A roof sandwich panel and method of processing and installing same

Abstract

The present application relates to a kind of roof sandwich panel and its processing installation method, including upper plate, filling layer and lower plate, the lower plate public edge is with lock nail platform, lock nail platform is firmly connected with purline, lock nail platform is fixed with upper plate by local fastener and prefabricated fastener and forms a solid body, connecting platform is provided with support foot, ensure screw firm, lower plate female edge and public edge cooperate, the lower plate of female edge extends to the lower side of public edge and is pressed by public edge, prefabricated fastener covers the public edge of upper plate, the female edge of upper plate is buckled with the public edge, while also covering prefabricated fastener of local lock nail platform, prefabricated fastener is the solid transition body of connecting upper plate and lower plate, can maximumly reduce the thermal bridge of upper plate and lower plate, ensure insulation effect, lock nail platform is a closed tubular profile, can make the lock nail on platform firmly lock sandwich panel, there is pre-hole in the closed tubular profile, polyurethane edge seal material can flow into closed tubular profile, to improve the strength of sandwich panel, improve the installation strength of sandwich panel, strong wind resistance.

Description

Technical Field

[0001] This invention relates to sandwich panels, and more particularly to a roof sandwich panel and its processing and installation method. Background Technology

[0002] Corrugated sandwich panels are used for building roofs and require waterproofing, fire resistance, and thermal insulation. With the widespread application of photovoltaic roofs, the installation of photovoltaic panels on corrugated sandwich panels places higher demands on their bending strength and wind load resistance. Existing products on the market also have a locking platform on one side of the bottom panel, filled with polyurethane foam. However, this locking platform is an open-loop structure. When the platform is pressed down by screws, the soft polyurethane foam underneath lacks rigid support, resulting in weak support strength. Consequently, the screws cannot be fully tightened, flattening the locking platform and causing them to loosen, significantly reducing the wind resistance of the sandwich panel. Furthermore, in existing technology, the corrugations in the middle of the sandwich panel are not fixed with nails, leaving the corrugations and steel purlins completely suspended and lacking wind load resistance. Therefore, it is necessary to design a roof sandwich panel with strong wind resistance. Summary of the Invention

[0003] In view of the shortcomings of the prior art, the purpose of this invention is to provide a roof sandwich panel and its processing and installation method to solve one or more problems in the prior art.

[0004] To achieve the above objectives, the technical solution of the present invention is as follows:

[0005] A roof sandwich panel has a male edge and a female edge at both ends, and includes an upper panel, a filling layer, and a lower panel arranged sequentially. The male edge of the lower panel is formed into a locking platform, which extends outward beyond the male edge of the upper panel. The locking platform is a closed tubular profile formed by the lower panel plane, the locking surface, the support legs, and the male and female mating surfaces. The locking platform is fixedly connected to the purlin by the lower end of fasteners, and the locking platform is also hooked to the male edge of the upper panel by fasteners and prefabricated fasteners. That is, the upper panel and the lower panel are connected by fasteners and prefabricated fasteners. The slab and purlin are connected as a whole. The mother edge of the lower slab is formed into a support platform. The support platform extends to the underside of the locking platform of another roof sandwich panel and presses the support platform onto the purlin through the locking platform. The mother edge of the upper slab is connected to the prefabricated fasteners connected to the locking platform of another roof sandwich panel. The filling layer includes a fire-resistant insulation layer in the middle of the upper and lower slabs and polyurethane foam sealing layers on both sides. Several pre-holes are opened on the locking surface or support feet of the locking platform to allow liquid polyurethane to enter the locking platform and seal the tubular profile.

[0006] As a further improvement to the above technical solution:

[0007] The support legs are vertically supported on the lower plate.

[0008] The lower end of the support foot can be bent to form a horizontal support foot.

[0009] The support foot is located on the outer edge of the upper plate, and the pre-hole is made on the support foot of the locking platform.

[0010] The support foot is located inside the male edge of the upper plate, and the pre-holes are respectively opened on the support foot and the surface of the locking pin platform.

[0011] The pre-hole is opened through the support foot and the surface of the locking pin platform.

