Double-curved-surface type load-bearing thermal insulation floating roof and manufacturing method thereof

Abstract

The invention relates to a double-curved-surface load-bearing heat preservation floating roof and a joggling type connection method thereof, is suitable for cross-seasonal heat storage water bodies with heat preservation and load bearing requirements, and belongs to the field of cross-seasonal heat storage / heat supply design and construction. The double-curved-surface type bearing floating roof is composed of two or three types of unit modules with different structural forms and tenons. Compared with the prior art, the invention innovatively expands the selectable range of thermal insulation materials, breaks through the limitation of traditional flexible materials, can select high-density polystyrene foam (HDPE) and other hard high-performance thermal insulation plates, reduces the heat conductivity coefficient by 40% (0.028 W / m.K) compared with the conventional materials, and significantly improves the thermal insulation efficiency; through mechanical structure optimization, the top cover module has a load-bearing function and can adapt to complex working condition requirements, and the application dimension of the system in scenes such as agricultural greenhouses and industrial factory buildings is expanded; standardized prefabricated parts and a joggling type connection technology are adopted, so that the structural complexity of the top cover is reduced by 60%, the construction period is shortened by 45%, free combination of modules is supported, and the engineering requirements of large cross-seasonal heat storage water bodies in different climate areas can be met in combination with the implementation method.

Description

Technical Field

[0001] The present invention belongs to the field of cross-season heat storage / heat supply design and construction, and specifically relates to a hyperbolic load-bearing thermal insulation floating roof and a manufacturing method thereof. Background Art

[0002] Carbon emissions from building heating in my country account for 25% of the national total, of which coal-fired heating in northern cities accounts for more than 70%, with annual carbon emissions reaching 550 million tons. In order to achieve the "dual carbon" goal, it is urgent to replace traditional fossil energy with renewable energy. Water-based solar inter-seasonal heat storage technology has high heat storage density (≥50kWh / m 3 ), long service life (>30 years) and low carbon characteristics, it has been listed as the preferred technology for decarbonization of building heating by the International Energy Agency (IEA). A large number of scientific studies and rich engineering practice experience have shown that this technology has high reliability and has been widely used at home and abroad. Many large-capacity hot water storage bodies have been put into actual operation. In my country, Beijing, Hebei, Tibet and other places have also built a number of hot water storage bodies of different volumes, providing an effective solution to local heating needs. However, the technical bottleneck of its core component, the thermal insulation top cover of the hot water storage body, has seriously restricted its large-scale application.

[0003] As the core subsystem of the water-based solar inter-seasonal heat storage and heating system, the cost of the hot water storage body accounts for the highest proportion in the entire system. Usually, the hot water storage body is excavated from the ground into a specific shape, and after basic treatment, an anti-seepage layer is laid, and then water is used as the heat storage medium. Its volume range is wide, ranging from hundreds of cubic meters to hundreds of thousands of cubic meters. In the composition of the hot water storage body, the insulation top cover plays a vital role. It not only directly determines the heat storage efficiency of the hot water storage body, but also is a key component to ensure the efficient operation of the system. In addition, in the cost of the hot water storage body, the insulation top cover accounts for the highest proportion, accounting for about 50% of the overall cost. In addition, large-scale hot water storage bodies occupy a large area, ranging from several thousand square meters to hundreds of thousands of square meters, which to a certain extent limits the application scenarios and scope of water-based solar inter-seasonal heat storage and heating technology. Chinese patent CN118653734A proposes an integrated load-bearing anti-seepage and thermal insulation floating roof system for hot water storage tanks, which is mainly used in hot water storage tanks in large-scale inter-seasonal heat storage systems. The system uses a unique floating roof structure design to effectively solve the problems of difficult construction, inconvenient drainage and inability to bear weight of traditional integrated floating roofs, while also having good thermal insulation performance. However, the article does not mention the performance of the system under extreme weather conditions (such as extreme cold, heavy rain, etc.), nor does it elaborate on the adaptability and optimization solutions of the system for hot water storage tanks of different sizes and shapes.

[0004] Therefore, designing an insulation roof cover with a reasonable structure, excellent insulation performance and load-bearing capacity has become the key to breaking through the current bottleneck of technical application and further expanding the application of water-based solar inter-seasonal heat storage and heating technology. Summary of the invention

[0005] In order to solve the above technical problems, the present invention proposes a hyperbolic load-bearing thermal insulation floating roof and a manufacturing method, which is applied to the field of cross-seasonal heat storage / heating design and construction. It is a floating roof with simple structure, stable and reliable, convenient maintenance, relatively low cost, and meets both thermal insulation and load-bearing functions.

