Composite wall structure panel and method of construction thereof

Abstract

The application provides a composite wall structure plate and a construction method thereof, which comprises a structure frame, a cavity for filling a thermal insulation layer is formed in the structure frame, end faces of the structure frame on both sides of the thermal insulation layer are respectively provided with an outer wall panel and an inner wall panel, a base plate is further arranged in a sandwich layer between the thermal insulation layer and the outer wall panel, an aluminum foil layer is glued to one side of the base plate close to the thermal insulation layer, the aluminum foil layer wraps the edges of the base plate to form a U-shaped edge sealing structure, and the base plate and the structure frame are fixed by air nails and gluing, the composite wall structure plate is used as an outer wall panel of a steel structure factory building, all materials of the wall of the factory building are integrated into one, the installation process is simplified, the structural strength is high, the safety in a long-term mounting process can be ensured, the protection of butt joint positions and internal laminated structures is perfect, moisture and mildew can be effectively prevented, the structural service life is greatly improved, and the application is suitable for wide promotion.

Description

Technical Field

[0001] This invention relates to the field of composite wall panel technology, specifically to a composite wall structure panel and its construction method. Background Technology

[0002] Currently, steel structure factory buildings mainly use a combination of purlins, profiled color steel plates, and insulation cotton to form the exterior wall style. The various components of this wall are generally installed in stages, which requires repeated use of lifting and raising machinery during the installation process, resulting in low construction efficiency and high installation costs.

[0003] To address the aforementioned issues, a novel composite thermal insulation thin-walled exterior wall panel, disclosed in the prior art (CN102733536A), is primarily composed of fiber-woven mesh reinforced concrete and thermal insulation wall material. The fiber-woven mesh reinforced concrete is composed of high-performance fine concrete and fiber-woven mesh, with the fiber-woven mesh serving as the reinforcing material. The thermal insulation wall material includes one or all of cement-based insulation boards and insulation powder. The aforementioned device also provides a method for preparing this novel composite thermal insulation thin-walled exterior wall panel. This device combines advantages such as long lifespan, lightweight thin walls, heat insulation, sound insulation, earthquake resistance, impact resistance, fire resistance, waterproofing, and simple installation and surface decoration processes. It is suitable for building exterior wall insulation and represents a novel composite thermal insulation building exterior wall structure with broad application prospects.

[0004] Although the above-mentioned device combines multiple composite structures to form an integral structure, the new type of composite thermal insulation thin-walled exterior wall panel still has obvious defects in use: the device uses a combination of woven fabric and concrete to form the main structure, but the nail holding strength of this structure is limited, and it may fall after installation, posing a significant safety hazard. At the same time, the edges of the device are not effectively protected, making it easy for water to enter and mold to grow. Summary of the Invention

[0005] The purpose of this invention is to provide a composite wall structure panel and its construction method to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] A composite wall structure panel includes a structural frame with cavities for filling an insulation layer. An outer wall panel and an inner wall panel are respectively installed on the end faces of the structural frame on both sides of the insulation layer. A substrate is also provided in the interlayer between the insulation layer and the outer wall panel. An aluminum foil layer is glued to the side of the substrate near the insulation layer, and the aluminum foil layer wraps around the edge of the substrate to form a U-shaped edge sealing structure. The substrate is fixed to the structural frame using pneumatic nails and adhesive bonding. The outer wall panel and the substrate are fixedly connected using adhesive bonding.

[0008] Preferably, the outer wall panel is a color steel flat panel formed by a monochrome coating, a stone coating, or a wood grain coating.

[0009] Preferably, the substrate is cut and shaped from cement fiberboard, calcium silicate board or gypsum board.

[0010] Preferably, the structural frame is welded together from a cold-formed galvanized steel frame and several equidistantly arranged cold-formed galvanized horizontal frames.

