Modular assembly wall system and assembly method thereof

Abstract

The invention discloses a modular assembly wall system and an assembly method thereof. The modular assembly wall system comprises a plurality of modular light wall units, connecting pieces between the adjacent wall units, fixing assemblies of walls and a building structure and an internal pipeline laying structure. Each modular light wall body unit comprises a graphene polymerization foaming core material, decorative surface layers are compounded on the two sides of the core material, and the decorative surface layers are selected from one or more combinations of calcium silicate boards, magnesium oxide boards, density boards, gypsum boards, light boards, glass or marble; the adjacent wall body units are in rapid butt joint through special connecting pieces, and the connecting pieces are made of galvanized steel or engineering plastic materials. Through a connecting piece structure, a fixing mode and a material system which are innovatively designed, rapid assembly, stable connection and function integration of the wall body are achieved, and the technical defects that an existing modular wall body is complex in connection, tedious in construction, single in function, poor in adaptability and the like are overcome.

Description

Technical Field

[0001] This invention relates to the field of building wall technology, and in particular to a modular assembled wall system and its assembly method. Background Technology

[0002] Traditional building walls are mostly constructed using on-site masonry or cast-in-place concrete techniques, which suffer from long construction cycles, significant material waste, severe noise and dust pollution, and high difficulty in subsequent renovations. With the development of prefabricated building technology, modular walls have gradually become a research hotspot in the industry. Through factory prefabrication and on-site assembly, they can effectively improve construction efficiency and reduce environmental impact.

[0003] Existing modular wall systems still suffer from several technical shortcomings: First, the connection structures between adjacent walls are complex, often employing welding or direct bolt connections, making installation and disassembly cumbersome and hindering precise positioning and rapid connection, thus affecting the overall flatness and stability of the walls. Second, the fixing methods between walls and ceilings / floors are mostly direct anchoring with expansion bolts, causing significant damage to the original building structure, insufficient seismic buffering performance, and leaving obvious traces after subsequent demolition. Third, the laying of internal pipes within the walls often involves on-site trenching, a complex process that easily damages the integrity of the wall structure and fails to meet the need for flexible adjustments to the wiring layout. Fourth, wall materials are mostly single-density boards or concrete blocks, resulting in heavy weight, poor thermal and sound insulation performance, and low fire resistance, making them unsuitable for the functional requirements of various scenarios such as education, healthcare, offices, and residences. Fifth, in old building renovation scenarios, traditional modular walls are difficult to adapt to the irregular structures of existing buildings, and the construction process easily causes secondary damage to the original decoration, resulting in low cost-effectiveness.

[0004] Therefore, developing a modular prefabricated wall system that is easy to connect, structurally stable, functionally integrated, and highly adaptable has become a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of existing technologies, such as weak multi-field coupling, interpolation mismatch, parameter rigidity, and poor compatibility. The purpose of this invention is to provide a modular assembled wall system that achieves rapid assembly, stable connection, and functional integration of the wall through innovative design of connector structure, fixing method, and material system, thereby solving the technical defects of existing modular wall systems, such as complex connection, cumbersome construction, single function, and poor adaptability.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a modular prefabricated wall system, characterized in that it includes several modular lightweight wall units, connectors between adjacent wall units, fixing components for the wall and the building structure, and an internal pipeline laying structure; the modular lightweight wall unit includes a graphene polymer foam core material, and the core material has composite decorative surface layers on both sides; the adjacent wall units are quickly connected by special connectors, the connectors being made of galvanized steel or engineering plastic, including a central arc-shaped cavity and connecting flanges on both sides, and cross-shaped or T-shaped plug-in pieces and sealing gaskets are provided on the connecting flanges; the wall units are fixed to the ceiling and the ground respectively by L-shaped reinforcing brackets at the top and bottom, one end of the L-shaped reinforcing bracket is anchored to the side of the wall unit, and the other end is connected to the building structure.