[0012] The upper plate is also formed with several protruding reinforcing ribs. The roof sandwich panel is connected to the reinforcing ribs, the fire-resistant insulation layer and the lower plate purlins by fasteners. The reinforcing ribs are provided with shoulders on both sides, and the reinforcing ribs are connected with caps by fastening the shoulders on both sides.

[0013] The cap has expansion grooves on the shoulders of the reinforcing ribs on both sides, and sealing strips are provided between the cap and the reinforcing ribs on both sides.

[0014] A method for processing and installing roof sandwich panels includes the following steps:

[0015] 1) Unwinding: The boards for processing the upper and lower panels are unwound separately by an uncoiler;

[0016] 2) Lower plate punching: Pre-punch holes in the corresponding positions on the lower plate using roller punching or flat punching;

[0017] 3) Forming: The upper plate is formed by a forming machine, and several reinforcing ribs are formed in the middle of the upper plate; the lower plate is formed into a locking platform and a support platform at both ends by a forming machine.

[0018] 4) Filling layer filling: Apply adhesive to the lower side of the upper plate and the upper side of the lower plate, and fill the refractory insulation material between the upper plate and the lower plate with adhesive. Inject polyurethane material into the positions on both sides of the refractory insulation material. The polyurethane foam material is initially in a liquid state. The liquid polyurethane foam material will enter the closed tubular profile of the locking platform through the pre-hole.

[0019] 5) Roof sandwich panel forming: After the filling layer is filled, it enters the crawler machine. The product is pressed in the crawler machine, so that the fire-resistant insulation material is formed into a fire-resistant insulation layer. At the same time, the product is heated in the crawler machine, so that the polyurethane foam material foams to form a polyurethane foam sealing layer, which seals the male and female edges of the roof sandwich panel. At the same time, the polyurethane foam material will also fill the inside of the closed tubular profile of the locking platform. Finally, it is cut into roof sandwich panels of appropriate size according to the length requirements.

[0020] 6) Roof Sandwich Panel Installation: Prefabricated fasteners are connected to the locking platform using fasteners. These fasteners hook onto the male edge of the upper panel, connecting the locking platform of the lower panel to the male edge of the upper panel. The lower end of the fasteners also secures the lower panel to the purlin. Then, the female edge of another roof sandwich panel is inserted into the male edge of the already connected roof sandwich panel. The support platform formed on the female edge of the lower panel of the other roof sandwich panel extends below the locking platform of the already connected roof sandwich panel. The locking platform presses the support platform of the unconnected roof sandwich panel onto the purlin. Then, the connected roof sandwich panels can press the unconnected roof sandwich panels onto the purlin. At the same time, the female edge of the unconnected roof sandwich panel is connected to the prefabricated fastener of the connected roof sandwich panel, thus completing the connection of the male and female edges of two adjacent roof sandwich panels. Then, the male edge of the unconnected roof sandwich panel is connected to the purlin using fasteners and prefabricated fasteners. In this way, the roof sandwich panels can be connected together in sequence and fixedly connected to the roof purlin.

[0021] As a further improvement to the above technical solution:

[0022] In step 6), when installing the roof sandwich panels, fasteners can be used to pass through the reinforcing ribs of the upper panel, the fire-resistant insulation filling layer, and the lower panel to further connect all the roof sandwich panels to the roof purlins. Finally, the caps are fastened to the reinforcing ribs, and the upper end of the reinforcing ribs is sealed together with the fasteners.

[0023] Compared with the prior art, the beneficial technical effects of the present invention are as follows:

[0024] 1) The locking platform of the lower plate of the roof sandwich panel is a closed tubular profile formed by the lower plate plane, the locking surface and the support feet. Because the locking platform has support feet, it can provide a strong support force to the locking surface. The fasteners will not flatten the locking platform, and the locking connection is reliable. The fasteners will connect the upper plate, the lower plate and the purlin into a solid whole, which can improve the overall wind resistance of the roof sandwich panel and make the roof sandwich panel installation more reliable. In addition, the locking platform has pre-holes to facilitate the filling of liquid polyurethane foam into the closed tubular profile of the locking platform, which improves the strength of the male edge of the lower plate of the sandwich panel.

