Modularized pneumatic membrane unit frame and roof connecting system

Abstract

The invention relates to a modular pneumatic membrane unit frame and roof connecting system which comprises a frame body formed by connecting profiles. The multi-layer film structure is integrated on the frame body and comprises a lower-layer air film, a protective net and an upper-layer air pillow which are sequentially arranged from bottom to top, and the protective net is fixed to the inner side of the frame body through a fastener; the core function layer and the inflation pipe connector which form the inflatable membrane roof are integrated on the unified and structural frame body, a standardized function unit which can be independently produced, transported and hoisted is formed, the unit is provided with the special main body connecting mechanism and the adjacent edge sealing drainage mechanism, and therefore the complex roof site construction is changed, and the construction efficiency is improved. Three clear and efficient standardized operation procedures of prefabricated unit production, connection of the units and the main body and sealing drainage between the units are divided, and the core problems of procedure disorder, low integration level and quality control difficulty caused by on-site spare part assembly in the prior art are fundamentally solved.

Description

Technical Field

[0001] This invention relates to the field of inflatable membrane structure technology, and specifically to a modular inflatable membrane unit frame and roof connection system. Background Technology

[0002] ETFE inflatable membrane structures are widely used in large public buildings such as stadiums and transportation hubs due to their excellent light transmittance, lightweight and high strength and modern appearance. These structures are usually composed of multiple layers of ETFE membrane material and need to work in conjunction with protective netting, inflation system and drainage system.

[0003] In existing technologies, the construction and installation of such structures face a core challenge: the multiple functional layers constituting the roof, such as the "lower air membrane, protective net, and upper air cushion," typically require separate high-altitude operations on the main steel structure, with each layer installed, positioned, and sealed on-site. This discrete high-altitude operation mode leads to low construction efficiency, complex procedures, poor integration between the functional layers and the supporting frame, as well as between the inflation and drainage systems and the structure, resulting in numerous interfaces. Consequently, on-site construction quality is highly dependent on worker skills and difficult to control consistently, ultimately affecting the overall airtightness, waterproof reliability, and long-term performance of the roof. The root cause lies in the lack of a frame system that can pre-integrate these multiple functional layers into a stable, standardized module in the factory and install it as a single unit.

[0004] Therefore, there is an urgent need to provide a modular inflatable membrane unit frame and roof connection system to solve the problems of low efficiency, difficult quality control, and poor reliability caused by high-altitude installation of discrete functional layers in the existing technology. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a modular inflatable membrane unit frame and roof connection system, which solves the problems of low efficiency, difficult quality control and poor reliability caused by the high-altitude installation of functional layers in the prior art in inflatable membrane structures.

[0006] To achieve the above objectives, the present invention provides a modular inflatable membrane unit frame and roof connection system, including a frame body, which is constructed by connecting profiles; The multi-layer membrane structure integrated on the frame body includes a lower air membrane, a protective net and an upper air cushion arranged sequentially from bottom to top. The protective net is fixed to the inside of the frame body by fasteners. At least two air inflator connectors are installed on the frame body for supplying air to the upper air cushion and the air chamber formed between the upper air cushion and the lower air film, respectively. The main connecting mechanism is located on the outside of the frame body and is used to connect the frame body to the main building structure. An adjacent edge sealing drainage mechanism is provided on the side of the frame body to achieve a sealed connection with adjacent similar frame bodies and jointly form a drainage channel.

[0007] By adopting this technical solution, the core functional layer constituting the inflatable membrane roof and the inflatable pipe joints are integrated into a unified, structural frame body, forming a standardized functional unit that can be independently produced, transported, and hoisted. This unit is equipped with a dedicated main body connection mechanism and an adjacent edge sealing and drainage mechanism, thereby breaking down the complex on-site roof construction into three clear and efficient standardized operation processes: prefabricated unit production, unit-to-main body connection, and inter-unit sealing and drainage. This fundamentally solves the core problems of chaotic processes, low integration, and difficult quality control caused by on-site assembly of loose parts in existing technologies, and realizes the transformation to an industrialized and modular construction mode.

[0008] Furthermore, the frame body is a polygonal closed frame welded from aluminum profiles; The protective mesh is made of stainless steel and is fixed to the inside of the frame body at intervals by self-tapping screws.