[0011] Preferably, the cold-formed galvanized steel frame has several equally spaced bolt connection holes on both sides, and adjacent cold-formed galvanized steel frames are bolted together by passing bolts through the corresponding bolt connection holes.

[0012] Preferably, the joint between the inner wall panel and the wall is also filled with a thermoplastic polyurethane joint layer or a joint adhesive filler layer.

[0013] Preferably, the insulation layer is uniformly laid in the cavity formed by the structural frame by filling with rock wool, glass wool or aerogel wool.

[0014] Preferably, the insulation layer is injected into the cavity formed by the structural frame using a polystyrene particle resin mortar or perlite resin mortar on-site pouring method, and the edge of the structural frame is provided with pouring holes for filling the cavity with the insulation layer.

[0015] Preferably, the cold-formed galvanized steel frame has pull-out openings on both sides of the bolt connection holes, communicating with the cavity. A drawer for placing the insulation layer is pulled out vertically within each pull-out opening. An insulation layer is embedded in the drawer. Several arrayed interlayer filling holes are formed on the side of the insulation layer near the aluminum foil layer and the inner wall panel. These interlayer filling holes communicate with a pipe-like frame within the insulation layer. A connector extends outward from the pipe-like frame near the pull-out opening, and the connector is threaded to one end of a tee joint on one side of the insulation layer drawer. The insulation layer drawer encloses and forms... The inner side of the U-shaped accommodating cavity is provided with equidistant joint filling holes. Several of these joint filling holes are connected to the connecting end of a tee joint via a connecting pipe embedded inside the insulation layer placement drawer. The tee joint is also connected to a foaming medium filling hole on the outside of the insulation layer placement drawer. Foaming medium is injected into the tee joint through the foaming medium filling hole, and finally the foaming medium flows out through the interlayer filling hole and the joint filling hole to fill the interlayer or joint around the insulation layer. A sealing cap is also threaded into the foaming medium filling hole. The insulation layer placement drawer is fixedly connected to the end face of the cold-formed galvanized steel frame by bolts.

[0016] A construction method for the aforementioned composite wall structure panel includes the following steps:

[0017] Step 1: After transporting the composite wall structure panel without the insulation layer and the separately stored insulation layer to the installation site, pull out the insulation layer placement drawer by pulling it out, and insert the separately stored insulation layer into the U-shaped receiving cavity formed by the insulation layer placement drawer. Then close the insulation layer placement drawer and fix the insulation layer placement drawer to the cold-formed galvanized steel frame by bolts.

[0018] Step 2: Fill the foaming medium filling holes with foaming material. The foaming material flows out from the interlayer filling holes and joint filling holes through the tee connector and fills the interlayer or joint around the insulation layer. After the foaming material cures, the insulation layer is installed, and the overall forming of the composite wall structure panel is completed. The composite wall structure panel is then hung up to complete the installation.

[0019] Step 3: When the insulation layer powders, degrades in performance, or a new type of insulation material with superior performance appears after long-term use, the original insulation layer needs to be replaced. This can be done by opening the insulation layer drawer, pulling out the original insulation layer, cleaning the drawer and the foam material inside, replacing it with a new insulation layer, and repeating steps one and two to complete the replacement and renewal of the insulation layer.

[0020] Compared with the prior art, the beneficial effects of the present invention are:

[0021] The composite wall structure panel of this invention is used as the exterior wall panel of a steel structure factory building. It combines multiple layers of the factory wall, simplifies the installation process, has high structural strength, and can ensure safety during long-term installation. At the same time, the joints and internal layer structure are well protected, effectively preventing moisture and mildew, greatly improving the service life of the structure, and is suitable for widespread application. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall stacked structure of the present invention;

[0023] Figure 2 This is a schematic diagram of the aluminum foil layer sealing structure of the present invention;

[0024] Figure 3 This is a schematic diagram of the drawer installation structure for placing the insulation layer according to the present invention;

[0025] Figure 4 This is a schematic diagram of the insulation layer of the present invention installed inside the insulation layer placement drawer;

[0026] Figure 5 This is a schematic diagram of the three-way connector connection structure of the present invention.

