A prefabricated wall system and its construction method

Abstract

This application relates to a prefabricated wall panel system, including an adjustable connecting assembly and panel assemblies. The adjustable connecting assembly includes X-axis, Y-axis, and Z-axis adjusting components. The X-axis adjusting components are spaced apart along the wall. One end of each Y-axis adjusting component is connected to the X-axis adjusting component, and the other end is engaged with the Z-axis adjusting component. The Z-axis adjusting component has an adjusting bolt at its connection end with the Y-axis adjusting component, and the other end is connected to the panel assembly. Adjacent panel assemblies are interconnected via connectors. This invention achieves three-dimensional adjustment of the panel assemblies through X-axis, Y-axis, and Z-axis adjusting components, facilitating installation and adjustment, and allowing for quick replacement of individual panels during later maintenance. The interconnection of components via bolts and connectors avoids the extensive welding work in traditional construction, and the resulting problems of welding deformation, increased costs, and environmental pollution.

Description

Technical Field

[0001] This application relates to the field of interior decoration technology, and in particular to a prefabricated wall system and construction method. Background Technology

[0002] Currently, common wall panel systems mainly include two types: one is aluminum panel with steel framing, and the other is composite metal panel with on-site welded framing and aluminum alloy base. Both of these wall panel systems have certain drawbacks.

[0003] The first type of wall system requires the installation of embedded parts on-site before the steel frame is welded, followed by the installation and adjustment of the aluminum panels. Because the aluminum panels and steel frame are separate systems before installation, the aluminum panels rely solely on their own strength, making it impossible to process them into larger panels and thus failing to meet the installation requirements for large-size panels. Secondly, the steel frame needs to be welded to the adapters, resulting in numerous welding points, a large amount of anti-corrosion work, and difficulty in ensuring quality.

[0004] Another type of wall panel system uses composite metal panels with folded edges during processing. These folded edges are then inserted into mounting grooves for fixation during installation. While this method enhances the overall strength of the panel by adding folded edges, allowing for larger panel sizes, the system lacks three-dimensional adjustment capabilities. Furthermore, the need to insert the folded edges into the mounting grooves often leads to corner cracking or severe deformation of external corners. The finished installation results in poor overall flatness, and damaged panels cannot be individually removed and replaced, hindering future maintenance. Summary of the Invention

[0005] Therefore, it is necessary to provide a prefabricated wall system and construction method to overcome the defects mentioned in the background art.

[0006] A prefabricated wall panel system includes an adjustable connection assembly and a panel assembly. The adjustable connection assembly includes an X-axis adjuster, a Y-axis adjuster, and a Z-axis adjuster. The X-axis adjusters are spaced apart along the wall. One end of each Y-axis adjuster is connected to the X-axis adjuster, and the other end is engaged with the Z-axis adjuster. The Z-axis adjuster is provided with an adjusting bolt at the connection end with the Y-axis adjuster, and the other end is connected to the panel assembly. Adjacent panel assemblies are connected to each other through connectors.

[0007] As a preferred embodiment of the prefabricated wall system of the present invention, the X-axis adjusting component includes a pair of spaced adjusting plates, each including a first limb plate and a second limb plate. The axial directions of the first limb plate and the second limb plate are perpendicular to each other. The first limb plate is provided with a first elongated hole arranged along its axial direction, and the second limb plate is provided with a second elongated hole arranged along its axial direction.

[0008] As a preferred embodiment of the prefabricated wall system in this invention, the first and second limb plates are provided with stiffening ribs.

[0009] As a preferred embodiment of the prefabricated wall system in this invention, the Y-axis adjusting component includes a third limb plate and a fourth limb plate, the radial directions of the third limb plate and the fourth limb plate are perpendicular to each other, the third limb plate is provided with a third elongated hole along its axial direction, and the fourth limb plate is provided with a first locking groove perpendicular to its axial direction.

[0010] As a preferred embodiment of the prefabricated wall system in this invention, a limiting hole is provided on one side of the third elongated hole.

