A prefabricated thermal insulation composite wall panel and building thermal insulation structure

Abstract

This utility model discloses a prefabricated insulated composite wall panel, including an insulation layer and a keel frame. The insulation layer and the keel frame are cured together to form an integral main panel. The keel frame includes an outer frame. When the outer frame includes one rectangular frame, it constitutes a planar wall panel; when the outer frame includes two mutually perpendicular rectangular frames, it constitutes a right-angle wall panel. This composite wall panel has strong self-supporting capacity, can be installed without relying on a building base, improving safety; it can also adapt well to building corners and is easy to construct. This utility model also discloses another building insulation structure, including first, second, third, and fourth right-angle wall panels. The first, second, third, and fourth right-angle wall panels are sequentially connected by bolts to form a continuous wall structure, with a roof at the top and a base plate at the bottom. This building insulation structure has independent load-bearing capacity and can be used as a low-rise residential building; it can also be quickly assembled and disassembled, making it suitable for use as a temporary building.

Description

Technical Field

[0001] This utility model relates to the field of building insulation technology, specifically to a prefabricated insulation composite wall panel and a building insulation structure. Background Technology

[0002] Currently, most commercially available thermal insulation wall panels are flat structures. These flat insulation wall panels are only used as an auxiliary insulation layer and do not have independent load-bearing capacity. In old building renovation projects, exterior walls often suffer from aging problems such as surface loosening and peeling due to long-term exposure to the natural environment. Since the anchoring method of existing flat insulation wall panels mainly relies on the connection with the aging exterior wall, the anchoring reliability of the flat insulation wall panels drops significantly when problems occur in the aging exterior wall, posing a risk of detachment and endangering building safety and the lives of users. In addition, corners in buildings require special reinforcement, but gaps are easily created when splicing flat insulation wall panels. At the same time, on-site reinforcement processes are complex and have limited effectiveness. These corners often become structural weak points in the insulation system, affecting the overall stability and safety.

[0003] Because traditional flat thermal insulation wall panels lack independent support structures, they must be attached to the building frame for stable installation when constructing low-rise buildings, making installation complex. This over-reliance on the building frame limits their applicability in various building environments. For example, in special scenarios such as offshore operations and disaster relief construction where there is no stable base, existing flat thermal insulation wall panels cannot provide additional support and stability, making it difficult to independently construct a stable wall structure. This significantly limits their application range and fails to meet the requirements for rapid and stable construction of building walls in these special scenarios. Utility Model Content

[0004] The purpose of this utility model is to provide a prefabricated thermal insulation composite wall panel. This composite wall panel has strong self-supporting capacity, can be installed without relying on the building base, thus improving safety; and can adapt well to building corners while facilitating construction.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A prefabricated thermal insulation composite wall panel includes a keel frame and an insulation layer. The keel frame is disposed within the insulation layer and is cured and bonded to the insulation layer to form an integral main panel. The keel frame includes an outer frame, and a connecting part is provided around the outer frame. The prefabricated thermal insulation composite wall panel includes a flat wall panel and a right-angle wall panel: when the outer frame includes only one rectangular frame, it constitutes a flat wall panel; when the outer frame includes two mutually perpendicular rectangular frames, it constitutes a right-angle wall panel.

[0007] Preferably, the keel frame further includes a grid connected inside the outer frame, the grid including a first support rod vertically arranged inside the outer frame and a second support rod perpendicularly intersecting the first support rod.

[0008] Preferably, the connecting part is a mounting hole evenly distributed around the outer frame.

[0009] Preferably, it also includes a concrete layer, which is disposed on both sides of the integral main board.

[0010] Preferably, it also includes a reinforcing mesh and fixing screws; the reinforcing mesh is disposed in the concrete layer and is fixed to the keel frame by fixing screws.

[0011] Preferably, it also includes a fiberglass layer, which is disposed on both sides of the integral motherboard.

[0012] Preferably, the joints between the prefabricated thermal insulation composite wall panels are filled with sealant.

[0013] Preferably, the outer frame is formed by welding several rectangular steel pipes, and the grille is also a rectangular steel pipe and is welded to the outer frame.