[0027] In the diagram: 1 Structural frame, 2 Insulation layer, 3 Cavity, 4 Outer wall panel, 5 Inner wall panel, 6 Base plate, 7 Aluminum foil layer, 8 Cold-formed galvanized steel frame, 9 Cold-formed galvanized horizontal frame, 10 Bolt connection hole, 11 Adhesive layer, 12 Pneumatic nail, 13 Pull-out opening, 14 Drawer placement in insulation layer, 15 Filling hole in interlayer, 16 Pipe-type skeleton, 17 Connector, 18 T-joint, 19 U-shaped accommodating cavity, 20 Joint filling hole, 21 Foaming medium filling hole, 22 Sealing cap, 23 Bolt hole. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] Please see Figure 1-5 The present invention provides a technical solution:

[0030] Example 1:

[0031] A composite wall structure panel includes a structural frame 1, with a cavity 3 inside the structural frame 1 for filling an insulation layer 2. An outer wall panel 4 and an inner wall panel 5 are respectively installed on the end faces of the structural frame 1 on both sides of the insulation layer 2. A base plate 6 is also provided in the interlayer between the insulation layer 2 and the outer wall panel 4. An aluminum foil layer 7 is glued to the side of the base plate 6 near the insulation layer 2. The aluminum foil layer 7 wraps the edge of the base plate 6 to form a U-shaped edge sealing structure. The base plate 6 is fixed to the structural frame 1 by air nails 12 and glue. The outer wall panel 4 and the base plate 6 are fixedly connected by glue.

[0032] In this embodiment, the structural frame 1 is made of galvanized steel. The advantage of adding a galvanized layer is that it effectively prevents the steel from oxidizing and corroding, forming a physical barrier to isolate the steel from oxygen, water, and other corrosive substances in the environment, thereby extending the service life of the steel. Simultaneously, the galvanized layer gives the steel good weather resistance, resisting erosion from ultraviolet radiation, high temperatures, rain, snow, and other natural environmental factors, reducing the aging rate of the steel. Furthermore, it improves the aesthetics of the steel. The structural frame 1 is welded from a cold-formed galvanized steel frame 8 and several equidistantly arranged cold-formed galvanized horizontal frames 9. The arrangement of the cold-formed galvanized horizontal frames 9 greatly improves the strength of the structural frame 1. An opening is provided within the structural frame 1 for filling the insulation layer 2. The cavity 3, filled by the insulation layer 2, provides heat and sound insulation. The outer wall panel 4 and inner wall panel 5 are installed on both the inner and outer layers of the structural frame 1, both made of steel plate, effectively protecting the internally encased layered structure. A base plate 6 is installed in the interlayer between the insulation layer 2 and the outer wall panel 4, securing the outer wall panel 4. The base plate 6 is connected to the structural frame 1 using pneumatic nails 12 and adhesive bonding. The outer wall panel 4 and base plate 6 are fixed together using adhesive bonding. This installation method ensures that there are no holes or fasteners on the surface of the outer wall panel 4, guaranteeing a neat installation. The adhesive bonding method provides high bonding strength, is irreversible, and has high durability. Furthermore, the outer wall panel 4... Color steel flat panels, formed with monochrome coatings, stone coatings, or wood grain coatings, further enhance the aesthetics of the facade through the coating application, while simultaneously protecting the steel structure wall panel 4. Furthermore, since the substrate 6 serves as the adhesive bonding mechanism for the wall panel 4, its structural stability determines the stability of the wall panel 4 connection. To ensure the lightweight and stability of the substrate 6, it is cut from cement fiberboard, calcium silicate board, or gypsum board. An aluminum foil layer 7 is used for further protection of the substrate 6 via adhesive bonding, and the edges of the substrate 6 are further wrapped with the aluminum foil layer 7 to form a U-shaped edge sealing structure, greatly improving the substrate 6's moisture-proof, mildew-proof, and deformation-proof performance. The structural stability of the substrate 6 directly results in the long-term stable adhesion of the wall panel 4. On the surface of the substrate 6, the substrate 6 is connected to the outer wall panel 4 by adhesive bonding. The stable structure formed by the adhesive prevents moisture from penetrating to the surface of the substrate 6. Furthermore, the outer wall panel 4 and the substrate 6, the substrate 6 and the aluminum foil layer 7, and the substrate 6 and the structural frame 1 are bonded together by hot melt adhesive to form an adhesive layer 11. Because hot melt adhesive has a fast bonding function and good durability and heat resistance, it can effectively bond different materials and is widely used in industrial production. In summary, by combining multiple connection methods such as welding, air nailing, and hot melt adhesive bonding, a stable structure is formed to withstand various loads, thereby greatly reducing the amount of steel used in the structure; the integrated form has high installation efficiency and low overall cost.

