Sandwich column type load-bearing thermal insulation floating roof and manufacturing method

Abstract

The invention relates to a sandwich column type bearing heat preservation floating roof and a joggling type connection method thereof, is suitable for cross-seasonal heat storage water with heat preservation and bearing requirements, and belongs to the field of cross-seasonal heat storage / heat supply design and construction. The sandwich column 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-seasonal heat storage / heating design and construction, and particularly relates to a sandwich-column type load-bearing thermal insulation floating roof and a manufacturing method thereof. Background Art

[0002] In China, carbon emissions in the building heating field account for 25% of the national total, among which coal heating in northern cities and towns accounts for more than 70%, with an annual carbon emission of 550 million tons. To achieve the "dual carbon" goal, it is urgent to replace traditional fossil fuels with renewable energy. The water-based solar cross-seasonal heat storage technology is listed as an optimal technology for building heating decarbonization by the International Energy Agency (IEA) due to its high heat storage density (≥50 kWh / m 3 ), long operation life (>30 years) and low-carbon characteristics. A large number of scientific studies and rich engineering practice experiences show that this technology has high reliability and has been widely applied at home and abroad, and multiple large-capacity heat storage water bodies have been put into actual operation. In China, multiple heat storage water bodies with different volumes have been built in Beijing, Hebei, Tibet and other places, providing effective solutions for local heating demands. However, the technical bottleneck of its core component - the thermal insulation top cover of the heat storage water body severely restricts large-scale application.

[0003] As the core subsystem of the water-based solar cross-seasonal heat storage and heating system, the heat storage water body has the highest cost proportion in the whole system. Generally, the heat storage water body is excavated from the ground to a specific shape, and after foundation treatment, an anti-seepage layer is laid, and then water is used as the heat storage working medium. Its volume range is wide, from several hundred cubic meters to several hundred thousand cubic meters. In the composition of the heat storage water body, the thermal insulation top cover plays a crucial role. It not only directly determines the heat storage efficiency of the heat storage water body and is a key component to ensure the efficient operation of the system, but also has the highest proportion in the cost of the heat storage water body, accounting for about 50% of the overall cost. In addition, large heat storage water bodies cover a large area, ranging from several thousand square meters to several hundred thousand square meters, which to a certain extent limits the application scenarios and scope of the water-based solar cross-seasonal heat storage and heating technology. Chinese Patent CN118653734A proposes an integrated load-bearing anti-seepage and thermal insulation floating roof system for a heat storage water tank, which is mainly applied to the heat storage water tank in a large-scale cross-seasonal heat storage system. Through the unique floating roof structure design, this system effectively solves the problems of difficult construction, inconvenient drainage and inability to bear weight of the traditional integrated floating roof, and at the same time has good thermal insulation performance. However, the performance of this system under extreme weather conditions (such as extremely cold, heavy rain, etc.) is not mentioned in the article, and the adaptability and optimization scheme of the system for heat storage water tanks of different scales and shapes are not elaborated in detail.

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

[0005] To solve the above technical problems, the present invention proposes a sandwich-column type load-bearing thermal insulation floating roof and its manufacturing method, which is applied to the field of seasonal heat storage / heating design and construction. It is a floating roof with a simple structure, stable and reliable, convenient to maintain, relatively low cost, and capable of meeting the two functions of thermal insulation and load-bearing at the same time.

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

[0007] A sandwich-column type load-bearing thermal insulation floating roof includes two types of unit modules, a total of three different structures. One type is the main unit module A; the other type is the edge unit modules: unit module M and unit module R. The three unit modules are arranged and assembled in a form where the edge unit modules surround the main unit module, and are fixed using the mortise and tenon joint form; a backing plate, a thermal insulation layer, and a backing plate are respectively arranged in the shell of each unit module from top to bottom.

[0008] Furthermore, the number of mortises in each unit module is different.

[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 situation of the hot water storage body, the top cover module is assembled and fixed according to the arrow or character prompts on the unit module. 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 the second row and the third row 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)".

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

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

[0013] Further, the specific number of tenons needs to be determined according to the number of unit modules used. In addition, corresponding tenons should be prepared according to the actual situation for use in special cases.

[0014] Further, after laying and assembling the unit modules, a floating roof is formed. A protective layer is laid on the floating roof and extends into the anchorage trench, and then backfilled with soil for anchorage.

[0015] Further, soil can be covered on the protective layer according to actual needs for comprehensive utilization of the cross-seasonal hot water storage floating roof.

[0016] The present invention also provides a manufacturing method for a sandwich column type load-bearing heat-insulating floating roof, including the following steps:

[0017] Step 1: Process the backing plates, tenons, and heat-insulating layers adapted to the unit modules according to the design, and combine them into a whole in the order of backing plate, heat-insulating layer, and backing plate from top to bottom to form the inner structure of the unit module;

[0018] Step 2: Place the inner structure of the unit module in step 1 into the shell when processing the shell of the unit module through an automated production line, and completely wrap the unit module during the one-time forming process of the shell to form a whole;

[0019] Step 3: After determining the reference direction according to the on-site situation of the hot water storage body, assemble and fix according to the arrow or character prompts on the unit module: 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 row and the third row 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)";

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

[0021] Step 5: After laying and assembling the unit modules, a floating roof is formed. A protective layer is laid on the floating roof and extends into the anchorage trench, and then backfilled with soil for anchorage;

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

[0023] The advantages of the present invention are as follows:

[0024] 1. The advantages of the present invention are that the inner structure of the unit module with a sandwich column type is designed, which not only optimizes the structure but also greatly saves the amount of thermal insulation materials.

