A light-weight thermal insulation composite external wall panel based on foamed aluminum

Abstract

The application discloses a light heat-preservation composite outer wall panel based on foamed aluminum, and relates to the technical field of building outer wall materials.The wall panel body is in a sandwich composite structure and is composed of a protective panel one, a foamed aluminum core layer and a protective panel two, and the retaining protrusions and the retaining grooves are in clearance fit.The application adopts the sandwich composite structure of the protective panel one-foamed aluminum core layer-protective panel two, realizes efficient heat preservation by virtue of the porous structure of the foamed aluminum, makes the fireproof grade of the outer wall panel reach the A-level standard by virtue of the non-combustible characteristics of the foamed aluminum, controls the overall self weight of the wall panel body to be 80-120 kg / m2 by virtue of the lightweight characteristics of the foamed aluminum core layer and the protective panel, effectively solves the technical difficulties that the heat preservation and fire prevention of the traditional outer wall panel are difficult to be considered together and the high self weight of the outer wall panel leads to the high load of the building body, considers the triple core requirements of heat preservation, fire prevention and light weight, and is suitable for the load requirements of multi-storey and high-rise buildings.

Description

Technical Field

[0001] This invention relates to the field of building exterior wall materials technology, specifically to a lightweight thermal insulation composite exterior wall panel based on aluminum foam. Background Technology

[0002] Exterior wall panels are a core component of a building's external envelope, primarily installed on the exterior walls to separate the building's interior from the external environment. They are crucial for ensuring the building's functionality and enhancing its performance. Their core functions include thermal insulation, fire resistance, waterproofing, sound insulation, and wind and impact resistance. They also serve aesthetic purposes and protect the building's main structure, directly impacting energy efficiency, safety, durability, and occupant comfort. Depending on their materials, structure, and function, exterior wall panels can be categorized into traditional concrete wall panels, aerated concrete blocks, integrated insulation and decoration panels, and metal composite wall panels, among others. They are widely used in the construction of new multi-story and high-rise buildings, as well as in the renovation of existing buildings, making them an indispensable building material in the modern construction industry. With the escalating global energy crisis and increasingly stringent building energy efficiency standards, the performance optimization and technological upgrading of exterior wall panels, as a core element of building energy conservation, have received widespread attention.

[0003] Existing thermal insulation exterior wall panels mostly use organic insulation materials (such as polystyrene boards and extruded polystyrene boards), which have good thermal insulation performance but low fire resistance, are easily combustible, and produce toxic fumes. In contrast, inorganic wall panels (such as concrete wall panels) have better fire resistance but poor thermal insulation performance, making it difficult to meet building energy conservation requirements. They also have problems such as insufficient interface bonding strength and easy delamination. Furthermore, traditional concrete exterior wall panels typically weigh 200-300 kg / m², which is quite heavy and significantly increases the load-bearing pressure on the main building structure. This makes them particularly unsuitable for high-rise buildings and renovation projects of existing buildings. In addition, due to their heavy weight, construction requires the use of lifting equipment, the on-site masonry process is complex, and the construction period is long. Moreover, the splicing method is simple and the sealing performance is poor, further affecting the thermal insulation and sound insulation effects.

[0004] Therefore, it is necessary to invent a lightweight thermal insulation composite exterior wall panel based on aluminum foam to solve the above problems. Summary of the Invention

[0005] The purpose of this invention is to provide a lightweight thermal insulation composite exterior wall panel based on aluminum foam, in order to solve the problems in the technology of thermal insulation exterior wall panels that are difficult to balance thermal insulation and fire protection, have insufficient interface bonding strength and are prone to delamination, have a large self-weight that increases the load-bearing pressure on the main building, have poor construction convenience, and have poor splicing and sealing performance that affects the thermal insulation and sound insulation effect.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a lightweight thermal insulation composite exterior wall panel based on aluminum foam, comprising a wall panel body, wherein the wall panel body adopts a sandwich composite structure, composed of a protective panel one, an aluminum foam core layer, and a protective panel two. The edges of the wall panel body are provided with mortise and tenon structures for splicing. The aluminum foam core layer is closed-cell aluminum foam, which is prepared by a mixed element rolling process, introducing magnesium and zinc elements to optimize the microstructure. The aluminum foam core layer is connected to the protective panel one and the protective panel two through an integrated concave-convex interlocking structure, and is further fixed by longitudinal reinforcing ribs. The concave-convex interlocking structure includes retaining protrusions, retaining grooves, and a high-temperature resistant adhesive. The retaining protrusions are integrally fixed on the top surface of the protective panel one and the bottom surface of the protective panel two, respectively. The retaining protrusions are distributed in a rectangular uniform array. The retaining grooves are respectively provided on the upper and lower surfaces of the aluminum foam core layer, and the retaining protrusions and retaining grooves form a gap fit.