[0033] Example 2:

[0034] The cold-formed galvanized steel frame 8 has several bolt connection holes 10 arranged at equal intervals on both sides. The adjacent cold-formed galvanized steel frames 8 are bolted together by passing bolts through the corresponding bolt connection holes 10.

[0035] The joint between the inner wall panel 4 and the wall is also filled with a thermoplastic polyurethane joint layer or joint adhesive filler layer.

[0036] In this embodiment, adjacent composite wall structure panels are bolted together using bolt holes 10 on the cold-formed galvanized steel frame 8. Bolting facilitates installation and disassembly and provides a stable connection. To further improve the sealing of adjacent composite wall structure panels, sealant can be applied to the joint between them to isolate and protect the joint. The joint between the inner wall panel 4 and the wall is filled with a thermoplastic polyurethane joint layer or a joint sealant filling layer. The thermoplastic polyurethane joint layer is bonded to the inner wall panel 4 using hot-melt technology. The flexibility of thermoplastic polyurethane effectively mitigates the risk of leakage due to cracks caused by thermal expansion and contraction. Alternatively, a joint sealant with good sealing, adhesion, and weather resistance can be used to form a joint sealant filling layer, ensuring reliable leak-proof performance.

[0037] Example 3:

[0038] The insulation layer 2 is uniformly laid in the cavity 3 formed by the structural frame 1 using rock wool, glass wool or aerogel wool filling method.

[0039] In this embodiment, the insulation layer 2 is composed of a rock wool layer, a glass wool layer, or an aerogel wool layer, all of which can effectively reduce the overall weight of the composite wall and have the effects of shock absorption, vibration prevention, sound insulation, and heat insulation.

[0040] Example 4:

[0041] The insulation layer 2 is injected into the cavity 3 formed by the structural frame 1 by on-site pouring of polystyrene particle resin mortar or perlite resin mortar. The edge of the structural frame 1 has pouring holes for filling the insulation layer into the cavity 3.

[0042] In this implementation, the insulation layer 2 is filled by on-site pouring. On-site pouring can be filled according to the specific state of the composite wall structure panel installation. The molding and use time of the insulation layer 2 is shorter, so that it has the best shock absorption, vibration prevention, sound insulation and heat insulation performance after installation.

[0043] Example 5:

