A prefabricated structure and construction method for large-area irregularly shaped aluminum ceiling panels

Abstract

This invention discloses a prefabricated structure and construction method for large-area irregularly shaped ceiling aluminum panels, including a base frame, irregularly shaped aluminum panels, and hook-and-loop components. The irregularly shaped aluminum panels are fixed to the base frame via the hook-and-loop components. All components—the base frame, the irregularly shaped aluminum panels, and the hook-and-loop components—are made of aluminum. The beneficial effects of this invention are: Prefabricated installation allows for pre-correction of the shape and unified leveling, resulting in a more regular overall shape and higher fidelity to irregular curved surfaces; prefabricated installation is suitable for large areas, complex irregular shapes, large spans, and high-clearance locations, offering greater adaptability to complex shapes; prefabricated installation provides stable stress, convenient testing, reliable overall hoisting and positioning, and superior node accuracy and structural stability; prefabricated installation significantly reduces high-altitude work time; labor input is reduced by 60%, and temporary work costs are reduced by 40%; improved accuracy solves the problem of connecting irregularly shaped ceiling designs; and increased efficiency: the on-site construction cycle is shortened by more than 60%, eliminating the need for on-site cutting and welding, and reducing conflicts arising from overlapping operations.

Description

Technical Field

[0001] This invention relates to the field of architectural decoration engineering technology, and in particular to a prefabricated structure and construction method for large-area irregularly shaped aluminum ceiling panels. Background Technology

[0002] Irregularly shaped aluminum ceiling panels are increasingly widely used in modern architectural interior and exterior decoration due to their unique shapes and smooth lines. Traditional installation methods for irregularly shaped aluminum panels often involve on-site welding, riveting, or fixing with universal connectors, which suffers from low construction precision, slow efficiency, high skill requirements for workers, and difficulty in controlling the overall shape. Especially for irregularly shaped ceilings with complex curved surfaces or requiring multiple panels to be spliced, achieving rapid, precise, and adjustable prefabricated installation while ensuring structural stability and aesthetic appeal remains a pressing technical challenge in this field.

[0003] Therefore, it is necessary to propose a prefabricated structure and construction method for large-area irregular-shaped aluminum ceiling panels to address the above issues. Summary of the Invention

[0004] In view of the shortcomings of the prior art, the purpose of this invention is to provide a prefabricated structure and construction method for large-area irregular-shaped aluminum ceiling panels to solve the above problems.

[0005] A prefabricated structure for large-area irregularly shaped ceiling aluminum panels includes a base frame, irregularly shaped aluminum panels, and hook-and-loop components. The irregularly shaped aluminum panels are fixed to the base frame via the hook-and-loop components. All components, including the base frame, irregularly shaped aluminum panels, and hook-and-loop components, are made of aluminum.

[0006] Preferably, the base frame is assembled from a main keel and hook keels.

[0007] Preferably, the irregularly shaped aluminum plate includes a first plate and a second plate, and the first plate and the second plate are connected by corner brackets and rivets.

[0008] Preferably, the outer surfaces of both the first and second plates are coated with colored paint.

[0009] Preferably, the first panel includes a first side panel, a second side panel, and a first back panel, which are fixedly assembled together by corner brackets and rivets.

[0010] Preferably, the second panel includes a third side panel, a fourth side panel, and a second back panel, which are fixedly assembled together by corner brackets and rivets.

[0011] Preferably, the hook assembly includes a first aluminum plate hook component, a second aluminum plate hook component, and a keel hook component. A construction method for a large-area irregularly shaped aluminum ceiling panel prefabricated structure, the steps of which are as follows: S1. Assemble the first panel: After cutting and bending the panel according to the detailed design, the first side panel and the second side panel are fixed to the first back panel using corner brackets and rivets to assemble the first panel. S2. Assemble the second panel: After cutting and bending the panel according to the detailed design, fix the third and fourth side panels to the second back panel with corner brackets and rivets to form the second panel; S3. Install LED strip: Make a hole in the middle of the first side panel of the first plate for positioning and pre-install the LED strip, so that the LED strip is integrally formed with the first plate; make a hole in the middle of the second plate according to the positioning and pre-install the LED strip, so that it is integrally formed with the second plate. S4. Assemble the irregular aluminum plate: Assemble the first plate and the second plate into a shaped aluminum plate using corner brackets and rivets, and lead the light wire out from the aluminum plate; S5. Install the base frame: Arrange the main keel in sections on the ceiling according to the positioning relationship of the aluminum panels, and then install and fix the hook keel and keel hook parts on the main keel to complete the fixing of the irregular aluminum panel base. S6. Install irregular aluminum plates: Assemble and install the first and second aluminum plate hooks on the irregular aluminum plates with the keel hooks on the base frame in an integrated manner.