[0014] In the aforementioned technical solution, the keel frame and insulation layer are tightly bonded together through a curing process to form an integral mainboard. The keel frame, consisting of a rectangular steel tube outer frame and support rods, is formed through welding. This keel frame provides a solid and reliable support structure for the wall panel, enhancing its strength and stability. Simultaneously, the insulation layer provides comprehensive protection and curing for the keel frame, creating a robust protective barrier that isolates it from external moisture, oxygen, and corrosive media. In humid environments, moisture cannot easily penetrate the surface of the keel frame, preventing the metal frame from rusting due to dampness. In areas with significant temperature differences, the insulation layer buffers the impact of temperature changes on the keel frame, reducing stress damage caused by thermal expansion and contraction, and fundamentally slowing down the aging process of the keel frame.

[0015] This invention utilizes right-angled wall panels. Traditional flat wall panels, when used in low-rise buildings, must be attached to a building frame for stable installation, resulting in excessive reliance on the building surface and significantly limiting their applicability in various building environments. In contrast, the right-angled wall panels of this invention do not require additional frame structures; their unique right-angle shape directly forms a stable support system. This support not only provides a solid foundation for themselves but also supports other flat wall panels, achieving mutual support and tight connection between the panels, thereby constructing a stable and reliable wall structure. The right-angled wall panels essentially integrate the functions of an external frame structure within themselves, eliminating dependence on external frames and improving the applicability of the wall panels in different building scenarios, providing a more efficient and convenient solution for the construction of low-rise buildings.

[0016] Another objective of this invention is to provide a building insulation structure that has independent load-bearing capacity and can be used as a low-rise residential building; at the same time, it can be quickly assembled and disassembled, making it suitable for use as a temporary building.

[0017] To achieve the above objectives, the present invention adopts the following technical solution:

[0018] A building insulation structure includes a first right-angle wall panel, a second right-angle wall panel, a third right-angle wall panel, and a fourth right-angle wall panel. The first right-angle wall panel, the second right-angle wall panel, the third right-angle wall panel, and the fourth right-angle wall panel are connected in sequence by bolts to form a continuous wall structure. A roof is provided on the top of the wall structure and the bottom is connected to the foundation.

[0019] Preferably, the system also includes several planar wall panels, which are connected as needed between the first right-angle wall panel and the second right-angle wall panel, between the second right-angle wall panel and the third right-angle wall panel, between the third right-angle wall panel and the fourth right-angle wall panel, or between the fourth right-angle wall panel and the first right-angle wall panel.

[0020] In the above technical solution, a continuous wall structure is formed by connecting the first, second, third, and fourth right-angle wall panels, as well as the flat wall panels, with bolts. A roof is fixedly connected to the top of the wall structure, and a foundation is fixedly connected to the bottom, forming an independent building that can be used as a low-rise residential building. Furthermore, because the bolted connections between the wall panels allow for quick assembly and disassembly, meeting the structural requirements of temporary buildings, this building insulation structure can also be used to construct temporary dwellings, such as barracks and resettlement housing. Attached Figure Description

[0021] Figure 1 This is a three-dimensional structural diagram of the right-angled wall panel including a concrete layer according to this utility model;

[0022] Figure 2This is a partial sectional view of a three-dimensional perspective of the right-angled wall panel including a concrete layer according to this utility model.

[0023] Figure 3 This is a three-dimensional structural diagram of the keel frame of the right-angle wall panel including the concrete layer according to this utility model.

[0024] Figure 4 This is a three-dimensional structural diagram of the planar wall panel including the concrete layer according to this utility model;

[0025] Figure 5 This is a top view schematic diagram of the foundation of this utility model;

[0026] Figure 6 This is a three-dimensional structural diagram of the connecting part of this utility model;

[0027] Figure 7 This is a schematic diagram showing the disassembled structure of the bolt rod and nut of this utility model;

[0028] Figure 8 This is a three-dimensional structural diagram of the planar wall panel including the fiberglass layer of this utility model;

[0029] Figure 9 This is a three-dimensional structural diagram of the wall structure of this utility model;

[0030] In the diagram, 1 is the keel frame; 11 is the outer frame; 12 is the grille; 121 is the first support rod; 122 is the second support rod; 2 is the insulation layer; 21 is the embedding groove; 3 is the concrete layer; 4 is the steel mesh; 5 is the fixing screw; 6 is the fiberglass layer; 7 is the connecting part; 71 is the circular through hole; 72 is the strip hole; 8 is the right-angle wall panel; 81 is the first right-angle wall panel; 82 is the second right-angle wall panel; 83 is the third right-angle wall panel; 84 is the fourth right-angle wall panel; 9 is the flat wall panel; 10 is the sealant; 20 is the foundation; 201 is the circumferential groove; 30 is the bolt rod; 301 is the blocking part; 40 is the nut; 401 is the snap-fit ​​protrusion. Detailed Implementation