[0007] Furthermore, both the first and second protective panels are made of high-strength aluminum alloy sheets, and their surfaces are treated with an integrated anti-weathering and anti-UV composite treatment. The anti-weathering and anti-UV treatment is achieved by spraying a fluorocarbon coating on the surface, with a coating thickness of 30-50μm.

[0008] Furthermore, the thickness of the first protective panel and the second protective panel is 20 to 30 millimeters.

[0009] Furthermore, the porosity of the aluminum foam core layer is controlled at 75% to 85%, the density is 0.3 to 0.7 g / cm³, and the thickness of the aluminum foam core layer is 50 to 100 mm.

[0010] Furthermore, the mortise and tenon structure includes a dovetail tongue, a dovetail groove, and a sealing strip. The dovetail tongue is fixed to one edge of the wall panel body, and the dovetail groove is correspondingly opened at the other edge of the wall panel body, and an interference fit is formed between the dovetail tongue and the dovetail groove.

[0011] Furthermore, the sealing strip is made of high-elasticity silicone weather-resistant adhesive strip, which is embedded in the reserved installation groove on the inner wall of the dovetail tenon. After locking, the sealing strip fits tightly against the dovetail tenon.

[0012] Furthermore, the high-temperature resistant adhesive is a modified epoxy adhesive, which fills the gaps in the interlocking structure.

[0013] Furthermore, the foamed aluminum core layer is provided with multiple longitudinal reinforcing ribs arranged in a uniform array at equal intervals. The multiple longitudinal reinforcing ribs are made of high-strength aluminum alloy, and the two ends of the longitudinal reinforcing ribs are fixedly connected to the top surface of the first protective panel and the bottom surface of the second protective panel, respectively.

[0014] Furthermore, the overall weight of the wall panel is controlled between 80 and 120 kg / m², the fire resistance rating reaches Class A, and the service life is no less than 25 years.

[0015] The technical effects and advantages provided by the present invention in the above technical solution are as follows: 1. This invention employs a sandwich composite structure of "protective panel one - aluminum foam core layer - protective panel two", combined with a mixed-element rolling process for the closed-cell aluminum foam core layer (introducing magnesium and zinc elements to optimize the microstructure), and precise parameter design with a porosity of 75% to 85% and a density of 0.3 to 0.7 g / cm³. It achieves efficient thermal insulation by relying on the porous structure of aluminum foam, and its non-combustible properties enable the exterior wall panel to reach the Class A fire resistance standard. At the same time, through the lightweight characteristics of the aluminum foam core layer and the protective panel, the overall weight of the wall panel is controlled at 80 to 120 kg / m². This effectively solves the technical pain points of traditional exterior wall panels, which are difficult to balance thermal insulation and fire resistance, and whose heavy weight leads to excessive building load. It meets the three core requirements of thermal insulation, fire resistance, and lightweight, and is suitable for the load requirements of multi-story and high-rise buildings. 2. This invention utilizes an integrated interlocking structure (a gap fit between retaining protrusions and retaining grooves) between the aluminum foam core layer and the protective panels on both sides. This is combined with a modified epoxy high-temperature resistant adhesive to fill the gaps, and further reinforced with high-strength aluminum alloy longitudinal reinforcing ribs for synergistic fixation. This forms a triple connection structure of "mechanical interlocking + adhesive fixing + reinforcing rib support," significantly improving the connection stability and structural load-bearing capacity between the core layer and the panels. This effectively prevents problems such as delamination, loosening, and separation during long-term use. Simultaneously, the protective panels are made of high-strength aluminum alloy sheets with a 30-50μm thick fluorocarbon coating for integrated weather resistance and UV resistance. Combined with the structural characteristics of the aluminum foam core layer, this ensures the exterior wall panel has a service life of no less than 25 years, significantly improving the product's durability and anti-aging capabilities, and reducing subsequent maintenance costs. 3. This invention utilizes a mortise and tenon structure along the edge of the wall panel body, employing an interference fit between dovetail tongues and dovetail grooves. A high-elasticity, weather-resistant silicone sealant strip is embedded and filled within the pre-reserved installation groove of the dovetail groove. After fitting, the sealant strip and dovetail tongue adhere tightly, achieving rapid modular assembly of the wall panel, improving construction efficiency, and effectively preventing air and water leakage at gaps, thus enhancing thermal insulation, sound insulation, and anti-seepage performance. Furthermore, the lightweight wall panel design eliminates the need for additional lifting equipment for on-site construction, further reducing construction difficulty and costs. It is suitable for new high-rise buildings and exterior wall renovation projects of existing buildings, possessing broad application scenarios and promotional value. Attached Figure Description