[0012] Preferably, the main keel, hook keel, and keel hook components are all prefabricated components in the factory and directly assembled on site in a modular manner.

[0013] Preferably, both the first and second plates are CNC cut, bent, painted and pre-assembled with accessories in the factory, and the dimensional accuracy of the plates is controlled within ±0.3mm.

[0014] Compared with the prior art, the present invention has the following advantages: 1. This invention features pre-correction and leveling of the prefabricated installation, resulting in a more regular overall shape and higher fidelity in the reproduction of irregular curved surfaces. Prefabricated installation is suitable for large-area, complex irregular shapes, large spans, and high-clearance locations, with stronger adaptability to complex shapes. Prefabricated installation provides stable stress, convenient testing, reliable overall hoisting and positioning, and superior node accuracy and structural stability. Prefabricated installation significantly reduces high-altitude work time, shortening the overall construction period by more than 30%. It also reduces labor input by 60%, temporary works costs by 40%, and material waste by 30%.

[0015] 2. Improved precision: Factory prefabrication ensures that the dimensional error of aluminum panel units is ≤0.3mm, and the connection accuracy of on-site snap-fit ​​assembly is ≤0.5mm, solving the problem of connecting irregularly shaped ceilings; Improved efficiency: On-site construction cycle is shortened by more than 60%, eliminating the need for on-site cutting and welding, and reducing conflicts between cross-operations. 3. Stable quality: Standardized prefabrication and modular assembly avoid errors from manual operation, and the flatness and uniformity of the aluminum panels meet the requirements of high-grade decoration. 4. Green and environmentally friendly: No cutting dust on site, meeting green construction standards; Reduced costs: Material loss rate is reduced from the traditional 15% to below 5%, and subsequent maintenance costs are reduced by 80%. Attached Figure Description

[0016] Figure 1 This is a structural diagram of the present invention; Figure 2 yes Figure 1 A1-A1 section structural diagram; Figure 3 yes Figure 1 A2-A2 section structural diagram; Figure 4 yes Figure 1 Structural diagram of section B1-B1; Figure 5 This is a partial structural diagram of the present invention; Figure 6 This is a diagram of the main keel structure of the present invention; Figure 7 This is a diagram of the hook-and-loop keel structure of the present invention; Figure 8 This is a structural diagram of the first section of the present invention; Figure 9 and Figure 10 This is a side view of the first plate structure of the present invention; Figure 11 This is a top view of the first section of the present invention; Figure 12 This is a structural diagram of the second section of the present invention; Figure 13 and Figure 14 This is a side view of the second plate structure of the present invention; Figure 15 This is a top view of the second section of the present invention.

[0017] The attached diagram is labeled as follows: 1. Base frame; 2. Irregular aluminum plate; 3. Hook-up assembly; 101. Main keel; 102. Hook-up keel; 21. First panel; 22. Second panel; 211. First side panel; 212. Second side panel; 213. First back panel; 221. Third side panel; 222. Fourth side panel; 223. Second back panel; 301. First aluminum plate hook-up piece; 302. Second aluminum plate hook-up piece; 303. Keel hook-up piece. Detailed Implementation

[0018] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0019] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0020] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0021] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings, but the present invention can be implemented in many different ways as defined and covered by the claims.

[0022] like Figure 1 and combined Figures 2 to 15 As shown, a prefabricated structure for a large-area irregularly shaped ceiling aluminum panel includes a base frame 1, an irregularly shaped aluminum panel 2, and a hook assembly 3. The irregularly shaped aluminum panel 2 is fixed to the base frame 1 by the hook assembly 3. The base frame 1, the irregularly shaped aluminum panel 2, and the hook assembly 3 are all made of aluminum.

[0023] Furthermore, the base frame 1 is assembled from the main keel 101 and the hook keel 102.

[0024] Furthermore, the irregularly shaped aluminum plate 2 includes a first plate 21 and a second plate 22, which are connected by corner brackets and rivets.

[0025] Furthermore, the outer surfaces of both the first plate 21 and the second plate 22 are coated with colored paint.