[0009] By adopting this technical solution, the aluminum profile closed frame is not only lightweight and corrosion-resistant, but more importantly, it is easy to achieve high-precision processing and welding, providing a flat and firm installation reference surface for the subsequent membrane sealing and fixing structure; the stainless steel protective net is directly fixed to the inside of the frame with self-tapping screws, forming a permanent safety protection integrated with the frame, avoiding the cumbersome and unstable process of hanging the protective net separately.

[0010] Furthermore, the frame body is provided with a sealing and fixing structure for fixing the edges of the lower air film and the upper air cushion.

[0011] By adopting this technical solution, the connection and sealing between the lower air membrane and the upper air cushion and the frame body are ensured.

[0012] Furthermore, the sealing and fixing structure includes reinforcing strips disposed at the edges of the lower air film and the upper air cushion, a slot on the frame body adapted to the reinforcing strips, an elastic sealing gasket covering the membrane material, and a pressure plate and fasteners that press the elastic sealing gasket and the edges of the membrane material onto the frame body.

[0013] By adopting this technical solution, the fit between the reinforcing strip and the slot on the frame body is enhanced, which first achieves precise mechanical positioning of the membrane material edge without slippage, and bears the main tensile force; the elastic sealing gasket generates uniform compression deformation under the pressure of the pressure plate, filling all micro-unevennesses and achieving airtightness; the pressure plate and fasteners provide controllable and durable clamping force; thus, the complex on-site sealing technology is transformed into an assembly process that can be standardized and mechanized in the factory.

[0014] Furthermore, the lower air film and the upper air cushion are respectively fixed to different sides of the frame body to form two air chambers.

[0015] By adopting this technical solution, two independent airtight cavities are formed by utilizing the three-dimensional spatial thickness of the frame body. There is no need to add any partition components in the plane of the frame body, which simplifies the frame design. At the same time, dual-cavity inflation becomes a function of the frame body, improving the system's functional flexibility and thermal performance potential.

[0016] Furthermore, the inflation tube connector includes a tube that penetrates the frame body, elastic sealing gaskets fitted on both sides of the tube, and a locking element.

[0017] By adopting this technical solution, the tube penetrates through the frame body, making it part of the frame body; the elastic sealing gaskets on both sides are compressed under the action of the locking device, ensuring circumferential sealing between the tube body and the corresponding hole wall of the frame body, fundamentally eliminating air leakage at that point.

[0018] Furthermore, the main connection mechanism includes mounting holes provided on the outside of the frame body for mounting bolts, anchors fixed to the main structure of the building, and adapters that connect the bolts and anchors after the mounting holes are installed.

[0019] By adopting this technical solution, the direct connection between the frame body and the main structure is decomposed into two more easily controlled standardized mechanical connections: the connection between the frame body and the adapter and the connection between the adapter and the main building structure. The adapter, as an adapter, can be flexibly designed to connect with the anchors, which greatly enhances the system's adaptability to different building structure forms and installation errors.

[0020] Furthermore, the adjacent edge sealing drainage mechanism includes: A snap-fit ​​structure formed by the extension of the profile of the frame body; A flexible water channel that snaps into the snap-fit ​​structure between two adjacent frame bodies; A cover plate is placed over the snap-fit ​​structure and is fixed to the frame body by fasteners. A sealing structure is provided between the cover plate and the frame body.

[0021] By adopting this technical solution, the snap-fit ​​structure extending from the frame body first provides alignment guidance for adjacent units and forms a natural drainage channel; the flexible drainage channel is snap-fitted and fixed as the main drainage channel, which can effectively collect and drain interface seepage water; the cover plate, as a covering layer, provides physical protection and forms a second line of defense.

[0022] Furthermore, the sealing structure includes sealant filling the joint between the cover plate and the frame body.

[0023] By adopting this technical solution, the sealant can adapt to the slight relative displacement between the cover plate and the frame caused by temperature changes and wind loads, fill all possible gaps, provide final and reliable watertightness assurance, and is easy to inspect and maintain.

[0024] Furthermore, a filling space is formed between the flexible water guide channel, the frame body, and the main building structure; The filling space is provided with an air supply pipe that connects to the air inflator, and is filled with thermal insulation material.

[0025] By adopting this technical solution, the regular space created after unit installation, located below the flexible water guide channel, is used to house the gas supply pipeline and insulation filler, avoiding the impact of exposed pipelines on aesthetics and durability. It also makes the construction of the insulation layer simple, continuous, and effective, realizing the integration of modular installation and high-performance building envelope.