[0016] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the overall front structure of the present invention; Figure 3 This is a three-dimensional structural diagram of the dovetail tenon of the present invention; Figure 4 This is a two-section three-dimensional structural diagram of the protective panel of the present invention; Figure 5 This is an exploded three-dimensional structural diagram of the protective panel one, the aluminum foam core layer, and the protective panel two of the present invention; Figure 6 This is a bottom-view perspective view of the three-dimensional structure of the retaining protrusion of the present invention; Figure 7 This is a schematic diagram of the three-dimensional structure of the longitudinal reinforcing rib of the present invention.

[0018] Explanation of reference numerals in the attached figures: 1. Wall panel main body; 101. Protective panel one; 102. Foam aluminum core layer; 103. Protective panel two; 1031. Fluorocarbon coating; 2. Mortise and tenon structure; 201. Dovetail tongue; 202. Dovetail groove; 203. Sealing strip; 3. Interlocking structure; 301. Retaining protrusion; 302. Retaining groove; 303. High temperature resistant adhesive; 4. Longitudinal reinforcing ribs. Detailed Implementation

[0019] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0020] The components of the embodiments of the invention described and shown in the accompanying drawings can typically be arranged and designed in a variety of different configurations. Therefore, the following detailed description of the embodiments of the invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention.

[0021] Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for 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. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0023] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0024] This invention provides, for example Figure 1-7 The illustrated lightweight thermal insulation composite exterior wall panel based on aluminum foam includes a wall panel body 1. The wall panel body 1 adopts a sandwich composite structure, composed of a protective panel one 101, an aluminum foam core layer 102, and a protective panel two 103. The edges of the wall panel body 1 are provided with mortise and tenon structures 2 for splicing. The aluminum foam core layer 102 is closed-cell aluminum foam and is prepared using a mixed element rolling process, introducing magnesium and zinc elements to optimize the microstructure. The aluminum foam core layer 102 is connected to the protective panel one 101 and the protective panel two 103 by an integrated interlocking structure 3. The interlocking structure 3 is further reinforced with longitudinal reinforcing ribs 4 for joint fixation. It includes retaining protrusions 301, retaining grooves 302 and high-temperature resistant adhesive 303. The retaining protrusions 301 are integrally fixed on the top surface of the first protective panel 101 and the bottom surface of the second protective panel 103, respectively. The retaining protrusions 301 are distributed in a rectangular uniform array. The retaining grooves 302 are respectively provided on the upper and lower surfaces of the aluminum foam core layer 102, and the retaining protrusions 301 and the retaining grooves 302 form a gap fit. The high-temperature resistant adhesive 303 is a modified epoxy adhesive, which is filled in the gaps of the interlocking structure 3.

[0025] In this embodiment, the gap fit between the retaining protrusion 301 and the retaining groove 302 significantly increases the contact area between the aluminum foam core layer 102 and the protective panel one 101 and the protective panel two 103, achieving mechanical interlocking positioning between the two and preventing relative displacement between the core layer and the panel. After the modified epoxy high-temperature resistant adhesive 303 fills the gap, a dual connection effect of "mechanical interlocking + adhesive fixing" is formed, which strengthens the connection stability between the core layer and the panel, effectively preventing problems such as delamination, loosening, and delamination during long-term use. At the same time, it improves the overall structural strength and impact resistance of the exterior wall panel, adapting to the mechanical requirements of long-term use of the exterior wall.

