Double-curved color-changing honeycomb aluminum plate

Abstract

This invention relates to the field of building decoration materials technology, and in particular to a hyperbolic iridescent honeycomb aluminum panel. It comprises, from top to bottom, an iridescent panel, a honeycomb core layer, and a base plate; the iridescent panel is composed of, from top to bottom, a wear-resistant protective layer, an iridescent coating, and an aluminum plate; a flexible solar photovoltaic module, which is a flexible copper indium gallium selenide solar cell or a flexible perovskite solar cell, is disposed between the iridescent panel and the honeycomb core layer; a heat-insulating buffer layer is disposed between the base plate and the honeycomb core layer. The hyperbolic iridescent honeycomb aluminum panel provided by this invention integrates decoration, protection, load-bearing capacity, heat insulation, sound insulation, and photovoltaic power generation. A single panel replaces multiple functional building materials, simplifies the building envelope structure, reduces the use of auxiliary materials, saves installation space, and offers high overall cost-effectiveness.

Description

Technical Field

[0001] This invention relates to the field of building decoration materials technology, and in particular to a hyperbolic iridescent honeycomb aluminum panel. Background Technology

[0002] With the rapid development of urban renewal, landmark irregular-shaped buildings, and BIPV photovoltaic buildings, curtain wall panels that combine curved shapes, artistic decoration, and clean energy power generation have become an industry necessity. Currently, existing conventional hyperbolic honeycomb aluminum panels and curved photovoltaic decorative panels have inherent defects in their structural design: traditional iridescent decorative coatings mostly adopt a high-shading solid color stacking structure, which completely blocks visible light transmission to ensure the surface color-changing decorative effect. This makes it impossible to build a light-transmitting coupling structure between the surface layer of the irregular hyperbolic panel and the photovoltaic power generation layer, resulting in the incompatibility between high-end iridescent decorative effects and curved solar photovoltaic power generation functions.

[0003] In existing technologies, pursuing a vibrant and artistic facade design necessitates abandoning the solar energy integration design of the curtain wall panels, using them merely as a single decorative component. Conversely, forcibly integrating flexible photovoltaic modules requires removing the functional iridescent coating, resulting in a simplistic and monotonous facade finish that fails to meet the aesthetic design requirements of high-end, irregularly shaped landmark buildings. This technological contradiction has long constrained the upgrading and development of hyperbolic irregularly shaped energy-saving curtain wall materials, hindering the integrated application of form, decoration, and power generation. Therefore, developing a hyperbolic iridescent honeycomb aluminum panel that can simultaneously achieve a translucent iridescent effect and curved photovoltaic power generation functionality is a pressing technical challenge in this field. Summary of the Invention

[0004] The purpose of this invention is to provide a hyperbolic iridescent honeycomb aluminum panel, which aims to solve the core technical problem that the iridescent decorative effect and the curved solar photovoltaic power generation function are incompatible in the prior art, and overcome the shortcomings of the existing hyperbolic honeycomb aluminum panels that only have a single decorative function and cannot simultaneously achieve a high-end iridescent appearance and solar energy utilization.

[0005] This invention provides a hyperbolic iridescent honeycomb aluminum panel, comprising an iridescent panel, a honeycomb core layer, and a base plate arranged sequentially from top to bottom; The iridescent panel is composed of a wear-resistant protective layer, an iridescent coating, and an aluminum plate arranged sequentially from top to bottom. A flexible solar photovoltaic module is provided between the iridescent panel and the honeycomb core layer. The flexible solar photovoltaic module is a flexible copper indium gallium selenide solar cell or a flexible perovskite solar cell. A heat-insulating buffer layer is provided between the base plate and the honeycomb core layer.

[0006] Furthermore, the aluminum plate has a thickness of 1.5~3.0mm, a tensile strength ≥150MPa, and a yield strength ≥110MPa.

[0007] Furthermore, the iridescent coating comprises a coloring layer, an iridescent interference layer, and a base coating layer arranged sequentially from top to bottom, with a total thickness of 25~45μm; The coloring layer is made of fluorocarbon colored paint and has a thickness of 15~25μm; The iridescent interference layer is a multilayer optical film composed of alternating nano-silica and nano-titanium dioxide. The number of layers in the multilayer optical film is 5 to 9, and the thickness of a single layer is 80 to 150 nm. The base coating is made of epoxy zinc-rich primer with a thickness of 5~10μm.

[0008] Furthermore, the iridescent interference layer is uniformly provided with multiple light-transmitting nanopores, and the visible light transmittance is 18%~30%.