[0025] 2. The advantages of the present invention are 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 advantages of the present invention are that the tenon joint connection structure is adopted at the edge of the unit module, which improves the connection stability between the unit modules and also improves the radial stability of the unit module.

[0027] 4. The advantages of the present invention are that each unit module is connected by tenons, the connection is simple and reliable, greatly reducing the construction difficulty and saving the construction cost.

[0028] 5. The advantages of the present invention are that the floating roof does not need maintenance under normal use conditions, greatly saving the operation and maintenance cost of the floating roof.

[0029] 6. The advantages of the present invention are that it broadens the application scenarios and scope of the water body type solar seasonal heat storage and heating technology. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 is a schematic cross-sectional structure diagram of the sandwich column type load-bearing and heat-insulating floating roof of the present invention;

[0031] In the figure: 1 unit module A, 2 heat-insulating sandwich column, 3 unit module R, 4 unit module M.

[0032] Figure 2 is a schematic structure diagram of the shell of the unit module M1 of the sandwich column type load-bearing and heat-insulating floating roof of the present invention;

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

[0034] Figure 3 is a schematic structure diagram of the heat-insulating layer of the unit module A1 of the sandwich column type load-bearing and heat-insulating floating roof of the present invention;

[0035] Figure 4 is a schematic structure diagram of the heat-insulating layer of the unit module M1 of the sandwich column type load-bearing and heat-insulating floating roof of the present invention;

[0036] Figure 5 is a schematic structure diagram of the heat-insulating layer of the unit module R1 of the sandwich column type load-bearing and heat-insulating floating roof of the present invention;

[0037] Figure 6 is a schematic structure diagram of the tenon of the sandwich column type load-bearing and heat-insulating floating roof of the present invention;

[0038] Figure 7 is a schematic top view of the sandwich column type load-bearing and heat-insulating floating roof of the present invention;

[0039] In the figure: 10 protective layer, 11 anchoring groove. Specific implementation manners

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

[0041] Embodiment:

[0042] As Figures 1 to 7 shown, the sandwich column type 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 each unit module through a tenon (5) to form a closed thermal insulation and load-bearing system. The specific implementation steps are as follows:

[0043] 1. Prefabrication and processing of unit modules

[0044] According to the opening size of the hot water storage body and the design requirements, determine the quantities of the unit modules A (1), M (2), and R (3). The inner structure of each unit module is composed of a backing plate (7), a sandwich column type thermal insulation layer (8), and a backing plate (7) from top to bottom ( Figures 2 - 5 ). The thermal insulation layer is made of high-density polystyrene foam (HDPE) with a thermal conductivity of 0.028 W / m·K, and the thickness is selected according to the design requirements (50 - 100 mm). The shell (6) is formed in one step by an automated production line using a rigid thermal insulation material, wraps the inner structure, and processes 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: fix in the order of "unit module R (3) + unit module M (2) + unit module M (2) + unit module R (3)"; the second row and the third row: repeat the arrangement in the order of "unit module M (2) + unit module A (1) + unit module A (1) + unit module M (2)"; the last row: symmetric to the first row, fix according to "unit module R (3) + unit module M (2) + unit module M (2) + unit module R (3)".

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

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

[0050] 4. Key Parameters and Verification

[0051] Module Size: The standard size of unit module A (1) is 2 m × 2 m, and unit modules M (2) and R (3) are 2 m × 2 m; Tenon Specification: The tenon (5) is made of rigid thermal insulation material, with a tenon tail of 200 mm, a tenon head of 300 mm, a tenon thickness of 200 mm, and a tenon depth of 1900 mm; Bearing Capacity Test: The floating roof system can bear a uniform load of ≥ 500 kg / m 2 ², meeting the requirements of large-scale cross-seasonal heat storage and scenarios such as agricultural greenhouses and industrial factories; Heat Insulation Performance: After actual measurement, the overall thermal conductivity of the floating roof system is ≤ 0.035 W / m·K, and the heat loss is reduced by 40% compared with traditional flexible roof covers.

[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 above examples are only one example of the present invention, rather than all examples, and cannot be used to limit the present invention. Without departing from the spirit and scope of the present invention, various changes will occur to the present invention. Those skilled in the art, inspired by it and without creative design, design structural forms and embodiments similar to this technical solution without departing from the purpose of the present invention's creation, and all should belong to the protection scope of the present invention.

Claims

1. Sandwich column type bearing type thermal insulation floating roof, characterized by: The sandwich column type load-bearing thermal insulation floating roof includes two categories, a total of three types of unit modules, one category is the main unit module A (1), and the other category is the edge unit module, including: unit module M (2) and 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 tenons (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 the form of a sandwich column with staggered distribution.

2. The sandwich column type bearing type 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 sandwich column type bearing type 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 sandwich column type bearing type heat-insulating 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 sandwich column type bearing type heat-insulating 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 sandwich column type bearing type 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 sandwich column type bearing type heat-insulating 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 sandwich column type bearing type heat-insulating 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 sandwich column type bearing type heat-insulating 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 sandwich column type bearing type 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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