[0026] Both protective panels 101 and 103 are made of high-strength aluminum alloy sheets. Their surfaces are treated with an integrated weather-resistant and UV-resistant composite coating. The weather-resistant and UV-resistant treatment is achieved by spraying a fluorocarbon coating 1031 on the surface, with a coating thickness of 30-50μm. The thickness of protective panels 101 and 103 is 20 to 30 mm. The porosity of the aluminum foam core layer 102 is controlled at 75% to 85%, and the density is 0.3 to 0.7 g / cm³. The thickness of the aluminum foam core layer 102 is 50 to 100 mm.

[0027] In this embodiment, protective panel 101 and protective panel 103 are made of high-strength aluminum alloy sheets, combined with a 30-50μm thick fluorocarbon coating 1031, which can effectively resist external weathering and ultraviolet erosion, delay panel aging, and improve the durability of the exterior wall panel. The panel thickness of 20 to 30 mm balances the strength and lightweight requirements of the panel, protecting the internal foam aluminum core layer 102 while reducing the overall weight of the wall panel body 1. The foam aluminum core layer 102 has a porosity of 75% to 85% and a density of 0.3 to 0.7 g / cm³. The density design achieves a balance between thermal insulation performance and structural strength. The porous structure effectively blocks heat transfer, achieving high-efficiency thermal insulation, while the closed-cell structure enhances the waterproof and sound insulation performance of the aluminum foam core layer 102. The application of mixed element rolling process further optimizes the microstructure of the aluminum foam core layer 102, avoiding the problems of uneven cell size and high pore breakage rate of traditional aluminum foam. At the same time, the non-combustible properties of aluminum foam ensure that the fire resistance rating of the exterior wall panel reaches Class A standard. The core layer thickness of 50 to 100 mm can flexibly adapt to the thermal insulation and energy-saving requirements of different regions.

[0028] The mortise and tenon structure 2 includes a dovetail tongue 201, a dovetail groove 202, and a sealing strip 203. The dovetail tongue 201 is fixed to one edge of the wall panel body 1, and the dovetail groove 202 is correspondingly opened at the other edge of the wall panel body 1. The dovetail tongue 201 and the dovetail groove 202 form an interference fit. The sealing strip 203 is a high-elasticity silicone weather-resistant strip. The sealing strip 203 is embedded and filled in the reserved installation groove on the inner wall of the dovetail groove 202. After the fit is closed, the sealing strip 203 and the dovetail tongue 201 are tightly fitted together.

[0029] In this embodiment, the interference fit between the dovetail tongue 201 and the dovetail groove 202 enables rapid modular splicing of the wall panel body 1. The splicing positioning is precise, requiring no additional positioning components and improving construction convenience. The high-elasticity silicone weather-resistant sealing strip 203 is embedded and tightly fitted to the dovetail tongue 201, which can effectively block air and water leakage at the splicing gaps, enhance the thermal insulation, sound insulation and anti-seepage performance of the exterior wall panel, and prevent external moisture and dust from entering the interior of the wall panel and damaging the connection structure between the core layer and the panel. The overall design of the mortise and tenon structure 2 not only improves the overall stability and mechanical properties of the wall panel after splicing, but also simplifies the construction process and provides a guarantee for rapid on-site masonry.

[0030] The foamed aluminum core layer 102 has multiple longitudinal reinforcing ribs 4 arranged in a uniform array at equal intervals. The multiple longitudinal reinforcing ribs 4 are made of high-strength aluminum alloy. The two ends of the longitudinal reinforcing ribs 4 are fixedly connected to the top surface of the protective panel 101 and the bottom surface of the protective panel 2 103, respectively. The overall self-weight of the wall panel body 1 is controlled between 80 and 120 kg / m², the fire resistance rating reaches Class A standard, and the service life is not less than 25 years.

[0031] In this embodiment, the longitudinal reinforcing ribs 4 are made of high-strength aluminum alloy and are uniformly arrayed inside the foam aluminum core layer 102. This effectively compensates for the insufficient structural strength of the foam aluminum core layer 102 itself. Together with the interlocking structure 3, they form a dual support structure of "interlocking + reinforcement," which significantly improves the impact resistance, bending resistance, and overall load-bearing capacity of the wall panel body 1, preventing deformation and damage during transportation, construction, and use. The fixed connection between the two ends of the longitudinal reinforcing ribs 4 and the protective panels on both sides further strengthens the overall connection between the core layer and the panels, ensuring uniform stress on the wall panel and extending its service life. The wall panel body has a self-weight design of 180 to 120 kg / m², which is 40% to 60% lighter than traditional concrete exterior wall panels, effectively reducing the load on the main building structure and adapting to the load requirements of multi-story and high-rise buildings. With a Class A fire resistance rating and a service life of not less than 25 years, the exterior wall panel meets the core requirements of building fire resistance and durability, reduces later maintenance costs, and has broad application value.