[0006] The present invention is achieved through the following technical solutions:

[0007] A hyperbolic load-bearing thermal insulation floating roof comprises two types, a total of three types of unit modules with different structures, one type is a main unit module A; the other type is an edge unit module: unit module M, unit module R; the three types of unit modules are arranged and assembled in the form of the edge unit module surrounding the main unit module, and are fixed by mortise and tenon; a pad, an insulation layer and a pad are respectively arranged in the shell of each unit module from top to bottom.

[0008] Furthermore, each of the unit modules has a different number of mortises.

[0009] Furthermore, the corresponding unit modules are arranged and combined in a fixed order.

[0010] Furthermore, after determining the reference direction according to the on-site conditions of the hot water storage body, assemble and fix the top cover module according to the arrow prompts or character prompts on the unit modules. The first row is arranged and fixed in the order of "unit module R (3) + unit module M (2) + unit module M (2) + unit module R (3)"; the second row is arranged and fixed in the order of "unit module M (2) + unit module A (1) + unit module A (1) + unit module M (2)"; the third row is arranged and fixed in the order of "unit module M (2) + unit module A (1) + unit module A (1) + unit module M (2)", and then repeat the second and third rows according to actual needs; the last row is arranged and fixed in the order of "unit module R (3) + unit module M (2) + unit module M (2) + unit module R (3)".

[0011] Furthermore, the tenons are connected one by one according to the mortises processed on the unit modules.

[0012] Furthermore, the specific quantity needs to be determined according to the size of the water surface opening of the cross-seasonal hot water storage body and the size of the three unit modules. In addition, corresponding unit modules should be prepared for use in special circumstances according to actual conditions.

[0013] Further, it is necessary to determine the specific number of tenons according to the number of units used. In addition, corresponding tenons should be provided for use in special circumstances according to actual conditions.

[0014] Furthermore, after the unit modules are laid and assembled, a floating roof is formed, and a protective layer is laid on the floating roof. The protective layer extends all the way to the anchoring trench and is covered with soil for anchoring.

[0015] Furthermore, the protective layer can be covered with soil according to actual needs to comprehensively utilize the floating roof of the cross-seasonal hot water storage body.

[0016] The present invention also provides a method for manufacturing a hyperbolic load-bearing thermal insulation floating roof, comprising the following steps:

[0017] Step 1: Process the pad, tenon, and insulation layer of the adaptable unit module according to the design, and assemble them into a whole in the order of pad, insulation layer, and pad from top to bottom to form the inner structure of the unit module;

[0018] Step 2: According to the design, the inner layer structure of the unit module in step 1 is placed into the shell when processing the shell of the unit module through an automated production line, and the unit module is completely wrapped in the shell to form a whole during the one-time molding process;

[0019] Step 3: After determining the reference direction according to the on-site conditions of the hot water storage body, assemble and fix the modules according to the arrows or characters on the modules: the first row is arranged and fixed in the order of “module R (3) + module M (2) + module M (2) + module R (3)”; the second row is arranged and fixed in the order of “module M (2) + module A (1) + module A (1) + module M (2)”; the third row is arranged and fixed in the order of “module M (2) + module A (1) + module A (1) + module M (2)”, and then the second and third rows are repeated according to actual needs; the last row is arranged and fixed in the order of “module R (3) + module M (2) + module M (2) + module R (3)”;

[0020] Step 4: Connect the tenons one by one according to the mortises processed on the unit modules;

[0021] Step 5: After laying and assembling the unit modules, a floating roof is formed, and a protective layer is laid on the floating roof. The protective layer extends all the way to the anchoring trench, and soil is covered and buried for anchoring;

[0022] Step 6: Cover the protective layer with soil according to actual needs to comprehensively utilize the floating roof of the cross-seasonal hot water storage body.

[0023] The advantages of the present invention are:

[0024] 1. The advantage of the present invention is that a hyperbolic unit module inner layer structure is designed, which optimizes the structure and saves the amount of thermal insulation material to a great extent.

[0025] 2. The advantage of the present invention is that the design structure can be flexibly adjusted according to actual needs, thereby adjusting the load-bearing and thermal insulation performance of the unit module.

[0026] 3. The advantage of the present invention is that the edge of the unit module adopts a mortise and tenon connection structure, which improves the connection stability between the unit modules and also improves the radial stability of the unit modules.

[0027] 4. The advantage of the present invention is that each unit module is connected by a tenon, the connection is simple and reliable, the construction difficulty is greatly reduced, and the construction cost is saved.

[0028] 5. The advantage of the present invention is that the unit modules do not require maintenance under normal use, which greatly saves the operation and maintenance costs of the floating roof.