[0009] Furthermore, the wear-resistant protective layer is made of transparent material, using fluorocarbon varnish or nano-ceramic coating, with a thickness of 5~10μm, a surface hardness ≥3H, and a friction resistance of ≥5000 cycles.

[0010] Furthermore, the honeycomb core layer includes a plurality of regular hexagonal honeycomb holes arranged in a matrix, the wall thickness of the honeycomb holes is 0.08~0.12mm, and the hole diameter is 6~12mm; the thickness of the honeycomb core layer is 10~30mm.

[0011] Furthermore, the honeycomb core layer, the heat insulation buffer layer, and the flexible solar photovoltaic module are bonded together using a two-component epoxy structural adhesive.

[0012] Furthermore, the flexible solar photovoltaic module has a thickness of 0.2~0.5mm, is adaptable to curved bending, and has a minimum adaptable bending radius of no more than 500mm; the outer surface of the flexible solar photovoltaic module is provided with an insulating and weather-resistant encapsulation film.

[0013] Furthermore, the thickness of the base plate is 1.0~2.0mm, the material of the base plate is the same as that of the aluminum plate, and the outer surface of the base plate is provided with an oxide film or a fluorocarbon protective coating, the thickness of the oxide film being ≥15μm.

[0014] Furthermore, the oxide film is formed through anodizing.

[0015] In summary, the present invention has the following beneficial effects: The technical solution provided by this invention integrates flexible solar photovoltaic modules between the iridescent panel and the honeycomb core layer, thus combining decorative building materials with new energy power generation functions. The material of the flexible solar photovoltaic modules can be adapted to the hyperbolic shape of the honeycomb aluminum panel without affecting the bending and forming of the panel. The panel can be used in building facades, curtain walls and other scenarios to generate natural light photovoltaic power, effectively reducing the overall energy consumption of the building and meeting the development needs of green building and low-carbon energy conservation.

[0016] The technical solution provided by this invention features a wear-resistant protective layer on the outermost layer of the iridescent panel, which can effectively resist external friction, scratches, and wind and sand erosion. A heat-insulating buffer layer is set between the base plate and the honeycomb core layer, which on the one hand blocks the conduction of cold and heat, improves the overall thermal insulation, sound insulation and noise reduction performance, and improves the indoor environment of the building; on the other hand, it has a buffering and shock-absorbing function, which can buffer external impact, dissipate vibration, improve the impact resistance of the panel, and at the same time relieve interlayer stress, avoiding delamination and cracking of the structural layers.

[0017] The hyperbolic honeycomb aluminum panel provided by this invention integrates decoration, protection, load-bearing, heat insulation, sound insulation, and photovoltaic power generation. A single panel replaces multiple functional building materials, simplifies the construction of the building envelope, reduces the use of auxiliary materials, saves installation space, and has a high overall cost performance. Attached Figure Description

[0018] 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.

[0019] Figure 1 This is a schematic diagram of the structure of the hyperbolic iridescent honeycomb aluminum panel in an embodiment of the present invention; Figure 2 This is an exploded view of the hyperbolic iridescent honeycomb aluminum panel in an embodiment of the present invention. Figure 3 This is an exploded view of the iridescent panel in an embodiment of the present invention.

[0020] Explanation of reference numerals in the attached drawings: 1-Iridescent panel; 101-Wear-resistant protective layer; 102-Iridescent coating; 1021-Coloring layer; 1022-Iridescent interference layer; 1023-Base coating; 103-Aluminum plate; 2-Flexible solar photovoltaic module; 3-Honeycomb core layer; 4-Heat insulation buffer pad layer; 5-Base plate. Detailed Implementation

[0021] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. 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 understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," 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 this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0023] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. Furthermore, the terms "installed," "connected," and "linked" should be interpreted broadly; for example, they may refer to a fixed connection, a detachable connection, or an integral connection; they may refer to a mechanical connection or an electrical connection; they may refer to a direct connection or an indirect connection through an intermediate medium; and they may 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] Example 1 A type of hyperbolic iridescent honeycomb aluminum panel, such as Figure 1 and Figure 2 As shown, from top to bottom, the components are: 1. Colorful panel; 2. Flexible solar photovoltaic module; 3. Honeycomb core layer; 4. Heat insulation buffer layer; 5. Base plate. An edge sealing component is installed on the outer side of the outer panel for sealing and reinforcement.