[0031] The present invention will be further described below with reference to the accompanying drawings:

[0032] like Figures 1 to 7As shown, a prefabricated thermal insulation composite wall panel includes a keel frame 1, which serves as the core supporting structure. The keel frame 1 is formed by welding several rectangular steel pipes. The rectangular steel pipes are Q235 rectangular steel pipes with specifications of 100mm × 50mm × 3mm, meeting the strength and rigidity requirements of the building frame. The keel frame 1 includes an outer frame 11 and a grid 12 welded inside the outer frame 11. The grid 12 includes several first support rods 121 and several second support rods 122. The first support rods 121 are spaced apart along the inner wall of the outer frame 11 and vertically supported inside the outer frame 11; the second support rods 122 are vertically and intersectingly connected to the first support rods 121 to form a grid-like support structure, further enhancing the overall rigidity of the keel frame 1. A connecting part 7 is evenly provided on the periphery of the outer frame 11. The connecting part 7 is specifically a mounting hole distributed at intervals along the edge of the outer frame 11. The mounting hole includes a circular through hole 71 and a strip hole 72 provided below the circular through hole. The circular through hole 71 and the strip hole 72 are connected. The wall panel is connected to the building frame or other wall panels by fixing the bolt rod 30 with nut 40 in the mounting hole.

[0033] The insulation layer 2 is made of polystyrene or polyurethane. The keel frame 1 is encased within the insulation layer 2 using a thermosetting or foaming process, positioning the keel frame 1 in the center of the insulation layer 2 to form an independent load-bearing main panel. Simultaneously, the grille 12 integrates with the insulation layer 2 and acts as an interlocking element, preventing the insulation layer 2 from shifting relative to the outer frame 11 under gravity. The keel frame 1 provides stable frame support for the insulation layer 2. The insulation layer 2 encases the keel frame 1, isolating it from external moisture, oxygen, and corrosive media, preventing rust due to dampness and stress damage due to temperature differences, fundamentally slowing down the aging process of the keel frame 1, and thus extending the service life of this prefabricated insulated wall panel.

[0034] This prefabricated thermal insulation composite wall panel also includes a steel mesh 4 and a concrete layer 3. The steel mesh 4 is positioned in the middle of the concrete layer 3 and is cast together with the concrete layer 3. The steel mesh 4 is placed at predetermined positions on both sides of the main panel. The fixing screw 5 passes through the steel mesh 4 and is fixedly connected at one end to the keel frame 1. The fixing screw 5 provides positioning support for the steel mesh 4. The connection between the steel mesh 4 and the fixing screw 5 can be welded or snap-fitted. Similarly, the connection between the fixing screw 5 and the keel frame 1 can also be welded, snap-fitted, or screwed. The concrete layer 3, with a thickness of 60mm, is located on both sides of the main panel and is cast onto the sides of the main panel after the steel mesh 4 has been installed. The concrete layer 3 is made of polystyrene particles, which can gradually reduce the outdoor ambient temperature, effectively protecting the insulation layer 2 and enhancing its insulation function.

[0035] In this embodiment, the concrete layer 3 is flush with the outer edge of the keel frame 1, and the insulation layer 2 is embedded between the concrete layer 3 and the keel frame 1, so that the outer edge of the insulation layer 2 forms a 1 mm embedding groove between the concrete layer 3 and the keel frame 1. By filling the embedding groove with concrete, the insulation layer 2 is completely wrapped and will not be exposed, so that the insulation layer 2 will not be burned in the event of a fire.

