filling blocks 3 arranged in three rows and disposed on an inner side of the structure layer, and a heat insulation layer 2. There is no specific requirement for a shape and dimension of the light-weight filling block 3, and it is normally square, rectangular, triangular and so on and has a dimension between 500 and 850 mm. The heat insulation layer 2 is attached to the outside of the light-weight filling block 3. The heat isolation layer 2 is disposed outside of the light-weight filling block 3, and the structure layer 1 is disposed on a lateral side of the external wallboard. The structure layer 1 fills a gap between the heat isolation layer 2 and the light-weight filling block 3, and attaches them altogether whereby forming the integral external wallboard. The heat isolation layer 2 is a squeezed foam board layer. The light-weight filling block 3 is a light-weight-material prefabricated plate having a bulk density less or equal to 500 kg/m2. The light-weight filling blocks 3 are parallel disposed on one layer, and a gap is disposed between adjacent light-weight filling blocks 3. The structure layer 1 is a reinforced concrete layer, and comprises a reinforced skeleton tablet 11 disposed around the integral composite prefabricated external wallboard and between the light-weight filling blocks 3, and a reinforced net 12 disposed outside the heat isolation layer 2 and connected to the reinforced skeleton tablet 11 The reinforced skeleton tablet 11 around the integral composite prefabricated external wallboard is formed by reinforcing bars that are bent and bound, and in the shape of a pane. The reinforced net 12 is a reinforced net formed via a circular weft knitting technology. Concrete is casted into the reinforced skeleton tablet 11 and the reinforced net 12, and gaps around the heat isolation layer 2 and the light-weight filling blocks 3 whereby forming a reinforced concrete layer. The concrete is fine-stone concrete having a C30-grade and a seepage-resistant grade of P6. The reinforced concrete layer attaches the light-weight filling blocks 3 and the heat isolation layer 2 whereby forming the integral external wallboard 3 whereby forming the integral external wallboard. Heat insulation materials are disposed in a gap between adjacent light-weight filling blocks 3 whereby forming the heat insulation layer 2. Light-weight pearlite mortar is used to float inner surface of the light-weight filling blocks 3 whereby forming inner surface 20 of the wallboard. A hoisting part 5 and multiple positioning holes 7 are disposed on the integral composite prefabricated external wallboard, and the hoisting part 5 is disposed at the top of the integral composite prefabricated external wallboard and operates to hoist the integral composite prefabricated external wallboard. The positioning holes 7 are vertically disposed on an upper end and a lower end of a side plate of the external wall, and operate to install and position the integral composite prefabricated external wallboard on the main frame 1. A pair of protruding parts 9 and grooves 8 are disposed on an upper end and a lower end of the integral composite prefabricated external wallboard, and the protruding parts 9 and the grooves 8 are fit with each other. The protruding parts 9 and the grooves 8 on adjacent stories are clutch connected. A semicircular vertical groove 15 is disposed on a side of the integral composite prefabricated external wallboard, and operates to increase space for waterproof and caulking processing between adjacent integral composite prefabricated external wallboards. Multiple wallboard mounts 6 are disposed in the integral composite prefabricated external wallboard, specifically in four corners in the integral composite prefabricated external wallboard, and connected to the main frame.

As shown in FIGS. 13-15, an integral composite prefabricated external wallboard with a pre-buried door frame 16 is illustrated. Other parts of the integral composite prefabricated external wallboard comprise a structure layer 1 operating as a support framework, two rows of light-weight filling blocks 3 disposed on an inner side of the structure layer, and a heat insulation layer 2. The light-weight filling blocks 3 are disposed on both sides of the door frame 16.

As shown in FIGS. 16-18, a floating windowsill 17 and a window frame 21 are pre-buried on the integral composite prefabricated external wallboard, and other parts of the integral composite prefabricated external wallboard comprise a structure layer 1 operating as a support framework, three rows of light-weight filling blocks 3 disposed on an inner side of the structure layer, and a heat insulation layer 2. The light-weight filling blocks 3 are disposed on both sides of the window frame 21 and below the floating windowsill 17. The floating windowsill 17 is casted and prefabricated via fine-stone concrete, and a heat insulation layer 18 is disposed in the floating windowsill 17.

As shown in FIGS. 24 and 25, a supporting plate 70 is disposed on the main frame 1 and operates to support and position the integral composite prefabricated external wallboard 202. The supporting plate 70 is a T-shaped plate, multiple positioning pins 72 are vertically disposed on a horizontal part thereof and multiple positioning holes 7 corresponding to the positioning pins 72 are disposed on a top surface and a bottom surface of the integral composite prefabricated external wallboard.

