Prefabricated carbon fiber composite board roof

Abstract

The utility model discloses a prefabricated assembly type carbon fiber composite board roof which comprises a waterproof layer and a form layer, the waterproof layer is a hydrophobic surface paint layer coated on the form layer, the form layer is a roof structure formed by splicing prefabricated carbon fiber composite building components according to design, and the carbon fiber composite building components are connected with the form layer. Comprising a polygonal high-density PU foam base layer, a connecting piece and a carbon fiber coating layer, grooves are formed in all corners of the PU foam base layer, the connecting piece comprises an embedded bottom plate and two folded edges forming an included angle, and long round holes are formed in the two folded edges; the pre-embedded bottom plate is arranged in the groove, and the carbon fiber coating layers are laid on the exposed surfaces of the PU foam base layer and the pre-embedded bottom plate layer by layer. According to the carbon fiber foam board prefabricated roof capable of being partitioned, the basic unit is a carbon fiber composite building component prefabricated in a factory, and the proportion and the thickness can be adjusted according to structural calculation requirements so that the modeling requirements of different spans can be met.

Description

Technical Field

[0001] The utility model relates to a curved surface configuration, such as the technical field of shell roofs. Background Art

[0002] In the construction industry, many projects require free and flexible curves in their shapes, and at the same time, they also require a light structure that is as small and thin as possible. Traditional shell structures often use metal components as structural supports, and then insulation, waterproofing, and finishing are done on the structural layer. When the external insulation layer contains structures such as support nodes, it usually requires a larger thickness, and there are many restrictions on the shape. Existing roof panel systems often use mold forming when it comes to specific shapes, but the specificity of the shape means that the mold can only be one-to-many or one-to-one, which is very costly and wastes materials.

[0003] The molding and manufacturing technology of resin-based composite materials has developed into an independent and cutting-edge modern engineering technology in recent decades. With the continuous accumulation of usage experience, resin-based composite materials have gradually entered other industries from aerospace. At present, the main markets for composite materials are roughly: aerospace field, such as aircraft cabins, fuel silos, rocket fairings, etc.; transportation and ship fields, such as small hull cabins, masts, decks, car shells, tails, battery compartments, high-speed rail fronts, etc.; wind turbine blades in the field of wind power generation; drones, bicycles, fishing rods, decorative parts in the sports and civilian fields, etc. If carbon fiber resin composite materials are used for the main structure in the construction field, such as roofs, etc., they can meet the requirements of light, small and thin structures.

[0004] However, in the current construction industry, the application of carbon fiber materials in main structural components is mainly aimed at the reinforcement of concrete components and steel structural components, such as carbon fiber wet-paste reinforcement at the bottom of beams, carbon fiber wet-paste reinforcement at the bottom of plates, and carbon fiber winding reinforcement at structural columns. At present, no carbon fiber products have been found to be used as main structural components. At the same time, the component connection methods of traditional carbon fiber composite materials, such as mechanical connection with external metal heads, or stacking and gluing, are not suitable for construction scenarios. Utility Model Content

[0005] The purpose of the utility model is to provide a prefabricated assembled carbon fiber composite panel roof for the above-mentioned problems in the prior art, which can be applied to various personalized roof shapes and can be prefabricated in a factory and spliced ​​on site.

[0006] The concept of this patent is as follows: In order to cope with the special-shaped curved surfaces and light and thin characteristics of architectural shapes, the architectural shapes can be decomposed into different component units through rational plate division. For example, the roof system can be divided into basic structural units spliced ​​by carbon fiber composite components, and then the proportion and thickness are adjusted according to the structural calculation requirements to achieve the shape requirements of different spans. After that, it is prefabricated in the manufacturer and transported to the site for splicing after confirmation.

[0007] In order to achieve the above purpose, the technical solution adopted by the utility model is as follows:

[0008] A prefabricated assembled carbon fiber composite panel roof, comprising a waterproof layer and a morphological layer, wherein the waterproof layer is a hydrophobic topcoat layer coated on the morphological layer, and the morphological layer is a roof configuration formed by splicing prefabricated carbon fiber composite building components according to a design, and the carbon fiber composite building components include a polygonal high-density PU foam base layer, a connector and a carbon fiber coating layer, each corner of the PU foam base layer is provided with a groove, and the connector includes a pre-embedded base plate and two folded edges at an angle, and oblong holes are provided on the two folded edges; the pre-embedded base plate is arranged in the groove, and the carbon fiber coating layer is laid layer by layer on the exposed surface of the PU foam base layer and the pre-embedded base plate.