[0007] Furthermore, the central arc-shaped cavity of the connector has a semi-circular or elliptical structure, with a reserved pipeline channel inside the cavity to accommodate electrical wires, network cables, or low-voltage cables, achieving integration of wall connection and pipeline laying; the thickness of the connecting flange is 0.3mm to 2mm, wherein the thickness of the galvanized steel connector is 0.3mm and the thickness of the engineering plastic connector is 2mm. The connecting flange is provided with positioning slots and insertion protrusions, and the connectors of adjacent wall units achieve precise docking through the interlocking of the slots and protrusions.

[0008] Furthermore, the graphene polymer foam core material is made by polymerizing and foaming graphene materials mixed with foaming particles. The core material forms a uniform closed-cell structure. The density of the core material is 200kg / m³~400kg / m³, and the total thickness is 30mm~150mm. It can be customized into a single-wall or double-wall structure. In the double-wall structure, a cavity is reserved in the middle to improve the thermal insulation and sound insulation performance.

[0009] Furthermore, the decorative surface layer and the graphene polymer foam core material are bonded together by a silicone layer with a thickness of 1mm to 3mm. The decorative surface layer is selected from one or more combinations of calcium silicate board, MDF, gypsum board, lightweight board, glass or marble, and the surface can be laminated with PP film, decorative film or metal decorative panel to adapt to different scene requirements.

[0010] Furthermore, the wall unit is equipped with a column-type cable tray structure. The cable tray extends from the top to the bottom of the wall unit, and the cable tray inlet is located on the side of the wall unit, which is connected to the arc-shaped cavity pipeline channel of the connector. The wires are connected to the junction box from the top cable tray through the column cable tray inlet, realizing the concealed laying and quick connection of the pipeline. The junction box is embedded in the decorative surface layer of the wall unit and is flush with the surface of the decorative surface layer.

[0011] Furthermore, the L-shaped reinforcing brackets are made of galvanized steel with a thickness of 2mm to 5mm. The two flanges of the brackets are respectively provided with elongated adjustment holes, which can be used to fine-tune the horizontal and vertical positions of the wall unit during installation. The brackets are connected to the wall unit with self-tapping screws or expansion bolts, and connected to the building structure with expansion bolts or chemical anchors.

[0012] Furthermore, the standard specifications of the modular lightweight wall unit are 1200mm×2440mm or 1200mm×3500mm, and special specifications can be customized. The wall unit is equipped with connector slots on all four sides, which can realize multi-directional splicing to form L-shaped, T-shaped or cross-shaped wall layouts.

[0013] An assembly method for a modular prefabricated wall system includes the following steps: S1: Measure and lay out the lines. Mark the installation positions of the wall units on the ceiling and floor according to the design drawings, and determine the fixing points of the L-shaped reinforcement brackets. S2: Fix the L-shaped reinforcing corner braces, anchor the corner braces to the ceiling and the ground at the marked points, and adjust the position of the corner braces to ensure horizontal and vertical accuracy; S3: Laying conduits, pre-threading electrical wires, network cables and other conduits into the upright cable trays and the arc-shaped cavity of the connectors, and reserving wiring ports; S4: Assemble the wall units. Fix the first wall unit to the L-shaped reinforcing bracket, and then assemble the subsequent wall units in sequence using connectors. Align the positioning slots and insertion protrusions to ensure a tight connection. S5: Install the 86 box and decorative surface layer. Embed the 86 box into the wall unit, connect the pipeline, and then seal the decorative surface layer to complete the wall leveling and cleaning. S6: Acceptance and commissioning, check the flatness of the wall, the stability of the connection and the continuity of the pipeline to ensure that it meets the design and usage requirements.