[0025] The iridescent panel 1, from top to bottom, includes a wear-resistant protective layer 101, an iridescent coating 102, and an aluminum plate 103, as follows: Figure 3 As shown.

[0026] The wear-resistant protective layer 101 is made of transparent material, using fluorocarbon varnish or nano-ceramic coating, with a thickness of 5~10μm, a surface hardness of not less than 3H, and a friction resistance of not less than 5000 cycles. In this embodiment, a transparent fluorocarbon varnish with a thickness of 8μm is used, which can effectively protect the underlying iridescent coating 102, resisting wind and sand abrasion, rain erosion, and ultraviolet oxidation aging, thereby improving the outdoor service stability of the board.

[0027] The iridescent coating 102 is one of the core improved structures of this invention. From top to bottom, it consists of a coloring layer 1021, an iridescent interference layer 1022, and a base coating 1023, with a total thickness of 25~45μm.

[0028] The coloring layer 1021 uses fluorocarbon colored paint with a thickness of 15~25μm. In this embodiment, fluorocarbon blue paint with a thickness of 20μm is used.

[0029] The iridescent interference layer 1022 is formed by alternating sputtering deposition of nano-silica and nano-titanium dioxide to create a multilayer optical thin film with 5 to 9 layers and a single-layer film thickness of 80 to 150 nm. Utilizing the physical effects of light interference, light refraction, and light diffraction, the material exhibits a gradient iridescent effect under different lighting angles. At the same time, the iridescent interference layer 1022 is uniformly provided with multiple light-transmitting nanopores with a diameter of 50 to 200 nm, an opening rate of 15% to 25%, and a visible light transmittance of 18% to 30%. This ensures a decorative effect without obstructing the light-gathering requirements of the underlying flexible solar photovoltaic modules.

[0030] The base coating 1023 is made of epoxy zinc-rich primer with a thickness of 5~10μm. In this embodiment, the thickness is 8μm. It not only provides anti-corrosion protection for the aluminum plate 103, but also enhances the adhesion between the iridescent interference layer 1022 and the aluminum plate 103.

[0031] The aluminum plate 103 has a thickness of 1.5~3.0mm, a tensile strength ≥150MPa, and a yield strength ≥110MPa. In this embodiment, a 3003 aluminum alloy plate with a thickness of 1.5mm is used. The aluminum plate 103 has a hyperbolic structure with a multi-segment continuous transition design. The number of segments is no less than two, and the radius of curvature is controlled between 500~5000mm. The transition between adjacent segments is smooth, and the transition angle does not exceed 5°, eliminating local stress concentration caused by sharp angles. This results in a smooth and natural overall curved surface, fully adapting to the styling requirements of various streamlined and irregularly shaped building facades. Preferred solution: The overall design features two continuous hyperbolic curved surfaces with radii of curvature of 1600mm and 2200mm respectively, and a transition angle of 3° between adjacent segments, resulting in a smooth surface without abrupt changes.

[0032] The flexible solar photovoltaic module 2 is positioned between the aluminum plate 103 and the honeycomb core layer 3. It uses flexible copper indium gallium selenide (CIGS) solar cells with a thickness of 0.2~0.5mm. It can be bent and shaped synchronously with the hyperbolic panel, with a minimum adaptable bending radius of no more than 500mm, and can be adapted to the curved surface of the hyperbolic panel for bending. The outer surface of the module is covered with an insulating and weather-resistant encapsulation film, providing insulation, waterproofing, and weather protection. In this embodiment, the module thickness is 0.3mm, and it is modularly arranged to fit the curved surface of the panel, resulting in uniform light transmission and stable power generation performance.

[0033] The honeycomb core layer 3 has a matrix-arranged hexagonal honeycomb structure with a cell wall thickness of 0.08~0.12mm, a cell diameter of 6~12mm, and a core layer thickness of 10~30mm. In this embodiment, it is made of 3003 aluminum foil with a wall thickness of 0.10mm, a cell diameter of 8mm, and a core layer thickness of 16mm. The upper and lower surfaces of the honeycomb core layer 3 are bonded to the flexible solar photovoltaic module 2 and the heat insulation buffer layer 4 respectively using a two-component epoxy structural adhesive.

[0034] The heat insulation buffer layer 4 is located between the honeycomb core layer 3 and the base plate 5. It has the functions of heat insulation, sound insulation and noise reduction, as well as shock absorption and damping. It can relieve interlayer stress and prevent structural layer delamination and cracking. Its thickness is 5mm. In this embodiment, a non-woven microporous heat insulation buffer layer is used, which is tightly bonded to the base plate 5.