[0032] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0033] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A lightweight thermal insulation composite exterior wall panel based on aluminum foam, comprising a wall panel body (1), characterized in that: The wall panel body (1) adopts a sandwich composite structure, which is composed of protective panel one (101), aluminum foam core layer (102) and protective panel two (103). The wall panel body (1) has a tenon and mortise structure (2) for splicing on the edge. The aluminum foam core layer (102) is closed-cell aluminum foam. The aluminum foam core layer (102) is prepared by mixed element rolling process, and magnesium and zinc elements are introduced to optimize the microstructure. The aluminum foam core layer (102) is connected to protective panel one (101) and protective panel two (103) by an integrated concave-convex interlocking structure (3). The structure is connected and reinforced with longitudinal reinforcing ribs (4) for joint fixation. The interlocking structure (3) includes a retaining protrusion (301), a retaining groove (302) and a high-temperature resistant adhesive (303). The retaining protrusion (301) is integrally fixed on the top surface of the first protective panel (101) and the bottom surface of the second protective panel (103). The retaining protrusion (301) is distributed in a rectangular uniform array. The retaining groove (302) is respectively located on the upper and lower surfaces of the aluminum foam core layer (102), and the retaining protrusion (301) and the retaining groove (302) form a gap fit.

2. The lightweight thermal insulation composite exterior wall panel based on aluminum foam according to claim 1, characterized in that: Both the first protective panel (101) and the second protective panel (103) are made of high-strength aluminum alloy sheet, and their surfaces are treated with integrated anti-weathering and anti-ultraviolet composite treatment. The anti-weathering and anti-ultraviolet treatment is a fluorocarbon coating (1031) sprayed on the surface, with a coating thickness of 30-50μm.

3. The lightweight thermal insulation composite exterior wall panel based on aluminum foam according to claim 2, characterized in that: The thickness of the first protective panel (101) and the second protective panel (103) is 20 to 30 millimeters.

4. The lightweight thermal insulation composite exterior wall panel based on aluminum foam according to claim 1, characterized in that: The porosity of the aluminum foam core layer (102) is controlled at 75% to 85%, the density is 0.3 to 0.7 g / cm³, and the thickness of the aluminum foam core layer (102) is 50 to 100 mm.

5. A lightweight thermal insulation composite exterior wall panel based on aluminum foam according to claim 1, characterized in that: The mortise and tenon structure (2) includes a dovetail tongue (201), a dovetail groove (202), and a sealing strip (203). The dovetail tongue (201) is fixed on one side edge of the wall panel body (1), and the dovetail groove (202) is correspondingly opened on the other side edge of the wall panel body (1). The dovetail tongue (201) and the dovetail groove (202) form an interference fit.

6. A lightweight thermal insulation composite exterior wall panel based on aluminum foam according to claim 5, characterized in that: The sealing strip (203) is made of high elastic silicone weather-resistant adhesive strip. The sealing strip (203) is embedded and filled in the reserved installation groove on the inner wall of the dovetail tenon (202). After locking, the sealing strip (203) and the dovetail tenon (201) fit tightly together.

7. The lightweight thermal insulation composite exterior wall panel based on aluminum foam according to claim 1, characterized in that: The high-temperature resistant adhesive (303) is a modified epoxy adhesive, which is used to fill the gaps in the interlocking structure (3).

8. A lightweight thermal insulation composite exterior wall panel based on aluminum foam according to claim 1, characterized in that: The foam aluminum core layer (102) has multiple longitudinal reinforcing ribs (4) arranged in a uniform array at equal intervals. The multiple longitudinal reinforcing ribs (4) are made of high-strength aluminum alloy. The two ends of the longitudinal reinforcing ribs (4) are fixedly connected to the top surface of the first protective panel (101) and the bottom surface of the second protective panel (103), respectively.

9. A lightweight thermal insulation composite exterior wall panel based on aluminum foam according to claim 1, characterized in that: The main body of the wall panel (1) has an overall self-weight controlled between 80 and 120 kg / m², a fire resistance rating of Class A, and a service life of not less than 25 years.

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