[0014] The beneficial effects of the present invention are as follows: (1) Adjacent walls are precisely connected by special connectors with arc-shaped cavities and cross or T-shaped plug-in pieces. Combined with top / bottom L-shaped reinforcing brackets, they can be quickly fixed to the building structure without on-site wet work. The construction cycle is shortened by more than 60% compared to traditional walls. They are also easy to disassemble and reassemble, facilitating later renovation and reconstruction. The positioning slots and plug-in protrusions of the connectors are designed to interlock with the sealing gaskets to ensure the flatness and sealing of the wall splicing. The L-shaped reinforcing brackets have adjustment holes, which can fine-tune the installation accuracy. They also provide vertical support and shock absorption, improving the overall structural stability. The arc-shaped cavity in the middle of the connector is connected to the column-type cable tray in the wall, realizing the integrated connection between the pipeline and the wall. There is no need for on-site grooving. The 86 box is flush with the decorative surface, making the wall neat and beautiful. The pipeline layout can be flexibly adjusted.

[0015] (2) The closed-cell structure of the graphene polymer foam core material reduces the weight of the wall to only 1 / 3 to 1 / 2 of that of a traditional brick wall, while also possessing Class A non-combustible properties and fire safety; the sound absorption coefficient is ≥0.6 and the thermal conductivity is ≤0.045W / (m²). It features excellent thermal insulation and soundproofing, as well as moisture-proof, mildew-proof, antibacterial, and easy-to-clean properties. The decorative surface can be made of calcium silicate board, glass, marble, etc., and can be laminated with PP film, decorative film, or metal veneer panels to suit the functional and aesthetic needs of different scenarios such as offices, medical facilities, and residences. In medical settings, PP film veneer can further meet antibacterial and disinfection requirements. Both the core material and the surface layer are environmentally friendly, free of formaldehyde and other harmful volatile organic compounds. The construction process is dust-free and noise-free. In renovation projects, there is no need to damage the original structure and decoration; wall units can be repeatedly disassembled and reused, conforming to the concepts of green building and circular economy.

[0016] (3) Standard specifications can be customized, supporting single / double wall structures, and can be spliced ​​into L-shaped, T-shaped and other layouts, suitable for new buildings and renovation of old buildings; low cost throughout the entire life cycle, convenient maintenance and renovation, and the overall cost performance is significantly better than traditional walls. It integrates structural support, decorative beauty, pipeline laying, fireproofing and heat insulation, sound insulation and moisture-proofing and other functions, without the need for additional construction procedures, providing a complete modular solution for building space partitioning. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention 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 the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a structural schematic diagram of the modular assembled wall system of the present invention; Figure 2 This is a detailed drawing of the connector of the present invention; Figure 3 This is a detailed drawing of the split connector of the present invention; Figure 4 This is a schematic diagram of the L-shaped reinforced hornbill structure of the present invention; Figure 5 This is a schematic diagram of the structure of Embodiment 3 of the present invention. Detailed Implementation

[0019] The following will be based on embodiments of the present invention. Figures 1-4The technical solutions in the embodiments of the present invention are clearly and completely described herein. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0020] Example 1 Standard office modular wall system This embodiment provides a modular prefabricated wall system suitable for standard office scenarios, with the following specific structure: Modular lightweight wall unit: It adopts a size of 1200mm×2440mm×90mm, with a graphene polymer foam core material density of 300kg / m³, a calcium silicate board decorative surface layer on both sides of the core material, and is bonded in the middle by a 2mm thick silicone layer. The surface of the decorative layer is coated with a light gray decorative film, which is suitable for the simple and beautiful needs of office scenes.

[0021] Connectors: The connectors are made of 0.3mm thick galvanized steel. The middle part is a semi-circular arc cavity with a diameter of 30mm, which can accommodate 2 network cables and 1 power cable. The connecting flanges on both sides are equipped with positioning slots and plug-in protrusions. The cross-shaped plug-in piece is 1mm thick and is matched with a 1mm thick butyl rubber sealing gasket to achieve sealing and positioning of adjacent walls.