[0029] 6. The advantage of the present invention is that it broadens the application scenarios and scope of water-based solar inter-seasonal heat storage and heating technology. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a schematic diagram of the cross-sectional structure of the hyperbolic load-bearing thermal insulation floating roof of the present invention;

[0031] In the figure: 1 unit module A, 2 thermal insulation hyperboloid, 3 unit module R, 4 unit module M.

[0032] Figure 2 It is a schematic diagram of the shell structure of the hyperbolic load-bearing thermal insulation floating roof unit module M1 of the present invention;

[0033] In the figure: 6 shell, 7 pad, 9 mortise.

[0034] Figure 3 It is a schematic diagram of the insulation layer structure of the hyperbolic load-bearing insulation floating roof unit module A1 of the present invention;

[0035] Figure 4 It is a schematic diagram of the insulation layer structure of the hyperbolic load-bearing insulation floating roof unit module M1 of the present invention;

[0036] Figure 5 It is a schematic diagram of the heat preservation layer structure of the hyperbolic load-bearing heat preservation floating roof unit module R1 of the present invention;

[0037] Figure 6 It is a schematic diagram of the structure of the hyperbolic load-bearing thermal insulation floating roof tenon of the present invention;

[0038] Figure 7 1. It is a top view schematic diagram of a hyperbolic load-bearing thermal insulation floating roof of the present invention;

[0039] In the figure: 10 protective layer, 11 anchoring trench. DETAILED DESCRIPTION

[0040] In order to better understand the purpose, structure and function of the present invention, the hyperbolic load-bearing thermal insulation floating roof and the manufacturing method of the present invention are described in detail with reference to the accompanying drawings.

[0041] Example:

[0042] like Figures 1 to 7 As shown, the hyperbolic load-bearing thermal insulation floating roof system mainly includes a hot water storage body, an anchoring groove (11), a protective layer (10), and a modular floating roof structure composed of a unit module A (1), a unit module M (2), and a unit module R (3). The floating roof connects the unit modules through a tenon (5) to form a closed thermal insulation load-bearing system. The specific implementation steps are as follows:

[0043] 1. Prefabrication of unit modules

[0044] The number of unit modules A (1), M (2), and R (3) is determined according to the opening size of the hot water storage body and the design requirements. The inner layer structure of each unit module is composed of a pad (7), a hyperbolic insulation layer (8), and a pad (7) assembled from top to bottom ( Figure 2-5 The insulation layer is made of high-density polystyrene foam (HDPE) with a thermal conductivity of 0.028W / m·K and a thickness selected according to design requirements (50-100mm). The shell (6) is formed in one step using a hard insulation material through an automated production line, wrapping the inner structure, and processing mortises (9) at preset positions ( Figure 2 ).

[0045] 2. On-site assembly and arrangement

[0046] After determining the reference direction of the hot water storage body, arrange the unit modules in the following order ( Figure 1 ):

[0047] The first row is fixed in the order of "unit module R (3) + unit module M (2) + unit module M (2) + unit module R (3)"; the second and third rows are repeatedly arranged in the order of "unit module M (2) + unit module A (1) + unit module A (1) + unit module M (2)"; the last row is symmetrical with the first row and fixed in the order of "unit module R (3) + unit module M (2) + unit module M (2) + unit module R (3)".

[0048] 3. Overall reinforcement and protection of floating roof

[0049] After the assembly is completed, a protective layer (10) is laid on the surface of the floating roof, and a heat-resistant protective film is used to cover the edge of the anchoring groove (11). The anchoring groove (11) is filled with soil and compacted to achieve the fixation of the floating roof and the edge of the hot water storage body. The protective layer (10) can be covered with soil (thickness ≥ 200 mm) according to actual needs for vegetation planting or comprehensive site utilization to further improve the thermal insulation effect.

[0050] 4. Key parameters and verification

[0051] Module size: The standard size of unit module A (1) is 2m×2m, and the standard size of unit modules M (2) and R (3) is 2m×2m; Tenon specifications: The tenon (5) is made of hard insulation material, with a tenon tail of 200mm, a tenon head of 300mm, a tenon thickness of 200mm, and a tenon depth of 1900mm; Load-bearing test: The floating roof system can bear ≥500kg / m 2 The uniformly distributed load can meet the needs of large-scale cross-season heat storage and agricultural greenhouses, industrial plants and other scenarios; Thermal insulation performance: According to actual measurements, the overall thermal conductivity of the floating roof system is ≤0.035W / m·K, which reduces heat loss by 40% compared with traditional flexible roofs.

[0052] Through the above steps, the construction of this embodiment is successfully completed.

[0053] The above examples illustrate the basic principles, main features and implementation processes of the present invention. The examples are only examples of the present invention, not all examples, and cannot be used to limit the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes. Those skilled in the art, inspired by the above, without departing from the purpose of the present invention, design structures and embodiments similar to the technical solution without creativity, all of which should belong to the protection scope of the present invention.