[0009] Furthermore, the morphological layer also includes a light-transmitting plate, such as a round glass on the top.

[0010] Furthermore, a layer of carbon fiber cloth is laid on the upper part of the roof configuration and fixed by resin glue.

[0011] Furthermore, the PU foam base layer is provided with a limiting pit at the side wall of the groove, and the outer edge of the embedded bottom plate is arranged in the limiting pit. Furthermore, the embedded bottom plate is fan-shaped, and the limiting pit is an arc-shaped pit adapted to the outer edge of the embedded bottom plate.

[0012] Furthermore, the PU foam base layer is hexagonal, and the angle between the two folded edges of the connecting piece is 120°. The height of the two folded edges is lower than the top surface of the PU foam base layer.

[0013] Furthermore, the thickness of the PU foam base layer is less than 1 / 10 of the span of the entire carbon fiber composite building component.

[0014] Furthermore, the connecting piece is an integrated bent sheet metal piece, and the two folded edges are bent at 90°.

[0015] Furthermore, the connecting member also includes bolts, and the bolts are used to connect adjacent carbon fiber composite building components when used.

[0016] Furthermore, the carbon fiber coating layer is a 3K (0-90) carbon fiber woven cloth and a 12K (0-90) carbon fiber woven cloth wrapped in multiple layers in sequence.

[0017] The above-mentioned prefabricated carbon fiber composite panel roof also includes an indoor ceiling system, which can adopt conventional light steel keel ceiling or directly paint. If a light steel keel ceiling is required, it is directly fixed on the connector of the carbon fiber composite building component, and the indoor lighting, air conditioning, fire protection and other pipelines can be integrated and installed on the ceiling.

[0018] The lower support of the prefabricated carbon fiber composite panel roof can be directly fixed to the beam, column and wall system of the house. If it is a building without beams, columns and walls, spaced steel column supports can also be provided.

[0019] Beneficial effects of the utility model:

[0020] The prefabricated and assembled carbon fiber composite panel roof provided by the utility model is designed to meet the characteristics of irregular curved surfaces and lightness of architectural shapes, and a divisible carbon fiber foam board prefabricated roof has been innovatively developed. The basic unit is a carbon fiber composite building component prefabricated in the factory, and the proportion and thickness can be adjusted according to the structural calculation requirements to achieve the modeling requirements of different spans. The carbon fiber foam board is used as the main structural component, which is quite light and thin compared to other structural materials such as steel structures or concrete. Through reasonable block division and splitting, many irregular hyperbolic shapes can be achieved, and the prefabrication and assembly of non-standard products can be realized, which reflects the practical application of BIM forward design.

[0021] The following is an example of the specific implementation of the present invention in conjunction with the accompanying drawings: BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 A schematic diagram of the morphological layers of a prefabricated assembled carbon fiber composite panel roof provided in an embodiment of the utility model.

[0023] Figure 2 A schematic diagram of the structure of a carbon fiber composite building component provided by an embodiment of the utility model.

[0024] Figure 3 A schematic diagram of a connecting piece of a carbon fiber composite building component provided by an embodiment of the utility model being separated from a groove of a PU foam base layer.

[0025] Figure 4 A partial cross-sectional view of a carbon fiber composite building component provided in an embodiment of the utility model.

[0026] Figure 5 A schematic cross-sectional view of a carbon fiber composite building component provided in an embodiment of the utility model.

[0027] Figure 6 A schematic diagram of the splicing of carbon fiber composite building components provided in an embodiment of the utility model.

[0028] Figure 7 A schematic diagram of the splicing and forming of carbon fiber composite building components provided in an embodiment of the utility model.

[0029] Figure 8 The present invention is a schematic diagram of a roof formed by splicing carbon fiber composite building components provided by an embodiment of the present invention.

[0030] Description of reference numerals:

[0031] 1PU foam base, 101 groove, 102 limit pit

[0032] 2 connector, 201 embedded base plate, 202 folded edge, oblong hole 202a, 203 bolt

[0033] 3 carbon fiber coating layers, 4 light-transmitting panels, 5 carbon fiber cloth layers DETAILED DESCRIPTION

[0034] The specific embodiments described herein are only used to explain the technical solution of this patent, rather than to limit the disclosed technical solution. It should also be noted that, for ease of description, only the parts related to the disclosed technical solution are shown in the drawings, rather than all structures.