[0026] Furthermore, the first panel 21 includes a first side panel 211, a second side panel 212, and a first back panel 213, which are fixedly assembled together by corner brackets and rivets.

[0027] Furthermore, the second panel 22 includes a third side panel 221, a fourth side panel 222, and a second back panel 223, which are fixedly assembled together by corner brackets and rivets.

[0028] Furthermore, the hook assembly 3 includes a first aluminum plate hook 301, a second aluminum plate hook 302, and a keel hook 303.

[0029] A construction method for a large-area irregularly shaped aluminum ceiling panel prefabricated structure, the steps of which are as follows: S1. Assemble the first plate 21: After cutting and bending the plate according to the detailed design, the first side plate 211 and the second side plate 212 are fixed and assembled with the first back plate 213 using corner brackets and rivets to form the first plate 21. S2. Assemble the second panel 22: After cutting and bending the panel according to the detailed design, the third side panel 221 and the fourth side panel 222 are fixed and assembled with the second back panel 223 using corner brackets and rivets to form the second panel 22. S3. Install the light strip: Make a hole in the middle of the first side plate 21 to position and pre-install the light strip, so that the light strip is integrally formed with the first plate 21; make a hole in the middle of the second plate 22 according to the positioning to pre-install the light strip, and finally form it integrally with the second plate 22. S4. Assemble the irregular aluminum plate 2: Assemble the first plate 21 and the second plate 22 into a shaped aluminum plate 2 using corner brackets and rivets, and lead the light wire out from the aluminum plate; S5. Install the base frame 1: According to the positioning relationship of the aluminum plate, the main keel 101 is arranged in sections on the ceiling, and then the hook keel 102 and the keel hook part 303 are installed and fixed on the main keel 101 to complete the fixing of the irregular aluminum plate 2 to the base. S6. Install the irregular aluminum plate 2: Assemble the first aluminum plate hook 301 and the second aluminum plate hook 302 on the irregular aluminum plate 2 with the keel hook 303 on the base frame 1.

[0030] Furthermore, the main keel 101, hook keel 102 and keel hook parts 303 are all prefabricated components in the factory and are directly modularly assembled on site.

[0031] Furthermore, both the first plate 21 and the second plate 22 are CNC cut, bent, painted and pre-assembled with accessories in the factory, and the dimensional accuracy of the plates is controlled within ±0.3mm.

[0032] Compared with existing technologies, the advantages of this invention are as follows: 1. Pre-assembly installation of this invention allows for pre-correction of the shape and unified leveling, resulting in a more regular overall forming effect and higher fidelity in the reproduction of irregular curved surfaces; prefabricated installation is suitable for large-area, high-difficulty irregular shapes, large spans, and high-clearance locations, and has stronger adaptability to complex shapes; prefabricated installation provides stable stress, convenient testing, reliable overall hoisting and positioning, and superior node accuracy and structural stability; prefabricated installation significantly reduces high-altitude operation time, shortening the overall construction period by more than 30%; labor input is reduced by 60%, temporary measures costs by 40%, and material waste by 30%. 2. Improved Precision: Factory prefabrication ensures that the dimensional error of aluminum panel units is ≤0.3mm, and the connection accuracy of on-site snap-fit ​​assembly is ≤0.5mm, solving the problem of connecting irregularly shaped ceilings; Increased Efficiency: On-site construction cycle is shortened by more than 60%, eliminating the need for on-site cutting and welding, and reducing conflicts between overlapping operations; 3. Stable Quality: Standardized prefabrication and modular assembly avoid errors from manual operation, and the flatness and joint uniformity of aluminum panels meet high-level decoration requirements; 4. Green and Environmentally Friendly: No cutting dust on-site, meeting green construction standards; Reduced Costs: Material loss rate is reduced from the traditional 15% to below 5%, and subsequent maintenance costs are reduced by 80%.

[0033] Technical Effect Verification Comparison Table:

[0034] Example 1: This embodiment provides a prefabricated structure for large-area hyperboloid irregular ceiling aluminum panels, which is applied to the decoration project of hyperboloid irregular ceiling in the atrium of a large commercial complex. The overall decoration area is not less than 800㎡, and the area of ​​a single set of irregular aluminum panel splicing unit is 55㎡.