[0025] 2) The lower end of the support foot can be bent to form a horizontal support foot, increasing the support area of ​​the support foot and further improving the support strength of the support foot;

[0026] 3) The locking platform can have pre-holes on both the support feet and the locking nail surface to increase the pre-hole area. This makes it easier for polyurethane foam material to flow into the closed tubular profile of the locking platform. Furthermore, the pre-holes on the support feet and the locking nail surface can be connected to form an L-shaped hole, further increasing the pre-hole area.

[0027] 4) Several protruding reinforcing ribs are formed on the upper plate, which can improve the support strength and wind resistance of the roof sandwich panel, so that the roof sandwich panel meets the installation requirements of photovoltaic products. The roof sandwich panel is connected to the roof purlin by screws passing through the reinforcing ribs, the insulation filling layer and the lower plate, ensuring reliable connection of the roof sandwich panel, improving wind load resistance, and further improving the wind load-bearing capacity of the roof. In addition, caps are connected to the reinforcing ribs to cover the screws and prevent water leakage at the screws from causing steel plate corrosion.

[0028] 5) Expansion grooves are provided on both sides of the cap at the shoulder position. The expansion grooves ensure that the cap can stably hold the shoulders on both sides of the reinforcing rib. A sealing strip is provided between the cap and the reinforcing rib on both sides to further ensure the sealing and prevent rainwater from leaking from the screws at the reinforcing rib and causing the steel plate to rust. Attached Figure Description

[0029] Figure 1 A cross-sectional view of the roof sandwich panel of Embodiment 1 is shown.

[0030] Figure 2 A schematic diagram of the connection between two adjacent roof sandwich panels in Embodiment 1 is shown.

[0031] Figure 3 A front view of the lower plate of the roof sandwich panel of Embodiment 1 is shown.

[0032] Figure 4 It shows Figure 3 Sectional view of AA.

[0033] Figure 5 A schematic diagram of the connection between two adjacent roof sandwich panels in Embodiment 2 is shown.

[0034] Figure 6 A front view of the lower plate of the roof sandwich panel in Embodiment 2 is shown.

[0035] Figure 7 It shows Figure 6 BB section view.

[0036] Figure 8 A schematic diagram of the connection between two adjacent roof sandwich panels in Embodiment 3 is shown.

[0037] Figure 9 A structural schematic diagram of the lower plate of the roof sandwich panel in Embodiment 3 is shown.

[0038] Figure 10 A schematic diagram of the connection between two adjacent roof sandwich panels in Embodiment 4 is shown.

[0039] Figure 11 A structural schematic diagram of the lower plate of the roof sandwich panel in Embodiment 4 is shown.

[0040] Figure 12 The diagram shows the processing flow of the roof sandwich panels in Examples 1 to 4.

[0041] The following markings are used in the attached diagram: 1. Top plate; 11. Reinforcing rib; 111. Shoulder; 2. Bottom plate; 21. Locking platform; 211. Bottom plate plane; 212. Locking surface; 213. Support leg; 214. Pre-drilled hole; 215. Support base; 216. Male and female mating surface; 22. Support platform; 3. Prefabricated fastener; 4. Fire-resistant insulation layer; 5. Polyurethane foam sealing layer; 6. Cap; 61. Expansion groove. Detailed Implementation

[0042] To make the objectives, technical solutions, and advantages of this invention clearer, the device proposed by this invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The advantages and features of this invention will become clearer from the following description. It should be noted that the accompanying drawings are in a very simplified form and use non-precise proportions, only for the purpose of conveniently and clearly illustrating the embodiments of this invention. Please refer to the accompanying drawings to make the objectives, features, and advantages of this invention more apparent and understandable. It should be understood that the structures, proportions, sizes, etc., depicted in the accompanying drawings are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the implementation conditions of this invention. Therefore, they do not have substantial technical significance. Any modifications to the structure, changes in the proportional relationships, or adjustments to the size, without affecting the effects and objectives achieved by this invention, should fall within the scope of the technical content disclosed in this invention.