[0036] The manufacturing process of this prefabricated thermal insulation composite wall panel involves the following steps: First, a curing mold is created, with pre-set keel frame positioning grooves and fixing screw guide holes within the mold. Bolt holes are pre-set on the keel frame 1, their positions corresponding to the fixing screw guide holes. Then, the keel frame 1 is inserted into the keel frame positioning groove, and the fixing screw 5 is passed through the fixing screw guide holes and screwed onto the keel frame 1. Next, polyurethane is injected, allowing the polyurethane material to foam and cure, forming an integral main board with the keel frame 1. After curing, the reinforcing mesh 4 is connected to the other side of the fixing screw 5, and the reinforcing mesh 4 is connected to the middle position inside the concrete layer 3 by pouring concrete layer 3. The concrete layer 3 encases both sides of the integral main board, forming a complete prefabricated thermal insulation composite wall panel.

[0037] In this embodiment, the prefabricated composite insulation wall panel includes a flat wall panel 9 and a right-angle wall panel 8. When the outer frame 11 includes only one rectangular frame, it constitutes the flat wall panel 9; when the outer frame 11 includes two mutually perpendicular rectangular frames, it constitutes the right-angle wall panel 8. Traditional flat wall panels, when used in low-rise buildings, must be attached to the building frame for stable installation, resulting in excessive reliance on the building frame and significantly limiting their applicability in different building environments. However, the right-angle wall panel 8 of this invention does not require other frame structures; it directly forms a stable support system based on its unique right-angle shape. This support not only provides a stable foundation for itself but also supports other flat wall panels 9, achieving mutual support and tight connection between the wall panels, thereby constructing a stable and reliable wall structure. The right-angle wall panel 8 essentially integrates the building frame structure within itself, eliminating reliance on the building frame, improving the applicability of the wall panel in different building scenarios, and providing a more efficient and convenient solution for the construction of low-rise buildings.

[0038] like Figure 8 As shown, in a preferred embodiment, fiberglass layers 6 are provided on both sides of the main board. The fiberglass layers 6 are applied to both sides of the main board by spraying to form a complete prefabricated composite insulation wall panel. The insulation wall panel with fiberglass layers 6 is suitable for old house renovation. Before construction, there is no need for large-scale repair of old exterior walls. The keel frame 1 can be directly anchored to the building frame by bolts through the connecting parts 7 on the keel frame 1, without needing to be attached to the old wall panel.

[0039] During installation, the right-angle wall panel 8 is first screwed directly onto the building frame to reinforce the internal and external corner joints. Then, the flat wall panels 9 are sequentially spliced, ensuring that both the right-angle wall panel 8 and the flat wall panel 9 are connected to the building frame. The wall panels are then fastened together using bolts 30. The middle section of the bolt 30 has a hexagonal cross-section. A hexagonal blocking part 301 is integrally formed at one end of the bolt 30, and a nut 40 is screwed onto the other end. The nut 40 has a locking protrusion 401, the width of which is the same as the width of the strip-shaped hole 72. The diameter of the circular hole 71 on the connecting part 7 is larger than the diameters of the hexagonal blocking part 301 and the nut 40, allowing the hexagonal blocking part 301 and the nut 40 to pass through the circular hole 71, facilitating the installation of the bolt 30. When connecting two wall panels, first, the bolt shank 30 is inserted between the connecting portions 7 of the two wall panels. Specifically, the end with the nut 40 is passed through the circular through-hole 71 of one wall panel, ensuring that the locking protrusion 401 on the nut 40 aligns with the slotted hole 72 on the wall panel. Simultaneously, the end with the hexagonal blocking part 301 is passed through the circular through-hole 71 of the other wall panel. The diameter of the bolt shank 30 is the same as the width of the slotted hole 72, allowing the bolt shank 30 to slide smoothly within the slotted hole 72 while providing sufficient stability after locking and fixing. Then, the bolt shank 30 is pressed down, allowing it to smoothly enter the slotted hole 72 from the circular through-hole 71. Finally, a wrench is used to lock the bolt shank 30 in place and tighten it, thus completing the connection between the wall panels. During the tightening of bolt rod 30, the nut 40 has a locking protrusion 401. When the locking protrusion 401 enters the slotted hole 72, it will lock and fix the nut 40, preventing it from moving during tightening. At this point, simply use a wrench to engage with bolt rod 30 and tighten it to easily achieve a stable connection between the two wall panels. Finally, use a special sealant 10, such as weather-resistant silicone sealant, to fill the joints, forming a continuous, seamless thermal insulation system. This prefabricated insulated composite wall panel is firmly installed and eliminates dependence on the building substrate. It connects directly to the building structure or via the keel frame 1 for self-supporting operation, preventing wall panel detachment during old building renovations and improving safety.