[0011] As a preferred embodiment of the prefabricated wall system in this invention, the Z-axis adjusting component includes a plate body, a second snap-fit ​​groove matching the first snap-fit ​​groove is provided at the bottom of one side of the plate body, a bolt assembly is provided above it, and a through hole is provided on the other side of the plate body.

[0012] As a preferred embodiment of the prefabricated wall system of the present invention, the panel assembly includes a composite metal plate, the inner side of which is provided with a frame, and the frame is connected to the composite metal plate by a connector.

[0013] As a preferred embodiment of the prefabricated wall system in this invention, the connectors include a first connector, a second connector, and a third connector. The first connector is located between the upper and lower ends of the frame and the composite metal plate, and the second and third connectors are located between the two sides of the frame and the composite metal plate, respectively. The second and third connectors are matched with each other.

[0014] As a preferred embodiment of the prefabricated wall system in this invention, the composite metal plate is provided with countersunk bolt holes at the connection between the connector and the connector.

[0015] The present invention also provides a construction method for the above-mentioned prefabricated wall system, comprising the following steps:

[0016] Preparation: Mark the anchor bolt holes on the wall according to the design drawings, drill the holes and clean them;

[0017] X-axis adjustment component installation: The X-axis adjustment component is initially connected to the wall by anchor bolts passing through the first elongated hole. Then, the elevation of the top surface of the second limb plate is adjusted to the design elevation, and the X-axis adjustment component is finally fixed.

[0018] Y-axis adjustment component installation: Initially connect the X-axis adjustment component and the Y-axis adjustment component by using bolts passing through the third and second elongated holes. Then, adjust the first retaining groove on the fourth limb plate to be flush and finally fix the Y-axis adjustment component.

[0019] Z-axis adjustment component installation: Connect it to the frame through the through hole;

[0020] Panel assembly installation: Connect the panel to the Y-axis connector using the second and first snap-fit ​​slots, adjust the bolt assembly to reach the design elevation, and finally install the remaining panel assemblies in sequence and snap them together.

[0021] The beneficial effects of this invention are:

[0022] 1. This invention enables the panel assembly to be adjusted in three-dimensional space through X-axis, Y-axis and Z-axis adjustment components, which facilitates installation and adjustment, and allows for quick replacement of individual panels during later maintenance;

[0023] 2. The present invention has an overall prefabricated structure, with each component connected to the others by bolts and connectors. This avoids the large amount of welding work in traditional construction, as well as the problems such as welding deformation, increased costs, and environmental pollution that result. It significantly improves installation efficiency, reduces labor costs, and shortens the construction cycle. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of the overall structure of the wall system in the embodiments of this application;

[0026] Figure 2 for Figure 1 Schematic diagram of the cross section at point AA;

[0027] Figure 3 for Figure 1 Schematic diagram of the cross section at point BB;

[0028] Figure 4 This is one of the structural schematic diagrams of the X-axis adjustment component in the embodiments of this application;

[0029] Figure 5 This is the second schematic diagram of the X-axis adjusting component in the embodiments of this application;

[0030] Figure 6 This is the third schematic diagram of the X-axis adjusting component in the embodiments of this application;

[0031] Figure 7 This is one of the structural schematic diagrams of the Y-axis adjustment component in the embodiments of this application;

[0032] Figure 8This is the second schematic diagram of the Y-axis adjustment component in the embodiments of this application;

[0033] Figure 9 This is the third schematic diagram of the Y-axis adjusting component in the embodiments of this application;

[0034] Figure 10 This is one of the structural schematic diagrams of the Z-axis adjustment component in the embodiments of this application;

[0035] Figure 11 This is the second schematic diagram of the Z-axis adjustment component in the embodiments of this application;

[0036] Figure 12 This is the third schematic diagram of the Z-axis adjustment component in the embodiments of this application;

[0037] Figure 13 This is a schematic diagram of the overall structure of the panel assembly in an embodiment of this application;

[0038] Figure 14 for Figure 13 Schematic diagram of the cross section at point C;

[0039] Figure 15 for Figure 13 Schematic diagram of the cross section at point DD;

[0040] Figure 16 This is a schematic diagram of the structure of the first connector in the embodiments of this application;

[0041] Figure 17 This is a schematic diagram of the structure of the second connector in the embodiments of this application;

[0042] Figure 18 This is a schematic diagram of the structure of the third connector in the embodiments of this application;

[0043] Explanation of reference numerals in the attached figures:

[0044] 1. X-axis adjusting component; 11. First limb plate; 12. Second limb plate; 13. First elongated hole; 14. Second elongated hole; 15. Stiffening rib.