[0035] The curvatures of the base plate 5 and the aluminum plate 103 are matched to form a symmetrical stress-bearing structure, avoiding the torsional deformation of the plate caused by uneven stress on one side of the curved surface. The base plate 5 is made of the same material as the aluminum plate 103, both using 3003 aluminum plate. The thickness of the base plate 5 is 1.0~2.0mm. In this embodiment, the thickness is 1.5mm. The outer surface of the base plate 5 is provided with an oxide film with a thickness of not less than 15μm. The oxide film is formed by anodizing, which improves the corrosion resistance, rust prevention and weather resistance of the base plate.

[0036] The edge sealing assembly uses aluminum profile edge sealing strips and reinforced corner brackets for assembly, and the gaps are filled with neutral silicone weather-resistant sealant to achieve side sealing, structural reinforcement and neat protection of the wiring.

[0037] Example 2 A hyperbolic iridescent honeycomb aluminum panel is described in this embodiment. The structure is basically the same as that of Embodiment 1, with the only difference being the material selection and dimensional parameters of each layer. The specific details are as follows: In this embodiment, the wear-resistant protective layer 101 adopts a nano-ceramic coating with a thickness of 10μm and a surface hardness of not less than 3H.

[0038] The total thickness of the iridescent coating 102 is 40 μm; the coloring layer 1021 uses fluorocarbon metallic gold paint with a thickness of 22 μm; the iridescent interference layer 1022 is composed of 9 layers of alternating optical films of silicon dioxide and titanium dioxide, with a single layer thickness of 100 nm, a nanopore diameter of 80~180 nm, an opening rate of 20%, and a visible light transmittance of 25%; the base coating 1023 has a thickness of 10 μm.

[0039] Aluminum Plate 103 is made of 5052 high-strength aluminum alloy plate with a thickness of 3.0mm; it adopts a multi-segment hyperbolic shape with smooth curve transition, making it suitable for use in hyperbolic curtain walls of large-size landmark buildings.

[0040] Flexible solar photovoltaic module 2 uses flexible perovskite solar cells with a thickness of 0.5mm.

[0041] The honeycomb core layer 3 has a wall thickness of 0.12mm, a pore size of 10mm, and a core layer thickness of 24mm, resulting in higher structural rigidity and wind pressure resistance.

[0042] The thickness of the heat insulation cushion layer 4 is 6mm.

[0043] The base plate 5 is made of 5052 aluminum plate with a thickness of 2.0mm; the oxide film on the surface of the base plate 5 is formed by anodizing, and the oxide film thickness is 20μm, which further improves the corrosion resistance and weather resistance.

[0044] This embodiment exhibits excellent overall structural strength, wind pressure resistance, power generation performance, and weather resistance, making it suitable for high-end applications such as large urban landmark buildings and BIPV photovoltaic integrated curtain walls.

[0045] Comparative Example 1 The conventional hyperbolic aluminum honeycomb panel is used, but the wear-resistant protective layer 101, iridescent coating 102, flexible solar photovoltaic module 2 and heat insulation buffer layer 4 of this invention are not provided. The material and thickness parameters of the remaining aluminum plate 103, honeycomb core layer 3 and base plate 5 are the same as those in Example 1.

[0046] Comparative Example 2 The ordinary iridescent hyperbolic honeycomb aluminum panel does not have the flexible solar photovoltaic module 2 and the heat insulation buffer layer 4, but the other structural parameters are the same as those in Example 1.

[0047] Comparative Example 3 Commercially available BIPV photovoltaic honeycomb aluminum panels have rigid photovoltaic panels, but lack the iridescent coating 102 and nano-transparent hole structure, making it impossible to achieve hyperbolic large-arc bending. They are only suitable for flat panel curtain walls, and the thickness of the remaining substrates is similar to that of Example 1.

[0048] Performance tests were conducted on Examples 1, 2, 1, 2, and 3 under the same standard environmental conditions. The test indicators included: areal density, flexural stiffness, wind pressure resistance, sound insulation, peak power generation per square meter, abrasion resistance cycles, and iridescent appearance. The test results are shown in Table 1. Table 1 Results of various performance tests

[0049] Compared to Comparative Examples 1 and 2, Examples 1 and 2 of the present invention add a heat insulation buffer layer and a holographic coating, which significantly improves the heat insulation, sound insulation, wear resistance and weather resistance, while also having a unique gradient holographic decorative effect, and the decorative artistry is far superior to that of conventional ordinary honeycomb aluminum panels.