[0044] The cold-formed galvanized steel frame 8 has pull-out openings 13 on both sides of the bolt connection holes 10, which communicate with the cavity 3. A vertically extending insulation layer drawer 14 is installed inside the pull-out opening 13. An insulation layer 2 is embedded in the insulation layer drawer 14. Several arrayed interlayer filling holes 15 are provided on the side of the insulation layer 2 near the aluminum foil layer 7 and the inner wall panel 5. These interlayer filling holes 15 communicate with a pipe-like frame 16 installed inside the insulation layer 2. A connector 17 extends outward from the pipe-like frame 16 near the pull-out opening 13. The connector 17 is threaded to one end of a tee connector 18 on one side of the insulation layer drawer 14. The insulation layer drawer 14 forms a U-shaped cavity. The inner side of the cavity 19 is provided with equidistant joint filling holes 20. Several joint filling holes 20 are connected to the connection end of the tee joint 18 through the connecting pipe embedded inside the insulation layer placement drawer 14. The tee joint 18 is also connected to the foaming medium filling hole 21 opened on the outside of the insulation layer placement drawer 14. Foaming medium is filled into the tee joint 18 through the foaming medium filling hole 21. Finally, the foaming medium flows out through the interlayer filling hole 15 and the joint filling hole 20 and fills the interlayer or joint around the insulation layer. A sealing cap 22 is also threaded into the foaming medium filling hole 21. The insulation layer placement drawer 14 is fixedly connected to the end face of the cold-formed galvanized steel frame 8 through bolt holes 23.

[0045] In this embodiment, the insulation layer 2 is installed in a detachable manner. It is inserted into the cavity 3 formed by the structural frame 1 through a pull-out insulation layer drawer 14, and the insulation layer drawer 14 is fixedly connected to the cold-formed galvanized steel frame 8 by a threaded connection. Since the independently installed insulation layer 2 will form a certain space gap with the surrounding layers after installation, the insulation layer 2 cannot fully fill and adhere to the inner wall panel 5, the insulation layer drawer 14, and the aluminum foil layer 7. Therefore, pipes are installed in each independently installed insulation layer 2. The frame 16 is connected to each interlayer filling hole 15 through the pipe frame 16. The inner side of the U-shaped accommodating cavity 19 of the insulation layer drawer 14 is provided with several seam filling holes 20. The interlayer filling holes 15 and seam filling holes 20 are connected to the foaming medium filling holes 21 through the T-connector 18. By adding foaming medium into the foaming medium filling holes 21, the independently set insulation layer 2 can be fully connected with the surrounding structure, thereby ensuring its sound insulation and heat insulation effect. This setting provides a structural basis for the later replacement of the insulation layer 2.

[0046] A construction method for the aforementioned composite wall structure panel includes the following steps:

[0047] Step 1: After transporting the composite wall structure panel without insulation layer 2 and the separately stored insulation layer 2 to the installation site, pull out the insulation layer placement drawer 14 by pulling it out, and insert the separately stored insulation layer 2 into the U-shaped receiving cavity 19 formed by the insulation layer placement drawer 14. Then close the insulation layer placement drawer 14 and fix the insulation layer placement drawer 14 to the cold-formed galvanized steel frame 8 by bolt fixing.

[0048] Step 2: Fill the foaming medium filling hole 21 with foaming material. The foaming material flows out from the interlayer filling hole 15 and the joint filling hole 20 through the tee connector 18 and fills the interlayer or joint around the insulation layer 2. After the foaming material cures, the installation of the insulation layer 2 is completed, and the overall forming of the composite wall structure panel is completed. The installation of the composite wall structure panel is completed by hanging the composite wall structure panel.

[0049] Step 3: When the insulation layer 2 shows signs of powdering, performance degradation, or the emergence of new insulation materials with superior performance after long-term use, the original insulation layer 2 needs to be replaced. This can be done by opening the insulation layer drawer 14, pulling out the original insulation layer 2, cleaning the insulation layer drawer 14 and the foam material inside, replacing it with a new insulation layer 2, and repeating steps one and two to complete the replacement and renewal of the insulation layer 2.