[0026] Compared with the prior art, the present invention has the following advantages: 1. The frame body serves as an integrated platform, pre-assembling the lower air-supported membrane, protective netting, upper air cushion, and inflation pipe joints into a complete structural unit on the ground. This changes the traditional high-altitude, layer-by-layer assembly operation mode, transferring the most complex and precision-required sealing and fixing work of the multi-layer membrane and netting to a factory or ground-based facility under controlled conditions. Furthermore, the unit is hoisted as a whole, requiring only on-site connections between the unit and the main structure, and between units themselves. This significantly reduces the amount of high-altitude work, simplifies on-site procedures, shortens the construction period, and fundamentally ensures the quality stability and reliability of key processes such as membrane sealing and protective netting installation.

[0027] 2. By arranging the insulation filler and gas supply pipelines within the naturally enclosed space formed by the flexible water channel, the frame body, and the main building structure, this layout eliminates the need for additional installation space or components for pipelines and insulation, achieving a concealed and integrated arrangement. This not only significantly simplifies the internal structure of the roof system and optimizes the building's internal height but also ensures a continuous insulation layer without thermal bridges, neat pipeline layout, and protection from external environmental influences, significantly improving the roof's overall physical performance and long-term reliability. Attached Figure Description

[0028] Figure 1 This is a simplified schematic diagram of the modular inflatable membrane unit frame and roof connection system in this invention after removing the pipes; Figure 2 This is a schematic diagram of the nodal structure of the modular inflatable membrane unit frame and roof connection system in this invention.

[0029] Explanation of reference numerals in the attached drawings: 1. Main building structure; 2. Frame body; 3. Lower air membrane; 4. Protective net; 5. Upper air cushion; 6. Cover plate; 7. Sealant; 8. Reinforcing strip; 9. Pressure plate; 10. Basalt wool board; 11. Bolt; 12. Adapter; 13. Anchor; 14. Air supply pipeline; 15. Inflation pipe joint; 16. Flexible water guide channel. Detailed Implementation

[0030] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0031] Please see the appendix Figure 1 and 2 The present invention provides a modular inflatable membrane unit frame and roof connection system, the core of which is a prefabricated unit that can complete the assembly of all functional layers on the ground, and a set of standardized interfaces that ensure reliable connection between the unit and the building body and sealed docking with adjacent units.

[0032] 1. Factory prefabrication of modular inflatable membrane units: First, the frame body 2 is manufactured; preferably, 6063-T5 or T6 aluminum alloy profiles conforming to standard GB / T:5237 are used. Through CNC blanking, corner bracket connection and welding, a polygonal (preferably triangular) closed frame is formed. The profile cross-section of this frame is designed according to the stress, and all key machining is completed in the factory. Mounting hole machining: On the outer flange of the profile on each side of the frame, mounting holes for mounting bolts 11 are machined. These mounting holes are preferably machined into elongated holes, with a length of 30mm and a width of 11mm, so as to provide an adjustment margin of ±10mm or more for subsequent mounting of bolts 11.

[0033] Slot forming: On the profile surface used to fix the membrane material, a special slot that precisely matches the cross section of the reinforcing strip is processed by extrusion or milling. For example, the slot can be designed as a dovetail groove or rectangular groove with a width of 6.3 mm and a depth of 8 mm to ensure the stable holding of the reinforcing strip.

[0034] Air tube installation hole: Drill a round hole at the preset position for installing the air tube connector 15. The diameter of the hole is slightly larger than the outer diameter of the tube body.

[0035] Next, install the protective net 4; the protective net 4 is made of 304 stainless steel mesh with a wire diameter of 2.0mm and a mesh size of 30mm×30mm. Lay it flat and tension it on the inside of the frame body 2; use A2-70 stainless steel self-tapping screws to firmly fix the protective net 4 to the inside of the frame body 2 at 150mm intervals. The screw length must ensure that the effective thread engagement depth is greater than the profile wall thickness.

[0036] Next, install the air hose connector 15. The core of the air hose connector 15 is an aluminum profile tube with external threads at both ends. During installation, pass it through the preset air hose mounting hole from the inside of the frame body 2. Insert a 2mm thick EPDM (ethylene propylene diene monomer) O-ring or flat washer between the contact surfaces of the tube and the frame body 2 as an elastic sealing gasket. Then, screw on the aluminum profile nut that matches the tube thread from the outside of the frame body 2. Tighten it to the specified value with a torque wrench to make the elastic sealing gasket compress by about 30% to achieve a reliable circumferential seal. Finally, fasten a section of PU or rubber air hose to the end of the tube located inside the frame body 2 with a stainless steel clamp.