[0043] Example 1

[0044] like Figures 1 to 4As shown, in this embodiment, the roof sandwich panel has a male side and a female side at both ends, and includes an upper panel 1, a filling layer, and a lower panel 2 arranged sequentially. The male side of the lower panel 2 is formed into a locking platform 21, which extends outward beyond the male side of the upper panel 1. The locking platform 21 is a closed tubular profile formed by the lower panel plane 211, the locking surface 212, the vertical support leg 213, and the male and female mating surfaces 216. The support leg 213 is located on the outer side of the male side of the upper panel 1. The locking platform 21 is fixedly connected to the purlin by the lower end of the screw, and the locking platform 21 is also hooked to the male side of the upper panel 1 by screws and prefabricated fasteners 3, that is, by screws. The upper plate 1, lower plate 2 and purlin are connected into a whole by the prefabricated fastener 3. The female edge of the lower plate 2 is formed into a support platform 22. The support platform 22 extends to the underside of the locking platform 21 of another roof sandwich panel and is pressed onto the purlin through the locking platform 21. The female edge of the upper plate 1 is connected to the prefabricated fastener 3 connected to the locking platform 21 of another roof sandwich panel. The filling layer includes a fire-resistant insulation layer 4 in the middle of the upper plate 1 and the lower plate 2 and a polyurethane foam sealing layer 5 on both sides. Several pre-holes 214 are opened on the support feet 213 of the locking platform 21 to allow liquid polyurethane to enter the locking platform 21 and close the tubular profile.

[0045] The upper plate 1 is also formed with several protruding reinforcing ribs 11, which can improve the strength of the roof sandwich panel. The roof sandwich panel is connected to the purlins by screws passing through the reinforcing ribs 11, the fire-resistant insulation layer 4 and the lower plate 2. The reinforcing ribs 11 are provided with shoulders 111 on both sides. The caps 6 are fastened to the reinforcing ribs 11 by the shoulders 111 on both sides. The caps 6 are provided with expansion slots 61 on both sides to match the shoulders 111 of the reinforcing ribs 11. Sealing strips are provided between the caps 6 and the reinforcing ribs 11 on both sides to improve the sealing performance.

[0046] Example 2

[0047] like Figures 5 to 7 As shown, the roof sandwich panel of this embodiment differs from that of Embodiment 1 in that the lower end of the support foot 213 can be bent to form a horizontal support foot 215. The support area can be increased by the support foot 215, which can further improve the support strength of the support foot 213.

[0048] Example 3

[0049] like Figure 8 , Figure 9 As shown, the roof sandwich panel of this embodiment differs from that of Embodiment 1 in that the support foot 213 is located inside the male side of the upper plate 1, and the pre-holes 214 are respectively opened on the support foot 213 and the locking surface 212 of the locking platform 21, which increases the area of ​​the pre-holes 214 on the locking platform 21 and can improve the efficiency of filling the closed tubular profile of the locking platform 21 with liquid polyurethane foam material.

[0050] Example 4

[0051] like Figure 10 , Figure 11 As shown, the roof sandwich panel of this embodiment differs from that of Embodiment 3 in that the lower end of the support foot 213 can be bent to form a horizontal support foot 215, and the pre-hole 214 is an "L" through hole that is opened on the support foot 213 and the locking nail surface 212 of the locking nail platform 21. The area of ​​the pre-hole 214 is further increased, which can further improve the efficiency of liquid polyurethane foam material filling into the closed tubular profile of the locking nail platform 21.

[0052] like Figure 12 As shown, the roof sandwich panel processing methods of Examples 1 to 4 include the following steps:

[0053] 1) Unwinding: The plates for processing upper plate 1 and lower plate 2 are unwound separately by an uncoiler;

[0054] 2) Lower plate punching: Pre-holes 214 are punched in the corresponding positions on the lower plate 2 by roller punching or flat punching;

[0055] 3) Forming: The upper plate 1 is formed by a forming machine, and several reinforcing ribs 11 are formed in the middle of the upper plate 1; the lower plate 2 is formed into a locking platform 21 and a support platform 22 at both ends by a forming machine.