As shown in FIGS. 19 and 20, a wallboard mount 6 is pre-buried in the integral composite prefabricated external wallboard. The wallboard mount 6 comprises a bolt sleeve 63 disposed in a structure layer 1 of the integral composite prefabricated external wallboard and being perpendicular to the wall of the integral composite prefabricated external wallboard. Internal thread is disposed on inner wall of the bolt sleeve 63, a connecting plate 62 perpendicular to the bolt sleeve 63 is disposed on a front part of the bolt sleeve 63, a connecting rod 65 is perpendicular thereto is disposed on a rear part of the bolt sleeve 63, and a reinforced skeleton tablet 61 is disposed outside the bolt sleeve 63. The connecting plate 62 and the connecting rod 65 are strengthening parts operating to improve stability of the bolt sleeve 63 in the structure layer 1 and connection strength of the wallboard mount 6.

As shown in FIGS. 2, 3, 4, 5, 6 and 8, connection between integral composite prefabricated external wallboards on the same storey and that between the integral composite prefabricated external wallboard and the main frame are illustrated, in which FIGS. 2 and 3 illustrate connection between integral composite prefabricated external wallboards at corners, and FIGS. 4, 5 and 6 illustrate connection between integral composite prefabricated external wallboards on the same storey on one side of the house. Integral composite prefabricated external wallboards 202 on the same storey are planarly connected, Adjacent ends of adjacent integral composite prefabricated external wallboard 202 are planes. The integral composite prefabricated external wallboard 202 is fixed on a joint between a steel column and a steel beam of the main frame 101 by fitting the wallboard mounts 6 disposed on four corners of the integral composite prefabricated external wallboard with a seismic and energy-dissipation connector. The seismic and energy-dissipation connector comprises a high-strength bolt 404. The wallboard mount 6 comprises a bolt sleeve disposed in the integral composite prefabricated external wallboard 202. The bolt 404 passes through a screw hole on the main frame 101, is thread connected to the sleeve and fixes the integral composite prefabricated external wallboard on the main frame 101. A damping pad 303 is disposed at a connection of the bolt and between the integral composite prefabricated external wallboard 202 and the main frame 101.

An end at a connection between two integral composite prefabricated external wallboards 202 on the same storey is a plane, and a vertical groove 15 is downwardly disposed on an end of each of the integral composite prefabricated external wallboards 202. The two vertical grooves 15 form a cavity. After installation of all integral composite prefabricated external wallboards is finished, a caulking sealing process is performed between ends of the integral composite prefabricated external wallboard 202 and in the cavity. As shown in FIG. 8, foaming polyurethane 53 is injected into a middle part of the gap and into the cavity, a pair of double-faced foaming rubber strips 52 are filled in both sides of the foaming polyurethane 53, and waterproof glue 51 is filled in a lateral outside thereof Alternatively, the foaming polyurethane is not injected into the cavity, and the double-faced foaming rubber strips 52 are filled in both sides of the cavity. The waterproof glue 51 filled in a lateral outside thereof fills a gap between the integral composite prefabricated external wallboard, which facilitate a waterproof effect.

As shown in FIGS. 7 and 9, connection between integral composite prefabricated external wallboard 202 on adjacent stories is illustrated. Integral composite prefabricated external wallboards on different stories are clutch connected, and protruding portions and grooves of the integral composite prefabricated external wallboards on different stories are clutch connected to each other. Caulk sealing and waterproof processing are performed in a gap therebetween. Foaming polyurethane 53 in injected into the middle of the gap, double-faced foaming rubber strips 52 are filled in both sides of the foaming polyurethane 53, and waterproof glue 51 is filled in a lateral outside thereof, whereby filling the gap between the integral composite prefabricated external wallboard 202 on adjacent stories and facilitating a waterproof effect.

As shown in FIGS. 21, 22 and 23, the invention uses light-weight laminated slabs as the top cover plate 103 and the floor cover plate 104. The light-weight laminated slab uses a hollow stripe board made of prefabricated and reinforced light aggregate concrete as a substrate 40. The substrate 40 is disposed on a tool-typed support frame 45. A reinforced skeleton tablet 42 and a reinforced net 43 are respectively disposed between the substrates 40 and on the substrate 40, and are casted via C30-grade fine-stone concrete 41 to form the light-weight laminated slab fixedly connected to the main frame 101. Since the substrate 40, namely the hollow stripe board can be directly disposed on the main frame 101 that is already constructed via the tool-typed support frame 45, the number of bottom formworks and supports is reduced, which improves production efficiency, reduces effect to surrounding environment. Post-casting of the light-weight laminated slab is the only wet construction process, after consolidation, the light-weight laminated slab is firmly combined with the main frame 1 to form a combined structure interacted by a composite concrete floor cover or top cover and the main frame and bearing different acting force of the house.