[0022] Fixing components: The L-shaped reinforcing brackets are made of 3mm thick galvanized steel with a flange length of 50mm. They are equipped with elongated adjustment holes and are fixed to the side of the wall unit with 4 self-tapping screws. They are also anchored to the ceiling and floor with M6 expansion bolts to ensure the stability of the wall.

[0023] Cable laying: Three-column cable trays are installed inside the wall unit. The cable tray entrance is located in the middle of the side of the wall and connects to the arc-shaped cavity of the connector. The 86 box is embedded in the lower part of the wall unit and flush with the decorative surface layer to realize the arrangement of power and network interfaces in the office workstation.

[0024] The assembly cycle of the wall system in this embodiment is 1 / 3 of that of traditional masonry walls. The construction process is dust-free and noise-free, the wall flatness deviation is ≤2mm, the fire resistance reaches Class A, the sound absorption coefficient is 0.65, and the thermal conductivity is 0.042W / (m²). K) fully meets the functional requirements of office scenarios.

[0025] Example 2 Modular wall system for educational settings This embodiment provides a modular prefabricated wall system suitable for educational scenarios, with the following specific structure: Modular lightweight wall unit: It adopts a size of 1200mm×3500mm×120mm, with a graphene polymer foam core material density of 350kg / m³. The core material is bonded with lightweight board decorative surface layer on both sides and a 3mm thick silicone layer in the middle. The surface of the decorative surface layer is coated with PP film, which has antibacterial and easy-to-clean properties and meets the hygiene requirements of medical scenarios.

[0026] Connectors: The connectors are made of 2mm thick engineering plastic material. The central part is an elliptical arc cavity with a long axis of 40mm, which can accommodate multiple medical low-voltage cables. The connecting flanges on both sides are equipped with positioning slots and plug-in protrusions. The cross-shaped plug-in piece is 2mm thick and is equipped with a 1mm thick silicone sealing gasket to achieve a sealed and sterile connection to the wall.

[0027] Fixing components: The L-shaped reinforcing brackets are made of 5mm thick galvanized steel with a flange length of 60mm. They are equipped with elongated adjustment holes and are fixed to the side of the wall unit with 6 self-tapping screws. They are also anchored to the ceiling and floor with M8 chemical anchors to improve seismic performance and meet the high requirements for structural stability in medical settings.

[0028] Pipeline installation: Four upright cable trays are installed inside the wall unit. The cable tray entrance is located on the upper side of the wall and connects to the arc-shaped cavity of the connector. The 86 box is embedded in the middle of the wall unit and flush with the decorative surface layer, realizing the concealed installation of power supply, oxygen and negative pressure suction pipelines of medical equipment.

[0029] The wall system in this embodiment achieves a fire resistance rating of Class A, an antibacterial rate of ≥99%, is easy to clean and disinfect, has minimal impact on the educational environment during construction, and allows for rapid adjustments to the wall layout and pipeline interfaces to suit the functional needs of classrooms and dormitories.

[0030] Example 3 Modular wall system for old building renovation This embodiment provides a modular prefabricated wall system suitable for old building renovation scenarios, with the following specific structure: Modular lightweight wall unit: It adopts a customized size of 1200mm×2600mm×100mm, with a graphene polymer foam core material density of 250kg / m³, and marble texture decorative film on both sides of the core material. It is bonded in the middle by a 1.5mm thick silicone layer, which can be adapted to the existing decoration style of old buildings and does not require additional wall decoration.

[0031] Connectors: Made of load-bearing steel, with a cavity diameter of 25mm. Pipelines enter directly from the load-bearing steel, integrating the load-bearing column with the wall. It can accommodate two power lines. The connecting flanges on both sides are equipped with positioning slots and plug-in protrusions. The cross-shaped plug-in piece is 1mm thick and comes with a 1mm thick rubber sealing gasket for quick splicing.