[0050] Compared to the conventional rigid photovoltaic honeycomb aluminum panel in Comparative Example 3, this invention uses flexible photovoltaic modules, which can be adapted to hyperbolic curved surfaces and bend into shape without the risk of cracking or failure. At the same time, it takes into account multiple functions such as colorful decoration, protection and heat insulation and photovoltaic power generation. Its comprehensive performance is more suitable for irregular buildings and high-end landmark BIPV curtain wall scenarios.

[0051] The embodiments of the present invention are superior to the comparative examples in key indicators such as structural rigidity, wind pressure resistance, power generation efficiency, and resistance to friction and aging. They achieve integrated decoration, structure, protection, energy-saving power generation, and sound insulation, solving the industry shortcomings of existing products such as single function, insufficient weather resistance, and inability to balance aesthetics and photovoltaic power generation.

[0052] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A hyperbolic iridescent honeycomb aluminum panel, characterized in that, It includes, from top to bottom, a color-changing panel (1), a honeycomb core layer (3), and a base plate (5); The iridescent panel (1) is composed of a wear-resistant protective layer (101), an iridescent coating (102), and an aluminum plate (103) arranged sequentially from top to bottom; A flexible solar photovoltaic module (2) is provided between the iridescent panel (1) and the honeycomb core layer (3). The flexible solar photovoltaic module (2) is a flexible copper indium gallium selenide solar cell or a flexible perovskite solar cell. A heat-insulating buffer layer (4) is provided between the base plate (5) and the honeycomb core layer (3).

2. The hyperbolic iridescent honeycomb aluminum panel according to claim 1, characterized in that, The aluminum plate (103) has a thickness of 1.5~3.0mm, a tensile strength ≥150MPa, and a yield strength ≥110MPa.

3. The hyperbolic iridescent honeycomb aluminum panel according to claim 1, characterized in that, The iridescent coating (102) includes a coloring layer (1021), an iridescent interference layer (1022), and a base layer (1023) arranged sequentially from top to bottom, with a total thickness of 25~45μm; The coloring layer (1021) is made of fluorocarbon colored paint and has a thickness of 15~25μm; The iridescent interference layer (1022) is a multilayer optical film with alternating layers of nano-silica and nano-titanium dioxide. The number of layers in the multilayer optical film is 5 to 9, and the thickness of a single layer is 80 to 150 nm. The base coating (1023) is an epoxy zinc-rich primer with a thickness of 5~10μm.

4. The hyperbolic iridescent honeycomb aluminum panel according to claim 3, characterized in that, The iridescent interference layer (1022) is uniformly provided with multiple light-transmitting nanopores, and the visible light transmittance is 18%~30%.

5. The hyperbolic iridescent honeycomb aluminum panel according to claim 1, characterized in that, The wear-resistant protective layer (101) is made of transparent material, using fluorocarbon varnish or nano-ceramic coating, with a thickness of 5~10μm, surface hardness ≥3H, and a friction resistance of ≥5000 times.

6. The hyperbolic iridescent honeycomb aluminum panel according to claim 1, characterized in that, The honeycomb core layer (3) includes a plurality of regular hexagonal honeycomb holes arranged in a matrix, the wall thickness of the honeycomb holes is 0.08~0.12mm, and the hole diameter is 6~12mm; the thickness of the honeycomb core layer (3) is 10~30mm.

7. The hyperbolic iridescent honeycomb aluminum panel according to claim 1, characterized in that, The honeycomb core layer (3) is bonded to the heat insulation buffer layer (4) and the flexible solar photovoltaic module (2) using a two-component epoxy structural adhesive.

8. The hyperbolic iridescent honeycomb aluminum panel according to claim 1, characterized in that, The flexible solar photovoltaic module (2) has a thickness of 0.2~0.5mm and is adaptable to curved bending, with a minimum adaptable bending radius of no more than 500mm; the outer surface of the flexible solar photovoltaic module (2) is provided with an insulating and weather-resistant encapsulation film.

9. The hyperbolic iridescent honeycomb aluminum panel according to claim 1, characterized in that, The thickness of the base plate (5) is 1.0~2.0mm. The material of the base plate (5) is the same as that of the aluminum plate (103). The outer surface of the base plate (5) is provided with an oxide film or a fluorocarbon protective coating. The thickness of the oxide film is ≥15μm.

10. The hyperbolic iridescent honeycomb aluminum panel according to claim 9, characterized in that, The oxide film is formed through anodizing.

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