[0056] 4) Filling layer filling: Apply adhesive to the lower side of the upper plate 1 and the upper side of the lower plate 2, and fill the refractory insulation material between the upper plate 1 and the lower plate 2. Inject polyurethane material into the positions on both sides of the refractory insulation material. The polyurethane foam material is initially in a liquid state. The liquid polyurethane foam material will enter the closed tubular profile of the locking platform 21 through the pre-hole 214.

[0057] 5) Roof sandwich panel forming; after the filling layer is filled, it enters the crawler machine. The product is pressed in the crawler machine to form the fire-resistant insulation material into the fire-resistant insulation layer 4. At the same time, the product is heated in the crawler machine to make the polyurethane foam material foam to form the polyurethane foam sealing layer 5, which seals the male and female edges of the roof sandwich panel. At the same time, the polyurethane foam material will also fill the inside of the closed tubular profile of the locking platform 21. Finally, it is cut into roof sandwich panels of appropriate size according to the length requirements.

[0058] 6) Roof sandwich panel installation: Prefabricated fasteners 3 are connected to the locking platform 21 using fasteners. The prefabricated fasteners 3 are hooked onto the male side of the upper panel 1, connecting the locking platform 21 of the lower panel 2 to the male side of the upper panel 1. The lower end of the fasteners also secures the lower panel 2 to the purlin. Then, the female side of another roof sandwich panel is inserted into the male side of the already connected roof sandwich panel, causing the support platform 22 formed on the female side of the lower panel 2 of the other roof sandwich panel to extend under the locking platform 21 of the already connected roof sandwich panel. The locking platform 21 of the top sandwich panel presses the support platform 22 of the unconnected roof sandwich panel onto the purlin. This allows the unconnected roof sandwich panel to be pressed onto the purlin by the connected roof sandwich panel. At the same time, the female edge of the top plate 1 of the unconnected roof sandwich panel is connected to the prefabricated fastener 3 of the connected roof sandwich panel, thus completing the connection between the male and female edges of two adjacent roof sandwich panels. Then, the male edge of the unconnected roof sandwich panel is connected to the purlin by fasteners and prefabricated fastener 3. This allows the roof sandwich panels to be connected together in sequence and fixedly connected to the roof purlin.

[0059] In step 6), when installing the roof sandwich panels, all the roof sandwich panels can be further connected to the roof purlins by fasteners passing through the reinforcing ribs 11 of the upper plate 1, the fire-resistant insulation layer 4 and the lower plate 2. Finally, the cap 6 is fastened to the reinforcing ribs 11 to cover the upper end of the reinforcing ribs 11 together with the fasteners.

[0060] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0061] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements should all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A roof sandwich panel, both ends of which are respectively male edge and female edge, and the roof sandwich panel comprises upper plate, filling layer and lower plate arranged in sequence, characterized in that: The male edge of the lower plate is shaped as a locking platform, which extends outward beyond the male edge of the upper plate, and the locking platform is a closed tubular profile formed by the lower plate plane, the locking surface, the support leg and the male-female matching surface, the locking platform is fixedly connected with the purlin through the lower end of the fastener, and the locking platform is also connected with the male edge of the upper plate through the fastener and the prefabricated fastener hook, that is, the upper plate, the lower plate and the purlin are connected into an integral whole through the fastener and the prefabricated fastener hook, the female edge of the lower plate is shaped as a support platform, the support platform extends to the lower side of the locking platform of another roof sandwich panel, and the support platform is pressed onto the purlin through the locking platform, the female edge of the upper plate is connected with the prefabricated fastener connected on the locking platform of another roof sandwich panel, the filling layer includes a fireproof and thermal insulation layer at the intermediate position between the upper plate and the lower plate and polyurethane foam sealing edge layers at the two side positions, and a plurality of pre-holes allowing liquid polyurethane foam material to enter the closed tubular profile of the locking platform are formed on the locking surface or the support leg of the locking platform, a plurality of protruding reinforcing ribs are also shaped on the upper plate, the roof sandwich panel is connected with the purlin through the fastener passing through the reinforcing rib, the fireproof and thermal insulation layer and the lower plate, and a cap is connected on the reinforcing rib.