[0037] Subsequently, the upper air cushion 5 is installed. The upper air cushion 5 is formed by heat-sealing and welding of ETFE membrane material, and its edges are heat-sealed with solid EPDM rubber rods with a diameter of Φ6mm as reinforcing strips 8 (preferably rubber rods). During installation, the reinforcing strips 8 are aligned and inserted into the special slots of the upper edge profile of the frame. The air nozzles on the upper air cushion 5 are connected to the air inflator pipe joints 15 corresponding to the air chambers on the upper air cavity of the inflatable membrane unit. A continuous EPDM sealing strip with a rectangular cross-section is laid on the membrane material of the upper air cushion 5 and on the overlapping surface with the frame body 2 as an elastic sealing gasket. Then, an aluminum profile pressure plate 9 with a cross-sectional shape matching the frame is placed on top, and it is evenly tightened with pan head stainless steel self-tapping screws. The tightening torque of the screws must ensure that the EPDM sealing strip is fully compressed to form an airtight barrier.

[0038] Finally, the lower air membrane 3 is installed; its process is symmetrical to that of the upper air cushion 5. The reinforcing strip 8 on the edge of the lower air membrane 3 is inserted into the corresponding special slot on the lower edge of the frame. The lower air cavity formed between the lower air membrane 3 and the upper air cushion 5 is naturally connected to the corresponding air pipe connector 15. The EPDM sealing strip is placed, the pressure plate 9 is covered and tightened. At this point, the lower air cavity is formed between the lower air membrane 3, the frame body 2 and the upper air cushion 5, and the upper air cushion 5 itself forms the upper air cavity. A modular inflatable membrane unit integrating double air cavities, protective nets and inflation interfaces is prefabricated.

[0039] 2. Preparations for the main roof structure: Measure and lay out the lines on the main building structure 1 (such as a steel space frame) to determine the installation center of each unit. At each installation point, use S15.5-30 stainless steel welded bolts as anchors 13 and weld them vertically to the surface of the main structure. Cut and drill a 5mm thick Q235 galvanized steel plate to make an adapter 12 and put it on the welded bolt. Tighten the nuts to complete the connection with the main building structure 1. The adapter 12 has a round hole that matches the welded bolt and an elongated hole for connecting bolts 11.

[0040] 3. On-site hoisting and connection of modular units: The prefabricated inflatable membrane unit is transported to the installation position using hoisting equipment. Bolts 11 are installed into the mounting holes of the frame body 2, and an EPDM flat washer is added to the bolt head. The bolt is then passed through the corresponding hole of the adapter 12, and finally the nut is tightened to complete the connection between the frame body 2 and the adapter 12. By adjusting the position of bolts 11 on the frame body 2, the planar position of the unit can be finely adjusted. By adjusting the nut between the adapter 12 and the stainless steel welded bolt, the height and angle can be finely adjusted. After all the inflatable membrane units are adjusted to the design position, they are finally tightened uniformly.

[0041] 4. Functional integration and sealing between units After all the inflatable membrane units are installed and fixed, the subsequent integration work is carried out. First, the gap between the adapter 12 of two adjacent inflatable membrane units is tightly filled with water-repellent basalt wool board 10 with a density of not less than 120kg / m³ as thermal insulation filler.

[0042] Then, install the drainage system; press a flexible water guide channel 16 made of TPV (thermoplastic vulcanized rubber) into the snap-fit ​​structure between the side profiles of the two adjacent frame bodies 2 along the joint direction of the inflatable membrane unit; TPV material has good elasticity and weather resistance.

[0043] Next, install the cover plate 6; the cover plate 6 can be made of 304 stainless steel plate with a thickness of 0.8mm bent into a water trough shape, or fluorocarbon coated aluminum plate with a thickness of 2.0mm; cover it on top of the flexible water guide channel 16 and the snap-fit ​​structure, and fix it to the frame body 2 with stainless steel self-tapping screws.

[0044] Finally, waterproof sealing is implemented; at all joints between the cover plate 6 and the frame body 2 profile, first fill with closed-cell polyethylene foam rods with a diameter slightly larger than the joint width as a backing, and then fully coat the surface with neutral silicone weather-resistant sealant 7 to form the final flexible waterproof sealing layer.