[0032] Fixing components: The L-shaped reinforcing brackets are made of 2mm thick galvanized steel with a flange length of 40mm. They are equipped with elongated adjustment holes and are fixed to the side of the wall unit with 3 self-tapping screws. They are also anchored to the ceiling and floor with M4 self-tapping screws to avoid damaging the old building structure and decoration.

[0033] Pipeline installation: Three-column cable trays are installed inside the wall unit. The cable tray entrance is located at the lower side of the wall and connects to the arc-shaped cavity of the connector. The 86 box is embedded in the lower part of the wall unit and is flush with the decorative surface, realizing the power interface arrangement of the new space in the old building.

[0034] The construction period of the wall system in this embodiment is 1 / 4 of that of traditional renovation methods. It does not require the removal of the original decoration, has minimal impact on residents' lives, can be quickly dismantled later, and the wall units can be reused, making it highly cost-effective.

[0035] Example 4 Modular wall system for dual-wall thermal insulation and soundproofing scenarios This embodiment provides a modular prefabricated wall system suitable for scenarios with high requirements for thermal insulation and soundproofing. The specific structure is as follows: Modular lightweight wall unit: It adopts a size of 1200mm×2440mm×150mm, which is a double wall structure with a 50mm cavity in the middle, filled with rock wool insulation material. The graphene polymer foam core material on both sides has a density of 300kg / m³. The outer side of the core material is composite glass decorative surface layer, and the middle is bonded by a 2mm thick silicone layer to improve thermal insulation and sound insulation performance.

[0036] Connectors: The connectors are made of 0.3mm thick galvanized steel. The middle part is an elliptical arc cavity with a major axis of 50mm, which can accommodate multiple pipelines. The connecting flanges on both sides are equipped with positioning slots and plug-in protrusions. The cross-shaped plug-in piece is 1mm thick and is equipped with a 2mm thick rubber sealing gasket to achieve sealing and connection of the double walls.

[0037] Fixing components: The L-shaped reinforcing brackets are made of 4mm thick galvanized steel with a flange length of 55mm. They are equipped with elongated adjustment holes and are fixed to the side of the double wall unit with 5 self-tapping screws. They are also anchored to the ceiling and floor with M6 expansion bolts to ensure the stability of the double wall structure.

[0038] Pipeline installation: Four upright cable trays are installed inside the wall unit. The cable tray entrance is located in the middle of the side of the wall and is connected to the arc-shaped cavity of the connector. The 86 box is embedded in the lower part of the wall unit and is flush with the decorative surface layer, realizing the concealed installation of pipelines in the case of thermal insulation and sound insulation.

[0039] The thermal conductivity of the wall system in this embodiment is as low as 0.035 W / (m²). With a sound absorption coefficient of 0.75, it has excellent thermal insulation and sound insulation performance, making it suitable for residential bedrooms, recording studios, and other scenarios where a high degree of quietness is required.

[0040] In summary, the modular prefabricated wall system of the present invention achieves rapid assembly, stable connection and functional integration of the wall through innovative design of connector structure, fixing method and material system. It has many advantages such as lightweight and high strength, fire resistance and heat insulation, sound insulation and moisture resistance, convenient construction and strong adaptability. It can be widely used in various scenarios such as office, medical, residential and old building renovation, and has significant economic and social benefits.

Claims

1. A modular prefabricated wall system, characterized in that, The system includes several modular lightweight wall units, connectors between adjacent wall units, fixing components for the wall and building structure, and internal pipeline laying structure. Each modular lightweight wall unit includes a graphene polymer foam core material with composite decorative surface layers on both sides. Adjacent wall units are quickly connected via specialized connectors made of galvanized steel or engineering plastic, including a central arc-shaped cavity and connecting flanges on both sides. The connecting flanges are equipped with cross-shaped or T-shaped inserts and sealing gaskets. Each wall unit is fixed to the ceiling and floor via L-shaped reinforcing brackets at the top and bottom, respectively. One end of each L-shaped reinforcing bracket is anchored to the side of the wall unit, and the other end is connected to the building structure.