2. The roof sandwich panel of claim 1, wherein: The support leg is vertically supported on the lower plate.

3. The roof sandwich panel of claim 2, wherein: The lower end of the support leg can be bent to form a horizontal support foot.

4. The roof sandwich panel of claim 2, wherein: The support leg is located at the outer position of the male edge of the upper plate, and the pre-hole is formed on the support leg of the locking platform.

5. The roof sandwich panel of claim 2, wherein: The support leg is located at the inner position of the male edge of the upper plate, and the pre-holes are respectively formed on the support leg and the locking surface of the locking platform.

6. The roof sandwich panel of claim 5, wherein: The pre-holes are through "L" through holes formed on the support leg and the locking surface of the locking platform.

7. The roof sandwich panel of claim 1, wherein: The reinforcing rib is provided with a shoulder on both sides, and the cap is connected on the reinforcing rib through the shoulders on both sides.

8. The roof sandwich panel of claim 7, wherein: The cap is provided with expansion notches inside to match the shoulders of the reinforcing rib, and a sealing strip is arranged between the cap and the reinforcing rib.

9. A roof sandwich panel processing and installation method, comprising the following steps: 1) unwinding: the plate materials of the upper plate and the lower plate are respectively unwound by an uncoiler; 2) lower plate punching: pre-holes are punched on the corresponding positions of the lower plate by roller punching or flat punching; 3) shaping: the upper plate is shaped by a shaping machine, and a plurality of reinforcing ribs are shaped in the middle of the upper plate; the lower plate is shaped into a locking platform and a support platform at both ends by a shaping machine; 4) filling layer filling: an adhesive is sprayed on the lower side of the upper plate and the upper side of the lower plate, and a fireproof and thermal insulation material is adhered and filled between the upper plate and the lower plate, and polyurethane foam material is injected at the positions on both sides of the fireproof and thermal insulation material, the initial state of the polyurethane foam material is liquid, and the liquid polyurethane foam material enters the closed tubular profile of the locking platform through the pre-holes; 5) roof sandwich panel shaping: after the filling layer filling is completed, the product enters a track-type tractor, and the product is pressed in the track-type tractor, so that the fireproof and thermal insulation material is shaped into a fireproof and thermal insulation layer, and at the same time, when the product is heated in the track-type tractor, the polyurethane foam material is foamed to form a polyurethane foam sealing edge layer, which seals the male and female edges of the roof sandwich panel, and at the same time, the polyurethane foam material also fills the inside of the closed tubular profile of the locking platform, and finally, the roof sandwich panel is cut into a suitable size according to the length requirement; 6) Roof sandwich panel installation: the prefabricated fastener is connected to the lock pin platform through the fastener, and the prefabricated fastener is hooked to the male edge of the upper plate, that is, the lock pin platform of the lower plate is connected with the male edge of the upper plate through the prefabricated fastener, and the lower end of the fastener also fixes the lower plate to the purlin, then the female edge of another roof sandwich panel is inserted into the male edge of the connected roof sandwich panel, so that the support platform formed on the female edge of the lower plate of another roof sandwich panel extends to the lower side of the lock pin platform of the connected roof sandwich panel, and the support platform of the unconnected roof sandwich panel is pressed on the purlin through the lock pin platform of the connected roof sandwich panel, that is, the unconnected roof sandwich panel is pressed on the purlin through the connected roof sandwich panel, at the same time, the female edge of the upper plate of the unconnected roof sandwich panel is connected to the prefabricated fastener of the connected roof sandwich panel, that is, the connection of the male edge and the female edge of the adjacent two roof sandwich panels is completed, then the male edge of the unconnected roof sandwich panel is connected to the purlin through the fastener and the prefabricated fastener, that is, the roof sandwich panels can be connected to each other in turn and fixedly connected with the purlin of the roof.

10. The method of manufacturing and installing roof sandwich panels according to claim 9, characterized in that: In step 6) roof sandwich panel installation, all roof sandwich panels are further connected to the purlin of the roof through the fastener penetrating the reinforcing rib, the fireproof and thermal insulation layer and the lower plate of the upper plate, and finally the cap is buckled to the reinforcing rib to cover the upper end of the reinforcing rib together with the fastener.

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