[0045] 2. Y-axis adjusting component; 21. Third limb plate; 22. Fourth limb plate; 23. Third elongated hole; 24. First locking groove; 25. Limiting hole

[0046] 3. Z-axis adjusting component; 31. Plate body; 32. Second snap-fit ​​groove; 33. Bolt assembly; 34. Through hole;

[0047] 4. Panel assembly; 41. Composite metal plate; 42. Frame;

[0048] 5. First connecting component;

[0049] 6. Second connector;

[0050] 7. Third connector. Detailed Implementation

[0051] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0052] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application 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 this application.

[0053] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0054] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0055] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0056] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0057] Example

[0058] This embodiment provides a prefabricated wall system, such as Figures 1 to 3 As shown, it includes an adjustment connection component and a panel component 4. The adjustment connection component is arranged at intervals along the wall. The panel component 4 is detachably connected to the adjustment connection component. Adjacent panel components 4 are interlocked with each other by connectors.

[0059] The adjustment connection assembly includes an X-axis adjustment component 1, a Y-axis adjustment component 2, and a Z-axis adjustment component 3. One end of the X-axis adjustment component 1 is connected to the wall, and the other end is connected to the Y-axis adjustment component 2. One end of the Z-axis adjustment component 3 is connected to the Y-axis adjustment component 2, and the other end is connected to the panel assembly 4.

[0060] like Figures 4 to 6 The X-axis adjusting component 1 includes a pair of adjusting plates arranged side by side at intervals. The adjusting plate includes a first limb plate 11 and a second limb plate 12. The axial directions of the first limb plate 11 and the second limb plate 12 are perpendicular to each other. The first limb plate 11 is provided with a first elongated hole 13 arranged along its axial direction. The second limb plate 12 is provided with a second elongated hole 14 arranged along its axial direction. The axial direction of the second elongated hole 14 is set as the X-axis.

[0061] In this embodiment, in order to enhance the structural stability of the adjustment plate, a stiffening rib 15 is provided between the first limb plate 11 and the second limb plate 12.

[0062] like Figures 7 to 9The Y-axis adjusting component 2 includes a third limb plate 21 and a fourth limb plate 22. The radial directions of the third limb plate 21 and the fourth limb plate 22 are perpendicular to each other. The third limb plate 21 is provided with a third elongated hole 23 along its axial direction. The axial direction of the third elongated hole 23 is set as the Y-axis. The fourth limb plate 22 is provided with a first snap-fit ​​groove 24 perpendicular to its axial direction.

[0063] In this embodiment, the third elongated hole 23 is provided with a limiting hole 25 on the side away from the fourth limb plate 22 for fixing fibers thereon.

[0064] like Figures 10 to 12 The Z-axis adjusting component 3 includes a plate 31. A second snap-fit ​​groove 32 matching the first snap-fit ​​groove 24 is provided at the bottom of one side of the plate 31. The axial direction of the second snap-fit ​​groove 32 is set as the Z-axis, and a bolt assembly 33 is provided above it. A through hole 34 is provided on the other side of the plate 31.

[0065] In use, the X-axis adjusting component 1 is connected to the wall by a bolt passing through the first elongated hole 13. The X-axis adjusting component 1 and the Y-axis adjusting component 2 are connected by bolts passing through the second elongated hole 14 and the third elongated hole 23, and the X-axis and Y-axis are adjusted through the second elongated hole 14 and the third elongated hole 23. After being adjusted to the design position, they are fixed by screws passing through the limiting hole 25. The Z-axis adjusting component 3 is connected to the panel assembly 4 through the through hole 34. The second snap-fit ​​groove 32 and the first snap-fit ​​groove 24 are snap-fitted together. The adjusting bolt assembly 33 adjusts the Z-axis direction.