[0035] The prefabricated structure includes a base frame 1, irregularly shaped aluminum plates 2, and hook-and-loop components 3, all made of aluminum. The base frame 1 is assembled from a main keel 101 and hook-and-loop keels 102. The irregularly shaped aluminum plates 2 include a first plate 21 and a second plate 22. The first plate 21 is assembled from a first side plate 211, a second side plate 212, and a first back plate 213, fixed together with corner brackets and rivets. The second plate 22 is assembled from a third side plate 221, a fourth side plate 222, and a second back plate 223, fixed together with corner brackets and rivets. The first plate 21 and the second plate 22 are connected by corner brackets and rivets, and both are coated with matte white paint. The hook-and-loop components 3 include a first aluminum plate hook 301, a second aluminum plate hook 302, and a keel hook 303.

[0036] The construction method steps in this embodiment are as follows: S1. In the factory, the sheet metal is CNC cut and bent according to the detailed design. The first side plate 211, the second side plate 212 and the first back plate 213 are fixed and assembled into the first plate 21 using corner brackets and rivets. The dimensional accuracy of the plate is controlled within ±0.3mm. S2. In the factory, the boards are CNC cut and bent according to the detailed design. The third side plate 221, the fourth side plate 222 and the second back plate 223 are fixed and assembled into the second plate 22 using corner brackets and rivets. The dimensional accuracy of the plate is controlled within ±0.3mm. S3. In the factory, make a hole in the middle of the first side plate 211 of the first plate 21 and pre-install the light strip. Make a hole in the corresponding position of the second plate 22 and pre-install the light strip so that the light strip and the plate are integrally formed. S4. In the factory, the first plate 21 and the second plate 22 are assembled into a shaped aluminum plate 2 using corner brackets and rivets, and the lamp wires are led out from the aluminum plate. S5. On-site, the main keel 101 is arranged according to the positioning relationship of the aluminum plates. The hook keel 102 and the keel hook parts 303 are fixedly installed on the main keel 101 to complete the assembly of the base frame 1. The main keel 101, hook keel 102 and keel hook parts 303 are all prefabricated components in the factory and are directly modularly assembled on-site. S6. On-site, the first aluminum plate hook 301 and the second aluminum plate hook 302 on the irregular aluminum plate 2 are assembled with the keel hook 303 on the base frame 1 using a snap-fit ​​method, and the hyperboloid shape is uniformly leveled and corrected.

[0037] In this embodiment, the irregular curved surface has a high degree of fidelity, the overall forming is regular, the on-site construction cycle is shortened by 62%, the labor input is reduced by 60%, the material loss rate is reduced to 4.2%, and the node accuracy and structural stability meet the requirements of high-end decoration.

[0038] Example 2: This embodiment provides a high-clearance, large-span irregular-shaped ceiling aluminum panel prefabricated structure, which is applied to the irregular-shaped ceiling project of a large exhibition center exhibition hall. The ceiling clear height is 9.5m and the single span is 16m, which is suitable for high-clearance, large-span construction scenarios.

[0039] The prefabricated structure includes a base frame 1, irregularly shaped aluminum plates 2, and hook-and-loop components 3, all made of aluminum. The base frame 1 is assembled from a thickened main keel 101 and a reinforced hook-and-loop keel 102. The irregularly shaped aluminum plate 2 includes a first plate 21 and a second plate 22. The first plate 21 is assembled from a first side plate 211, a second side plate 212, and a first back plate 213. The second plate 22 is assembled from a third side plate 221, a fourth side plate 222, and a second back plate 223. The outer surface of the plates is sprayed with metallic silver-gray paint, and the built-in light strip is prefabricated as an integrated unit. The hook-and-loop components 3 consist of an anti-detachment first aluminum plate hook 301, a second aluminum plate hook 302, and a load-bearing optimized keel hook 303.

[0040] The construction method steps in this embodiment are as follows: S1. Factory CNC cutting and bending of sheet metal, fixing and assembling the first side plate 211, the second side plate 212 and the first back plate 213 into the first plate 21, completing the spraying and pre-installation of the light strip. S2. Factory CNC cutting and bending of the sheet material, fixing and assembling the third side plate 221, the fourth side plate 222 and the second back plate 223 into the second plate 22, and completing the spraying and pre-installation of the light strip. S3. The first section 21 and the second section 22 are assembled in the factory to form the irregular aluminum plate 2 and lead out the light wires; S4. On-site, the prefabricated main keel 101 and hook keel 102 are modularly assembled in the factory, and the keel hook parts 303 are fixed to complete the installation of the base frame 1. S5. The irregular aluminum plate 2 is hoisted on site as a whole, and the first aluminum plate hook 301, the second aluminum plate hook 302 and the keel hook 303 are engaged and assembled. After the installation is completed, the node accuracy and structural stability are tested.