[0035] Before discussing the exemplary embodiments in more detail, it should be mentioned that the structures of the device components and / or modules themselves mentioned in the embodiments, if not described in detail, are understandable to those skilled in the art based on the existing public technology or commercially available products.

[0036] refer to Figure 1-4 The prefabricated assembled carbon fiber composite panel roof provided in this embodiment includes a waterproof layer and a morphological layer, wherein the waterproof layer is a hydrophobic topcoat layer coated on the morphological layer, and the morphological layer is a roof configuration formed by prefabricated carbon fiber composite building components spliced ​​according to a design, and the carbon fiber composite building components include a polygonal high-density PU foam base layer 1, a connector 2 and a carbon fiber coating layer 3, each corner of the PU foam base layer 1 is provided with a groove 101, and the connector 2 includes a pre-embedded bottom plate 201 and two folded edges 202 at an angle, and oblong holes 202a are provided on the two folded edges 202; the pre-embedded bottom plate 201 is arranged in the groove 101, and the carbon fiber coating layer 3 is laid layer by layer on the exposed surface of the PU foam base layer 1 and the pre-embedded bottom plate 201.

[0037] If natural lighting is needed, a light-transmitting plate 4 may be further provided on the morphological layer. Figure 1 The circular glass etc. shown is set on the top.

[0038] A layer of carbon fiber cloth 5 is laid on the upper part of the roof configuration and fixed with resin glue to further enhance the overall roof strength.

[0039] The connectors 2 installed at each corner of the PU foam base layer 1 can be fixed together by gluing or limiting, preferably limiting. Therefore, a limiting pit 102 can be further provided at the side wall of the groove 101, and the outer edge of the embedded bottom plate 201 is provided in the limiting pit 102. When the embedded bottom plate 201 is fan-shaped, the limiting pit 102 is set as an arc pit, which is adapted to the outer edge of the embedded bottom plate 201.

[0040] The PU foam base layer 1 is preferably hexagonal, which has good adaptability. At this time, the angle between the two folded edges 202 of the corresponding connecting piece 2 is 120°. The height of the two folded edges 202 of the connecting piece 2 is preferably lower than the top surface of the PU foam base layer 1.

[0041] When the thickness of the PU foam base layer 1 is less than 1 / 10 of the span of the entire carbon fiber composite building component, it can well balance lightness and stress resistance.

[0042] The folded edges of the connector 2 can be formed by welding or bending, and preferably an integrated bent sheet metal part is used, and it is preferable that the two folded edges 202 are bent at 90°.

[0043] The connector 2 further comprises bolts 203, which are used to connect adjacent carbon fiber composite building components. The bolts 203 are of a type that matches the oblong holes on the folded edges 202, and when both are of industry standard sizes, commercially available parts can be used.

[0044] The carbon fiber coating layer 3 is preferably composed of multiple layers of 3K (0-90) carbon fiber woven cloth and 7 layers of 12K (0-90) carbon fiber woven cloth wrapped in sequence.

[0045] refer to Figure 6 , Figure 7 , adjacent carbon fiber composite building components are assembled together through pre-buried connectors. The connector folds on adjacent composite panels are connected and fixed by cylindrical head hexagonal bolts and fastened with matching nuts. Resin structural glue can be used to fill the gaps during on-site installation.

[0046] In the factory, CNC is used to process the matured foam block into a hyperbolic hexagonal plate with a thickness of 30mm and a side length of about 600mm. The six corners of each plate are milled with a fan-shaped depression with a radius of 85mm and a depth of 20mm, and the arc is milled at an obtuse angle of 141°. On this basis, a 3mm limit pit is milled downward at the top of the fan. Metal connectors can be cut using a full-plate laser cutting in the factory, and the two folded edges are formed by bending the pre-cut folded edges 90° through the sheet metal bending process. The bottom plate of the finished metal connector is placed on the processed foam substrate, and the height of the two folded edges is lower than the top surface of the carbon fiber composite plate. Use 2 layers of 12K (0-90) carbon fiber cloth to completely wrap the bottom plate and fix it with a universal spray glue, and then lay the cut 7 layers of 3K + 6 layers of 12KT300 carbon fiber cloth in layers to wrap it.