Claims

1. Hyperbolic load-bearing thermal insulation floating roof, characterized by: The hyperbolic load-bearing thermal insulation floating roof comprises two categories, a total of three types of unit modules, one category is a main unit module A (1), and the other category is an edge unit module, including: a unit module M (2) and a unit module R (3); the three types of unit modules are arranged and assembled in the form of the edge unit module surrounding the main unit module, and are fixed by using a tenon (5); a pad (7), a thermal insulation layer (8) and a pad (7) are respectively arranged in the shell (6) of each unit module from top to bottom, wherein the thermal insulation layer adopts a hyperbolic form with staggered distribution.

2. The hyperbolic load-bearing thermal insulation floating roof according to claim 1, characterized in that: The top cover module is made of hard heat-insulating material and has mortises (9) machined at corresponding positions.

3. The hyperbolic load-bearing thermal insulation floating roof according to claim 1 or 2, characterized in that: The unit module A (1) of the main unit module has four mortises, the unit module M (2) of the edge unit module has three mortises, the unit module R (3) has two mortises, and all modules at the four corners and edges can be obtained by rotating the unit module R (3) and the unit module M (2).

4. The hyperbolic load-bearing thermal insulation floating roof according to claim 3, characterized in that: After determining the reference direction, the first row of the floating roof is arranged and fixed in the order of "unit module R (3) + unit module M (2) + unit module M (2) + unit module R (3)"; the second row is arranged and fixed in the order of "unit module M (2) + unit module A (1) + unit module A (1) + unit module M (2)"; the third row is arranged and fixed in the order of "unit module M (2) + unit module A (1) + unit module A (1) + unit module M (2)", and then the second and third rows are repeated according to actual needs; the last row is arranged and fixed in the order of "unit module R (3) + unit module M (2) + unit module M (2) + unit module R (3)".

5. The hyperbolic load-bearing thermal insulation floating roof according to claim 4, characterized in that: The material type and thickness of the hard heat-insulating material (9) should be selected according to the design and cost requirements of the top cover.

6. The hyperbolic load-bearing thermal insulation floating roof according to claim 1, characterized in that: The specific number of unit modules needs to be determined based on the size of the water surface opening of the inter-seasonal hot water storage body and in combination with the sizes of the three unit modules.

7. The hyperbolic load-bearing thermal insulation floating roof according to claim 1, 4, 5 or 6, characterized in that: The specific number of the tenons (5) is determined according to the number of unit modules used.

8. The hyperbolic load-bearing thermal insulation floating roof according to claim 1, 4, 5 or 6, characterized in that: After laying and assembling the unit modules, a floating roof is formed, and a protective layer (10) is laid on the floating roof. The protective layer (10) extends all the way into the anchoring trench (11), and is covered with soil for anchoring.

9. The hyperbolic load-bearing thermal insulation floating roof according to claim 1, 4, 5 or 6, characterized in that: The protective layer (10) can be covered with soil to comprehensively utilize the floating roof of the cross-seasonal hot water storage body.

10. The method for manufacturing a hyperbolic load-bearing thermal insulation floating roof according to any one of claims 1 to 9, characterized in that: The steps include: Step 1: Process the pad, insulation layer and tenon of the adaptable unit module according to the design, and assemble them into a whole in the order of pad, insulation layer and pad from top to bottom to form the inner structure of the unit module; Step 2: According to the design, the inner layer structure of the unit module in step 1 is placed into the shell when processing the shell of the unit module through an automated production line, and the unit module is completely wrapped in the shell to form a whole during the one-time molding process; Step 3: After determining the reference direction according to the on-site conditions of the hot water storage body, assemble and fix the modules according to the arrows or characters on the modules: the first row is arranged and fixed in the order of "module R (3) + module M (2) + module M (2) + module R (3)"; the second row is arranged and fixed in the order of "module M (2) + module A (1) + module A (1) + module M (2)"; the third row is arranged and fixed in the order of "module M (2) + module A (1) + module A (1) + module M (2)", and then the second and third rows are repeated according to actual needs; the last row is arranged and fixed in the order of "module R (3) + module M (2) + module M (2) + module R (3)"; Step 4: Connect the tenons one by one according to the mortises processed on the unit modules; Step 5: After laying and assembling the unit modules, a floating roof is formed, and a protective layer is laid on the floating roof. The protective layer extends all the way to the anchoring trench, and soil is covered and buried for anchoring; Step 6: Cover the protective layer with soil according to actual needs to comprehensively utilize the floating roof of the cross-seasonal hot water storage body.

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