[0041] This embodiment can significantly reduce the time spent working at heights by 75%, ensure on-site assembly and connection accuracy of ≤0.5mm, meet the structural load stability requirements for large-span applications, reduce subsequent maintenance costs by 81%, and comply with green construction standards.

[0042] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A prefabricated structure for large-area irregularly shaped ceiling aluminum panels, characterized in that: It includes a base frame (1), an irregular aluminum plate (2) and a hook assembly (3). The irregular aluminum plate (2) is fixed to the base frame (1) by the hook assembly (3). The base frame (1), the irregular aluminum plate (2) and the hook assembly (3) are all made of aluminum.

2. The prefabricated structure of a large-area irregularly shaped ceiling aluminum panel as described in claim 1, characterized in that: The base frame (1) is assembled from the main keel (101) and the hook keel (102).

3. The prefabricated structure of a large-area irregularly shaped ceiling aluminum panel as described in claim 1, characterized in that: The irregular aluminum plate (2) includes a first plate (21) and a second plate (22), which are connected by corner brackets and rivets.

4. The prefabricated structure of a large-area irregularly shaped ceiling aluminum panel as described in claim 3, characterized in that: The outer surfaces of the first plate (21) and the second plate (22) are both sprayed with colored paint.

5. The prefabricated structure of a large-area irregularly shaped ceiling aluminum panel as described in claim 3, characterized in that: The first panel (21) includes a first side panel (211), a second side panel (212) and a first back panel (213), which are fixedly assembled by corner brackets and rivets.

6. The prefabricated structure of a large-area irregularly shaped ceiling aluminum panel as described in claim 3, characterized in that: The second panel (22) includes a third side panel (221), a fourth side panel (222), and a second back panel (223), which are fixedly assembled with corner brackets and rivets.

7. The prefabricated structure of a large-area irregularly shaped ceiling aluminum panel as described in claim 1, characterized in that: The hook assembly (3) includes a first aluminum plate hook (301), a second aluminum plate hook (302), and a keel hook (303).

8. A construction method for a large-area irregular-shaped aluminum ceiling panel prefabricated structure as described in any one of claims 1-7, characterized in that: The method and steps are as follows: S1. Assemble the first panel (21): After cutting and bending the panel, fix the first side panel (211) and the second side panel (212) to the first back panel (213) using corner brackets and rivets to assemble the first panel (21); S2. Assemble the second panel (22): After cutting and bending the panel, fix the third side panel (221) and the fourth side panel (222) to the second back panel (223) using corner brackets and rivets to assemble the second panel (22). S3. Install the light strip: Make a hole in the middle of the first side plate (211) of the first plate (21) for positioning and pre-install the light strip, so that the light strip is integrally formed with the first plate (21); make a hole in the middle of the second plate (22) according to the positioning and pre-install the light strip, so that it is integrally formed with the second plate (22). S4. Assemble the irregular aluminum plate (2): Assemble the first plate (21) and the second plate (22) into an irregular aluminum plate (2) using corner brackets and rivets, and lead the lamp wire out from the irregular aluminum plate (2); S5. Install the base frame (1): According to the positioning relationship of the irregular aluminum plate (2), the main keel (101) is arranged in sections on the ceiling, and then the hook keel (102) and the keel hook parts (303) are installed and fixed on the main keel (101) to complete the fixing of the irregular aluminum plate (2) base. S6. Install the irregular aluminum plate (2): The first aluminum plate hook (301) and the second aluminum plate hook (302) on the irregular aluminum plate (2) are assembled and integrated with the keel hook (303) on the base frame (1).

9. The construction method of a large-area irregular-shaped aluminum ceiling panel prefabricated structure as described in claim 8, characterized in that: The main keel (101), hook keel (102) and keel hook parts (303) are all prefabricated components in the factory and are directly modularly assembled on site.

10. The construction method of a large-area irregular-shaped aluminum ceiling panel prefabricated structure as described in claim 8, characterized in that: The first plate (21) and the second plate (22) are both CNC cut, bent, painted and pre-assembled with accessories in the factory, and the plate size accuracy is controlled within ±0.3mm.

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