[0047] Usually, the embedded bottom plate 1 and the two folded edges 2 are bent at 90°. Figure 7Taking the hexagonal composite panel with the best adaptability as an example, the function of prefabricated and assembled roof of carbon fiber composite panels was realized in a certain experimental project. During on-site installation, the formed carbon fiber composite panel unit with embedded connectors is set in the exact position by positioning methods such as laying out lines and marking points, and then all carbon fiber composite panel units are fixed by bolts to complete the forming of the entire curved roof. This standard splicing unit that can be prefabricated in the factory is simple, fast and accurate during on-site construction, which meets the requirements of projects with minimalist architectural shapes. The support at the bottom of the roof can be directly fixed to the beam, column and wall system of the house. If it is a building without beams, columns and walls, spaced steel column supports can also be set up. See the construction effect diagram. Figure 8 .

[0048] The use of carbon fiber composite building components can achieve many special-shaped hyperbolic shapes, which can not only meet the structural forming of various curved buildings, but also realize the prefabrication and assembly of non-standard products according to parameter design, and quickly assemble the roof. Carbon fiber composite building components can adapt to multiple angles of splicing at each unit node, and can be fine-tuned and calibrated during installation. In a series of simulation experiments and tests, they have passed the structural force calculation and met the requirements of building construction.

[0049] The above is an example of the preferred implementation of the utility model, but the invention of the utility model is not limited to the described embodiments. Technical personnel familiar with the field can also make various equivalent deformations or substitutions without violating the spirit of the utility model. These equivalent deformations or substitutions are all included in the scope defined by the claims of this application.

Claims

1. A prefabricated carbon fiber composite panel roof, characterized in that: The invention comprises a waterproof layer and a morphological layer, wherein the waterproof layer is a hydrophobic topcoat layer coated on the morphological layer, and the morphological layer is a roof configuration formed by prefabricated carbon fiber composite building components spliced ​​according to a design; the carbon fiber composite building component comprises a polygonal high-density PU foam base layer (1), a connecting piece (2) and a carbon fiber coating layer (3), wherein each corner of the PU foam base layer (1) is provided with a groove (101), the connecting piece (2) comprises a pre-buried base plate (201) and two folded edges (202) at an angle, and the two folded edges (202) are provided with oblong holes (202a); the pre-buried base plate (201) is arranged in the groove (101), and the carbon fiber coating layer (3) is laid layer by layer on the exposed surfaces of the PU foam base layer (1) and the pre-buried base plate (201).

2. The prefabricated carbon fiber composite panel roof according to claim 1, characterized in that: The PU foam base layer (1) is provided with a limiting pit (102) at the side wall of the groove (101), and the outer edge of the embedded bottom plate (201) is arranged in the limiting pit (102).

3. The prefabricated carbon fiber composite panel roof according to claim 1, characterized in that: The thickness of the PU foam base layer (1) is less than 1 / 10 of the overall span of the carbon fiber composite building component.

4. The prefabricated carbon fiber composite panel roof according to claim 1, characterized in that: The PU foam base layer (1) is hexagonal, and the angle between the two folded edges (202) of the connecting piece (2) is 120°.

5. The prefabricated carbon fiber composite panel roof according to claim 2, characterized in that: The embedded bottom plate (201) is fan-shaped; the limiting pit (102) is an arc-shaped pit adapted to the outer edge of the embedded bottom plate (201).

6. The prefabricated carbon fiber composite panel roof according to claim 1, characterized in that: The heights of the two folded edges (202) are lower than the top surface of the PU foam base layer (1).

7. The prefabricated carbon fiber composite panel roof according to claim 1, characterized in that: The connecting member (2) further comprises a bolt (203), and the bolt (203) is used to connect adjacent carbon fiber composite building components when in use.

8. The prefabricated carbon fiber composite panel roof according to claim 1, characterized in that: The carbon fiber coating layer (3) is a plurality of layers of 3K (0-90) carbon fiber woven cloth and 12K (0-90) carbon fiber woven cloth wrapped in sequence.

9. The prefabricated assembled carbon fiber composite panel roof according to any one of claims 1 to 8, characterized in that: The morphological layer also includes a light-transmitting plate (4).

10. The prefabricated carbon fiber composite panel roof according to any one of claims 1 to 8, characterized in that: A layer of carbon fiber cloth is laid on the entire upper part of the roof configuration.

11. The prefabricated assembled carbon fiber composite panel roof according to any one of claims 1 to 8, characterized in that: It also includes an indoor light steel keel ceiling fixed on a connecting piece (2) of a carbon fiber composite building component.

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