[0066] like Figures 13 to 15 As shown, the panel assembly 4 includes a composite metal plate 41, and a frame 42 is provided on the inner side of the composite metal plate 41. The frame 42 is connected to the composite metal plate 41 by connectors and structural adhesive.

[0067] The composite metal plate 41 has an inwardly folded edge, and it is "cold-processed" during secondary processing, which can avoid the panel flatness problem caused by the "hot-processing" welding process used in traditional aluminum plate panels.

[0068] The frame 42 is made of metal and includes longitudinal bars and transverse bars. A pair of longitudinal bars are arranged side by side at intervals, and multiple transverse bars are arranged between the pair of longitudinal bars. The frame 42 is connected to the composite metal plate 41 by connectors around its perimeter and structural adhesive.

[0069] The connectors include a first connector 5, a second connector 6, and a third connector 7, such as... Figure 16 The first connector 5 shown is located between the upper and lower ends of the frame 42 and the composite metal plate 41, and is used to support the upper and lower sides of the composite metal plate 41 to prevent deformation during transportation and installation; Figure 17 and Figure 18 The second connector 6 and the third connector 7 shown are respectively disposed on both sides of the frame 42 and between the composite metal plate 41. The two are used to support and protect the sides of the composite metal plate 41. At the same time, the ends of the second connector 6 and the third connector 7 are matched with each other to connect adjacent panel assemblies 4.

[0070] In this embodiment, the connector is connected to the composite metal plate 41 by rivets, and structural adhesive is also filled between the connector and the composite metal plate 41. Unlike the point stress of traditional panels, the present invention makes it line stress and surface stress by laying structural adhesive, which makes the structural stress more reasonable. The connector is connected to the frame 42 by bolts.

[0071] In this embodiment, to make the panel assembly 4 more aesthetically pleasing, the composite metal plate 41 is provided with countersunk bolt holes at the connection between it and the connector.

[0072] This invention enables prefabricated installation of the wall system, which significantly improves installation efficiency, reduces labor costs, and shortens the construction cycle. It also features adjustable functionality, making it easy to disassemble and replace the wall panels after installation.

[0073] This embodiment also provides a construction method for the above-mentioned prefabricated wall system, including the following steps:

[0074] According to the dimensions shown in the design drawings, the anchor bolt holes are accurately laid out and positioned. The operators drill and clean the holes according to the positioning holes, then install the anchor bolts, and then connect and fix the X-axis adjusting component 1 to the main structure through the first elongated hole 13 and the anchor bolts. During this process, the operators can use the first elongated hole 13 on the X-axis adjusting component 1 to adjust the vertical elevation of the X-axis adjusting component 1 to achieve the elevation required by the drawings and finally fix it.

[0075] The surveyor then marked the Y-axis positioning dimension line of the Y-axis adjusting component 2 onto the X-axis adjusting component 1 according to the dimensions in the drawing. At the same time, the vertical center line of the Y-axis adjusting component 2 was marked on the corresponding structural surface. The operator temporarily connected the Y-axis adjusting component 2 to the second elongated hole 14 of the X-axis adjusting component 1 using stainless steel bolts. The operator then adjusted the Y-axis adjusting component 2 to ensure that the two first locking grooves 24 on the Y-axis adjusting component 2 were in the correct position. After confirming that the Y-axis adjusting component 2 was installed correctly, the stainless steel bolts were tightened, and stainless steel screws were used to limit the Y-axis adjusting component 2 through the limiting hole 25 to prevent it from sliding.

[0076] The operator then assembles the panel assembly 4 and the Z-axis adjustment component 3 together using stainless steel screws.

[0077] The operator hangs the assembled panel assembly 4 on the Y-axis adjusting component 2 through the second locking groove 32 on the Y-axis adjusting component 2, pushes the panel assembly 4 to slide along the Y-axis adjusting component 2 and enter the first locking groove 24 of the Y-axis adjusting component 2, and finally uses the bolt assembly 33 to make the final elevation adjustment of the panel assembly 4. Finally, the remaining panel assemblies 4 are installed in sequence and locked together.