Construction of the house of the invention comprises steps of:

  • 1. Firstly, an architecture design scheme is determined, a detailed construction drawings are made based thereon according to standardization and digitalization, foundation construction of the house is performed based on the detailed construction drawings, and large-scale production of upper parts such as the integral composite prefabricated external wallboard, the stair, the bathroom, the balcony, the light-weight laminated slab and so on is conducted in factories.
  • 2. After foundation construction of the base is completed, the main frame is installed, which comprising installing steel columns and then steel beams, connection between the steel columns and the steel beams is implemented by high-strength bolts or welding.
  • 3. After the main frame is constructed, the enclosed wall is installed, the integral composite prefabricated external wallboard using light-weight filing block and heat insulation materials, and post-casting, high-strength, waterproof and fine-stone concrete of the reinforced net are casted with doors and windows to form an integral external wallboard. After inside and outside decoration, the integral external wallboard is transmitted to the field for installation, which replaces traditional processes such as installing scaffolds, house walls, decorating and so on. The integral composite prefabricated external wallboards can be installed sequentially and upwardly with the main frame or on different stories simultaneously after the main frame is constructed. A supporting plate is disposed on a supporting point of the main frame, multiple positioning holes are disposed on the external wallboard are aligned with positioning pins disposed on the supporting plate. The integral composite prefabricated external wallboard is disposed on the supporting plate, and then a damping pad is disposed in a gap between the integral composite prefabricated external wallboard and the main frame, high-strength bolts are used for tightening and fixing via optimized fastening force. The damping pad is capable of implementing a seismic and energy dissipation effect, reducing force applied by an earthquake to the house, and improving seismic performance of the house. Integral composite prefabricated external wallboards on different stories are clutch connected, sealing and waterproof caulking processing is performed on connection between integral composite prefabricated external wallboards on different stories and that between integral composite prefabricated external wallboards on the same storey, whereby ensuring firm connection between the integral composite prefabricated external wallboards. A gap between the integral composite prefabricated external wallboard is disposed on the main frame, which makes it convenient to perform caulking sealing on the gap between integral composite prefabricated external wallboards and ensures connecting quality.
  • 4. After installation and construction of the enclosed wall are completed, the floor cover plate and the top cover plate are installed. The floor cover plate and the top cover plate use light-weight laminated slabs, the light-weight laminated slabs use hollow stripe boards made of prefabricated and reinforced light aggregate concrete as substrates, and the substrate is disposed on the tool-typed support frame. A reinforced skeleton tablet and a reinforced net are respectively disposed between the substrates and on an upper surface of the substrate, casted via C30-grade fine-stone concrete, and fixedly connected to the main frame.
  • 5. Processes such as production of the wall, the sanitary wares and other accessories, decorative processing and so on are implemented in factories. Then, they are transmitted to the field for installation and connected to the reserved pipe joint.
  • 6. The separation wall: a hollow stripe board is prefabricated in factories according to a required size and transmitted to the field for connection and installation.
  • 7. The balcony: it is integrally prefabricated according to design drawings and disposed on the steel beam protruding from the main frame.
  • 8. The stair: it is sectional prefabricated according to design drawings and installed on the steel beam of the main frame in a stair case.
  • 9. Electric circuits: they are buried according to design drawings at the time the wallboard is prefabricated and post-casting of the floor top cover is performed, and circuits are installed as indoor decoration is performed.
  • 10: Water supply and sewerage pipelines: pipelines are installed in reserved pipeline holes after the floor cover plate is constructed.

Table 1 indicates analysis and comparison between consumables of the invention and those of a traditional cast-in-situ reinforced concrete house.

TABLE 1 Analysis and comparison of consumables (applicable for multi-storey and small sized multi-storey houses) Consumables per Number Position Specific project square house area Remark 1 Main I. the energy-saving structure house 1. steel framework 42-50 kg/m2 2. hollow stripe board 0.85 m2/m2 substrate made of reinforced light- weight concrete 3. post-casting C30 0.065 m3/m2 concrete 4. reinforced net 7.5 kg/m2 laminated slab II. traditional cast-in- situ reinforced concrete house 1. reinforcements of 52-70 kg/m2 cast-in-situ C25 reinforced concrete 2. cast-in-situ C25 0.22 m2/m2 concrete 3. wood form 1.6-1.8 m2/m2 can be reused for 3-4 times 4. top bracing 40 kg/m2 renewable 2 External I. integral composite wallboard prefabricated external wallboard 1. light-weight-material 0.13 m3/m2 prefabricated plate 2. 25 mm squeezed 0.025 m3/m2 foam board 3. C30 fine-concrete 0.06 m3/m2 composite layer and decorative surface 4. installation and 0.6-0.7 m/m2 caulking sealing II. traditional block external wall 1. 200 mm foaming 0.23/m2 concrete block 2. cement mortar 1 m2/m2 substrate 3. 30-50 mm plastic- 1 m2/m2 extrusion-plate heat insulation layer 4. combined layer 1 m2/m2 5. protection layer and 1 m2/m2 decorative surface 6. scaffold equipments 1 m2/m2 7. vertical transportation 1 m2/m2 of various materials