[0050] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A composite wall structure panel, comprising a structural frame, wherein a cavity for filling an insulation layer is formed within the structural frame, and an outer wall panel and an inner wall panel are respectively installed on the end faces of the structural frame on both sides of the insulation layer, characterized in that: A substrate is also provided in the interlayer between the insulation layer and the outer wall panel. An aluminum foil layer is glued to the side of the substrate near the insulation layer. The aluminum foil layer wraps the edge of the substrate to form a U-shaped sealing structure. The substrate is fixed to the structural frame by air nails and glue. The outer wall panel and the substrate are fixedly connected by glue. The structural frame is welded together from a cold-formed galvanized steel frame and several equidistantly arranged cold-formed galvanized horizontal frames. The cold-formed galvanized steel frame has several bolt connection holes arranged at equal intervals on both sides. The adjacent cold-formed galvanized steel frames are bolted together by passing bolts through the corresponding bolt connection holes. The joint between the inner wall panel and the wall is also filled with a thermoplastic polyurethane joint layer or joint adhesive filler layer. The cold-formed galvanized steel frame has pull-out openings on both sides of the bolt connection holes, communicating with the cavity. A drawer for the insulation layer is pulled out vertically through each pull-out opening. The insulation layer is embedded within the drawer. Several arrayed interlayer filling holes are formed on the side of the insulation layer near the aluminum foil layer and the inner wall panel. These interlayer filling holes communicate with a pipe-like frame within the insulation layer. A connector extends outward from the pipe-like frame near the pull-out opening, and the connector is threaded to one end of a tee joint on the side of the insulation layer drawer. The opening formed by the insulation layer drawer... The inner side of the U-shaped accommodating cavity is provided with equidistant joint filling holes. Several of these joint filling holes are connected to the connecting end of a T-joint via a connecting pipe embedded inside the insulation layer placement drawer. The T-joint is also connected to a foaming medium filling hole on the outside of the insulation layer placement drawer. Foaming medium is injected into the T-joint through the foaming medium filling hole, and finally the foaming medium flows out through the interlayer filling hole and the joint filling hole to fill the interlayer or joint around the insulation layer. A sealing cap is also threaded into the foaming medium filling hole. The insulation layer placement drawer is fixedly connected to the end face of the cold-formed galvanized steel frame by bolts.

2. The composite wall structure panel according to claim 1, characterized in that: The outer wall panel is a color steel flat panel formed by a monochrome coating, stone coating, or wood grain coating.

3. A composite wall structure panel according to claim 2, characterized in that: The substrate is cut and shaped from cement fiberboard, calcium silicate board or gypsum board.

4. A composite wall structure panel according to claim 3, characterized in that: The insulation layer is uniformly laid in the cavity formed by the structural frame by filling with rock wool, glass wool or aerogel wool.

5. A composite wall structure panel according to claim 4, characterized in that: The insulation layer is injected into the cavity formed by the structural frame by on-site pouring of polystyrene particle resin mortar or perlite resin mortar. The edge of the structural frame has pouring holes for filling the cavity with the insulation layer.

6. A construction method for installing the composite wall structure panel as described in claim 5, characterized in that, Includes the following steps: Step 1: After transporting the composite wall structure panel without the insulation layer and the separately stored insulation layer to the installation site, pull out the insulation layer placement drawer by pulling it out, and insert the separately stored insulation layer into the U-shaped receiving cavity formed by the insulation layer placement drawer. Then close the insulation layer placement drawer and fix the insulation layer placement drawer to the cold-formed galvanized steel frame by bolts. Step 2: Fill the foaming medium filling holes with foaming material. The foaming material flows out from the interlayer filling holes and joint filling holes through the tee connector and fills the interlayer or joint around the insulation layer. After the foaming material cures, the insulation layer is installed, and the overall forming of the composite wall structure panel is completed. The composite wall structure panel is then hung up to complete the installation. Step 3: When the insulation layer powders, degrades in performance, or a new type of insulation material with superior performance appears after long-term use, the original insulation layer needs to be replaced. This can be done by opening the insulation layer drawer, pulling out the original insulation layer, cleaning the drawer and the foam material inside, replacing it with a new insulation layer, and repeating steps one and two to complete the replacement and renewal of the insulation layer.

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