[0045] 5. System Connection and Debugging Connect the pre-installed air hoses of each inflatable membrane unit to the pre-installed air supply line 14 on the roof via quick-connect couplings. Start the inflation system and inflate to 50% of the design pressure. Check the shape of all units and the airtightness of the connection points. If there are no abnormalities, continue to inflate to 100% of the design working pressure (e.g., 250Pa for the upper air chamber and 150Pa for the lower air chamber). An intelligent control system can be integrated to automatically stabilize the pressure based on sensor feedback.

[0046] Through the above steps, this invention transforms the complex inflatable membrane roofing project into standardized modular factory production and on-site assembly construction, achieving a comprehensive improvement in efficiency, quality, and reliability while ensuring high performance indicators.

[0047] In another, more complete embodiment, an active melting film mechanism is also included, which works in conjunction with an intelligent control system. When a fire occurs indoors, the active melting film mechanism is activated by the intelligent control system to actively melt and cut off the upper air cushion 5 and the lower air film 3, thereby creating a smoke outlet on the roof to effectively control the danger.

[0048] The present invention has been described in detail above with reference to the accompanying drawings and embodiments. Those skilled in the art can make various modifications to the present invention based on the above description. Therefore, certain details in the embodiments should not be construed as limiting the present invention, and the scope of protection of the present invention shall be defined by the appended claims.

Claims

1. A modular inflatable membrane unit frame and roof connection system, characterized in that, include: The frame itself is constructed from connected profiles; The multi-layer membrane structure integrated on the frame body includes a lower air membrane, a protective net and an upper air cushion arranged sequentially from bottom to top. The protective net is fixed to the inside of the frame body by fasteners. At least two air inflator connectors are installed on the frame body for supplying air to the upper air cushion and the air chamber formed between the upper air cushion and the lower air film, respectively. The main connecting mechanism is located on the outside of the frame body and is used to connect the frame body to the main building structure. An adjacent edge sealing drainage mechanism is provided on the side of the frame body to achieve a sealed connection with adjacent similar frame bodies and jointly form a drainage channel.

2. The modular inflatable membrane unit frame and roof connection system according to claim 1, characterized in that: The frame body is a polygonal closed frame welded from aluminum profiles; The protective mesh is made of stainless steel and is fixed to the inside of the frame body at intervals by self-tapping screws.

3. The modular inflatable membrane unit frame and roof connection system according to claim 1, characterized in that: The frame body is provided with a sealing and fixing structure for fixing the edges of the lower air film and the upper air cushion.

4. The modular inflatable membrane unit frame and roof connection system according to claim 3, characterized in that: The sealing and fixing structure includes reinforcing strips disposed at the edges of the lower air film and the upper air cushion, slots on the frame body that are adapted to the reinforcing strips, elastic sealing gaskets covering the membrane material, and pressure plates and fasteners that press the elastic sealing gaskets and the edges of the membrane material onto the frame body.

5. The modular inflatable membrane unit frame and roof connection system according to claim 4, characterized in that: The lower air membrane and the upper air cushion are fixed to different sides of the frame body to form two air chambers.

6. The modular inflatable membrane unit frame and roof connection system according to claim 1, 4 or 5, characterized in that: The inflation tube connector includes a tube that penetrates the frame body, elastic sealing gaskets fitted on both sides of the tube, and a locking element.

7. The modular inflatable membrane unit frame and roof connection system according to claim 1, characterized in that: The main connection mechanism includes mounting holes for installing bolts on the outside of the frame body, anchors fixed to the main structure of the building, and adapters that connect the bolts and anchors after the bolts are installed in the mounting holes.

8. The modular inflatable membrane unit frame and roof connection system according to claim 1, characterized in that: The adjacent edge sealing drainage mechanism includes: A snap-fit ​​structure formed by the extension of the profile of the frame body; A flexible water channel that snaps into the snap-fit ​​structure between two adjacent frame bodies; A cover plate is placed over the snap-fit ​​structure and is fixed to the frame body by fasteners. A sealing structure is provided between the cover plate and the frame body.

9. The modular inflatable membrane unit frame and roof connection system according to claim 8, characterized in that: The sealing structure includes sealant filling the joint between the cover plate and the frame body.

10. The modular inflatable membrane unit frame and roof connection system according to claim 8, characterized in that: A filling space is formed between the flexible water guide channel, the frame body, and the main building structure; The filling space is provided with an air supply pipe that connects to the air inflator, and is filled with thermal insulation material.

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