Remarks:

  • 1. Indoor decoration, facilities such as bath rooms, kitchens and so on, architectural modeling of doors and windows, and decorative processing are the same and will not be compared in economic.
  • 2. Cost spent on foundation construction can be reduced by 15-25% according to different geological conditions since weight of upper structure thereof is decreased by approximately 30-40%.
  • 3. Construction time of traditional field construction is long as being limited by a main construction procedure, procedures of the invention can be performed simultaneously and construction time thereof is reduced by 40-50%. As construction time is extended for one month, interest cost is increased by 1%-2%. Economic benefit of the invention embodies capital amount and capital flow cost.

Test on the House of the Invention

1. Structure Loading Test on the Floor Cover Plate Made by the Light-Weight Laminated Slab

The loading test aims at testing stress of relevant positions of the floor cover structure (containing the steel beam of the floor cover) under the action of loading, and deforming and crack development of the structure part. The test is conducted by Shenzhen Institute of House Research Co., Ltd, and test report is also written thereby.

Test basis: Standard Methods for Testing of Concrete Structures (China national standard GB50152-92)

The floor cover plate employs a bi-directional plate (bi-directional forced) with a span of 4 m×4.5 m, and a unidirectional plate (unidirectional forced) with a span of 2.5 m. The loading test is conducted for two times, the first loading test comprises a scenario where stress of surrounding supporting steel beams varies as the floor cover made of laminated slabs is constructed, loading is stopped as a load value of the unidirectional plate is twice than a designed standard load value. Mid-span deflection of the plate is only 0.84 mm (Lo/2976), mid-span stress of a plate rib is 32N/mm2, and negative reinforcement stress of a support is 54N/mm2.

As a load value of the bidirectional late is 4.2 times than a designed standard load value and a first crack appears, loading is stopped. Short mid-span deflection of the plate is 4.32 mm (Lo/926), and long mid-span deflection of the plate is 6.35 mm (Lo/710).

Central Reinforced Stress:

    • short mid-span stress of a plate rib 61N/mm2
    • long mid-span stress of a plate rib 52N/mm2
    • short negative reinforcement of a support 54N/mm2
    • long negative reinforcement of a support 32.4N/mm2

To demonstrate bearing capability of the light-weight laminated plate to be damaged, another damage load test is conducted.

A unidirectional plate: load value thereof is 7.5 times than a designed standard load (namely 35 KN/m2), the maximum mid-span deflection is 6.4 mm (Lo/390), since loading blocks are highly piled, it is impossible to load any more.

A bi-directional plate: load value thereof is 13 times than a designed standard load (namely 32.5 KN/m2), the mid-span deflection is 12.85 mm (Lo/311), and a width of the crack at the bottom of the plate is 1.5 mm. At this time the floor cover plate is regarded as entering a plastic deforming phase. The test indicates the floor cover plate made of the light-weight laminated slab has high bearing capacitance and enough safety reservation.

2. Heat Resistance Test on the Integral Composite Prefabricated External Wallboard

The loading test and heat resistance test are conducted by Shenzhen Institute of House Research Co., Ltd, and test report is also written thereby. The test is based on China national standard GB/T13475-92 named “House Element-Determination of Steady-state Thermal Transmission Properties-Calibrated and guarded hot box”. A test equipment employs a BW-1212WT-type stable heat transmission test system JN002.

Test condition: air temperature in the hot box is 35° C., air temperature in the cool box is −10° C. Air flow rate in the hot box is natural convection, and air flow rate in the cool box is 3 m/s. Heat transmission direction of samples is from warm to cool. Airflow direction in the cool box is upward. Emissivity on inner surface of the box is 0.85. The samples' state is natural drying.

By comparison of heat resistance, materials such as the light-weight-material prefabricated plate, the squeezed form plate and so on are selected as materials having heat insulation effect in the laminated external wallboard. The reinforced net is casted via C30-grade fine-stone concrete and post-casted in an embedded form. After the heat resistance test, a thermal conductivity is 1.05 W/m·K, which is less than an index of 1.5 W/m·K defined by the Power-saving Standard for thermal conductivity of wall.