[0078] Wall panel removal and maintenance:

[0079] If a unit panel that has been installed is damaged, the operator can first remove the ceiling panel of the panel assembly 4, including the two adjacent panel assemblies 4. Then, lift the two adjacent panel assemblies 4 from the first snap-fit ​​groove 24 of the Y-axis adjusting part 2 and slide them to both sides to separate the damaged panel assembly 4 from the adjacent panel assembly 4. Then, remove the damaged panel assembly 4 from the wall and replace it with a new panel assembly 4. The restoration process of the panel assembly 4 can be carried out in the reverse order of disassembly.

[0080] 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.

[0081] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A prefabricated wall panel system, comprising an adjustable connection assembly and a panel assembly, characterized in that: The adjustment connection assembly includes an X-axis adjustment component, a Y-axis adjustment component, and a Z-axis adjustment component. The X-axis adjustment component is arranged at intervals along the wall. One end of the Y-axis adjustment component is connected to the X-axis adjustment component, and the other end is engaged with the Z-axis adjustment component. The Z-axis adjustment component is provided with an adjustment bolt at the connection end with the Y-axis adjustment component, and the other end is connected to the panel assembly. Adjacent panel assemblies are connected to each other through connectors. The X-axis adjusting component includes a pair of spaced adjusting plates, each comprising a first limb plate and a second limb plate. The axial directions of the first limb plate and the second limb plate are perpendicular to each other. The first limb plate is provided with a first elongated hole arranged along its axial direction, and the second limb plate is provided with a second elongated hole arranged along its axial direction. The Y-axis adjusting component includes a third limb plate and a fourth limb plate. The radial directions of the third limb plate and the fourth limb plate are perpendicular to each other. The third limb plate is provided with a third elongated hole along its axial direction, and the fourth limb plate is provided with a first locking groove perpendicular to its axial direction. The Z-axis adjusting component includes a plate body. A second snap-fit ​​groove matching the first snap-fit ​​groove is provided at the bottom of one side of the plate body, and a bolt assembly is provided above it. A through hole is provided on the other side of the plate body.

2. The prefabricated wall system according to claim 1, characterized in that, The first and second limb plates are provided with stiffening ribs.

3. The prefabricated wall system according to claim 2, characterized in that, A limiting hole is provided on one side of the third elongated hole.

4. The prefabricated wall system according to claim 3, characterized in that, The panel assembly includes a composite metal plate, and a frame is provided on the inner side of the composite metal plate. The frame is connected to the composite metal plate by a connector.

5. The prefabricated wall system according to claim 4, characterized in that, The connectors include a first connector, a second connector, and a third connector. The first connector is located between the upper and lower ends of the frame and the composite metal plate. The second and third connectors are located between the two sides of the frame and the composite metal plate, respectively. The second and third connectors are matched with each other.

6. The prefabricated wall system according to claim 5, characterized in that, The composite metal plate is provided with countersunk bolt holes at the connection between it and the connector.

7. A construction method for constructing the prefabricated wall system as described in claim 6, characterized in that, Includes the following steps: Preparation: Mark the anchor bolt holes on the wall according to the design drawings, drill the holes and clean them; X-axis adjustment component installation: The X-axis adjustment component is initially connected to the wall by anchor bolts passing through the first elongated hole. Then, the elevation of the top surface of the second limb plate is adjusted to the design elevation, and the X-axis adjustment component is finally fixed. Y-axis adjustment component installation: Initially connect the X-axis adjustment component and the Y-axis adjustment component by using bolts passing through the third and second elongated holes. Then, adjust the first retaining groove on the fourth limb plate to be flush and finally fix the Y-axis adjustment component. Z-axis adjustment component installation: Connect it to the frame through the through hole; Panel assembly installation: Connect the panel to the Y-axis connector using the second and first snap-fit ​​slots, adjust the bolt assembly to reach the design elevation, and finally install the remaining panel assemblies in sequence and snap them together.

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