2. The modular prefabricated wall system according to claim 1, characterized in that: The central arc-shaped cavity of the connector is semi-circular or elliptical in shape, with a reserved pipeline channel inside to accommodate electrical wires, network cables, or low-voltage cables, thus integrating wall connection and pipeline laying. The thickness of the connecting flange is 0.3mm to 2mm, with galvanized steel connectors having a thickness of 0.3mm and engineering plastic connectors having a thickness of 2mm. The connecting flange is provided with positioning slots and insertion protrusions, and the connectors of adjacent wall units achieve precise docking through the interlocking of the slots and protrusions.

3. The modular prefabricated wall system according to claim 1, characterized in that: The graphene polymer foam core material is made by polymerizing and foaming graphene materials with foam particles. The core material has a uniform closed-cell structure. The density of the core material is 200kg / m³~400kg / m³, and the total thickness is 30mm~150mm. It can be customized into a single wall or double wall structure. The double wall structure has a cavity reserved in the middle to improve the thermal insulation and sound insulation performance.

4. A modular prefabricated wall system according to claim 1, characterized in that: The decorative surface layer is bonded to the graphene polymer foam core material via a silicone layer with a thickness of 0.1mm to 1mm. The decorative surface layer is selected from one or more combinations of calcium silicate board, magnesium oxide board, MDF, gypsum board, lightweight board, glass, or marble. The surface can be laminated with PP film, decorative film, or metal decorative panel to adapt to different scene requirements.

5. A modular prefabricated wall system according to claim 1, characterized in that: The wall unit is equipped with a column-type cable tray structure. The cable tray extends from the top to the bottom of the wall unit. The cable tray inlet is located on the side of the wall unit and is connected to the arc-shaped cavity of the connector. The wires are connected to the junction box from the top cable tray through the column cable tray inlet, realizing the concealed laying and quick connection of the pipeline. The junction box is embedded in the decorative surface layer of the wall unit and is flush with the surface of the decorative surface layer.

6. A modular prefabricated wall system according to claim 1, characterized in that: The L-shaped reinforcing brackets are made of galvanized steel with a thickness of 2mm to 5mm. The two flanges of the brackets are provided with elongated adjustment holes, which can be used to fine-tune the horizontal and vertical positions of the wall unit during installation. The brackets are connected to the wall unit with self-tapping screws or expansion bolts, and connected to the building structure with expansion bolts or chemical anchors.

7. A modular prefabricated wall system according to claim 1, characterized in that: The standard dimensions of the modular lightweight wall unit are 1200mm×2440mm or 1200mm×3500mm, and special dimensions can be customized. The wall unit is equipped with connector grooves on all four sides, which can realize multi-directional splicing to form L-shaped, T-shaped or cross-shaped wall layouts.

8. An assembly method for a modular prefabricated wall system according to any one of claims 1-7, characterized in that: Includes the following steps: S1: Measure and lay out the lines. Mark the installation positions of the wall units on the ceiling and floor according to the design drawings, and determine the fixing points of the L-shaped reinforcement brackets. S2: Fix the L-shaped reinforcing corner braces, anchor the corner braces to the ceiling and the ground at the marked points, and adjust the position of the corner braces to ensure horizontal and vertical accuracy; S3: Laying conduits, pre-threading electrical wires, network cables and other conduits into the upright cable trays and the arc-shaped cavity of the connectors, and reserving wiring ports; S4: Assemble the wall units. Fix the first wall unit to the L-shaped reinforcing bracket, and then assemble the subsequent wall units in sequence using connectors. Align the positioning slots and insertion protrusions to ensure a tight connection. S5: Install the 86 box and decorative surface layer. Embed the 86 box into the wall unit, connect the pipeline, and then seal the decorative surface layer to complete the wall leveling and cleaning. S6: Acceptance and commissioning, check the flatness of the wall, the stability of the connection and the continuity of the pipeline to ensure that it meets the design and usage requirements.

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