While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.

Claims

1. An energy-saving house, comprising wherein

a main frame;
an enclosed wall;
a floor cover plate;
a top cover plate;
a separation wall;
a bathroom; and
a stair;
said enclosed wall is assembled by multiple integral composite prefabricated external wallboards and fixed on said main frame via a seismic and energy-dissipation connector; and
said bathroom and said stair are integrally prefabricated and directly installed.

2. The energy-saving house of claim 1, wherein said floor cover plate and said top cover plate are light-weight laminated slabs.

3. The energy-saving house of claim 2, wherein

said light-weight laminated slab uses a hollow stripe board made of prefabricated and reinforced light aggregate concrete as a substrate;
a reinforced skeleton tablet is disposed between said substrates;
a reinforced net is disposed on an upper surface of said substrate; and
high-strength and waterproof fine stone concrete is disposed between said substrates and on the upper surface of said substrate and operates to cover said reinforced skeleton tablet and said reinforced net.

4. The energy-saving house of claim 1, wherein said floor cover plate and said top cover plate are directly fixed on said main frame.

5. The energy-saving house of claim 1, wherein said frame is a steel frame formed by steel columns and steel beams connected to each other.

6. The energy-saving house of claim 1, wherein said frame is a steel frame.

7. The energy-saving house of claim 1, wherein a wallboard mount is pre-buried in said integral composite prefabricated external wallboard.

8. The energy-saving house of claim 7, wherein said wallboard mount cooperates with said seismic and energy-dissipation connector whereby fixing said integral composite prefabricated external wallboard on said main frame.

9. The energy-saving house of claim 7, wherein

said seismic and energy-dissipation connector comprises a bolt;
said wallboard mount comprises a bolt sleeve disposed in said integral composite prefabricated external wallboard; and
said bolt passes through a screw hole on said main frame and is connected to said bolt sleeve whereby fixing said integral composite prefabricated external wallboard on said main frame.

10. The energy-saving house of claim 9, wherein a damping pad is disposed at a connection of said bolt and between said integral composite prefabricated external wallboard and said main frame.

11. The energy-saving house of claim 1, wherein integral composite prefabricated external wallboards on the same storey are planarly connected.

12. The energy-saving house of claim 1, wherein integral composite prefabricated external wallboards on different stories are clutch connected, and the connection is caulk sealed.

13. The energy-saving house of claim 1, wherein

a supporting plate is disposed on said main frame and operates to support said integral composite prefabricated external wallboard;
multiple positioning pins are vertically disposed on said supporting plate; and
multiple positioning holes are disposed on a top surface and a bottom surface of said integral composite prefabricated external wallboard and correspond to said positioning pins.

14. The energy-saving house of claim 1, wherein

said integral composite prefabricated external wallboard comprises a structure layer, at least one light-weight filling block disposed on an inner side of said structure layer, and a heat insulation layer;
said heat insulation layer is attached to an outer side of said light-weight filling block;
said structure layer is disposed on a lateral outside of said integral composite prefabricated external wallboard; and
said structure layer fills a gap between said heat insulation layer and said light-weight filling block and attaches said heat insulation layer to said light-weight filling block whereby forming said integral composite prefabricated external wallboard.

15. The energy-saving house of claim 1, wherein

said bathroom comprises sanitary wares and accessories; and
said bathroom is integrally or separately prefabricated from polyester composites.

16. A method for producing an energy-saving house, comprising

performing foundation construction of the energy-saving house;
installing a main frame;
disposing an integral composite prefabricated external wallboard on said main frame;
installing multiple floor cover plates and top cover plates on different stories;
installing a pipeline system, a prefabricated bathroom, a stair and an enclosed wall; and
installing a facing of an inner wall and other accessories.
Patent History
Publication number: 20100024323
Type: Application
Filed: Aug 4, 2009
Publication Date: Feb 4, 2010
Applicant: (Shenzhen)
Inventors: Zhenxi HUANG (Shenzhen), Hao HU (Shenzhen), Chun YANG (Shenzhen), Zhong YAN (Shenzhen), Yinghui ZHANG (Shenzhen)
Application Number: 12/534,920
Classifications
Current U.S. Class: Means Compensating Earth-transmitted Force (e.g., Earthquake) (52/167.1); Multilevel (52/236.3); Barrier Construction (52/745.05)
International Classification: E04H 1/00 (20060101); E04H 9/02 (20060101); E04B 1/00 (20060101);