[0040] In this embodiment, a fixing screw 5 is provided between the fiberglass layer 6 and the keel frame 1 to enhance the connection between the fiberglass layer 6 and the keel frame 1. The outer edge of the fiberglass layer 6 is flush with the outer edge of the keel frame 1. The insulation layer 2 is embedded between the fiberglass layer 6 and the keel frame 1, forming a 1 mm groove between the outer edge of the insulation layer 2 and the fiberglass layer 6 and the keel frame 1. The groove is filled with fiberglass by spraying, so that the insulation layer 2 is completely covered and not exposed, so that the insulation layer 2 will not be burned in the event of a fire.

[0041] The shape of the prefabricated thermal insulation composite wall panel in this utility model is not limited to right-angle wall panel 8 and flat wall panel 9. Other shapes of wall panels, such as curved wall panels, can also be matched according to the building frame and user needs.

[0042] like Figure 9 As shown, a building insulation structure includes a first right-angle wall panel 81, a second right-angle wall panel 82, a third right-angle wall panel 83, and a fourth right-angle wall panel 84. The first right-angle wall panel 81, the second right-angle wall panel 82, the third right-angle wall panel 83, and the fourth right-angle wall panel 84 are all prefabricated insulation composite wall panels with concrete layers 3 connected to both sides of an integral main panel. During the construction process, the bottom of the four right-angle wall panels is connected to the foundation 20, and a circumferential groove 201 is preset on the foundation 20. The width of the circumferential groove 201 is greater than the width of the wall panel. The first right-angle wall panel 81, the second right-angle wall panel 82, the third right-angle wall panel 83, and the fourth right-angle wall panel 84 are placed sequentially inside the circumferential groove 201. The tops of these four panels are then anchored to the roof. The positions of the right-angle wall panels are adjusted, and bolts 30 are used to securely connect them, forming a continuous and complete wall structure. Finally, concrete is poured into the circumferential groove 201, ensuring the bottom of the wall panels is firmly connected to the foundation. This wall structure, thanks to the unique shape and secure connection of the right-angle wall panels, possesses a certain degree of independent load-bearing capacity, providing a reliable supporting foundation for the entire building.

[0043] To further meet diverse architectural needs and spatial layout requirements, this building insulation structure is also equipped with several flat wall panels 9. During actual construction, based on specific spatial planning and functional requirements, the flat wall panels 9 are flexibly connected between the first right-angle wall panel 81 and the second right-angle wall panel 82, between the second right-angle wall panel 82 and the third right-angle wall panel 83, between the third right-angle wall panel 83 and the fourth right-angle wall panel 84, or between the fourth right-angle wall panel 84 and the first right-angle wall panel 81. Bolts 30 are also used for connection, ensuring a firm and stable connection between the flat wall panels 9 and the right-angle wall panels 8. Finally, sealant 10, such as weather-resistant silicone sealant, is used to fill the joints. At this point, a complete independent building insulation structure is initially formed. This building insulation structure can be used as a low-rise residential building, providing residents with basic living space and a comfortable living environment.

[0044] In addition, the wall panels of this building's insulation structure can also be used for temporary housing construction. In this case, either a prefabricated insulation composite wall panel with a main panel connected to concrete layers 3 on both sides or a main panel connected to fiberglass layers 6 on both sides can be used. The wall panels can be connected to the foundation 20 using circumferential grooves 201, bolt connections, or other easy-to-assemble and disassemble connection methods. Bolts 30 are used to connect the joints 7 of the two wall panels. This connection method is not only simple and easy to operate, but also allows for rapid assembly and disassembly. When temporary housing needs to be built, such as barracks or resettlement housing, workers can quickly assemble the wall panels, shortening construction time and improving work efficiency. After the temporary building is used, the wall panels can be quickly disassembled for easy transportation and storage, allowing for repeated use and reducing construction costs. Furthermore, due to the tight and stable connection between the wall panels, the entire building structure has high strength and stability, meeting the requirements for temporary buildings in different environments.

[0045] This embodiment is merely an illustration of the concept and implementation of this utility model, and is not intended to limit it. Under the concept of this utility model, the technical solution without substantial changes is still within the protection scope.

Claims

1. A prefabricated thermal insulation composite wall panel, comprising a keel frame and an insulation layer, characterized in that, The keel frame is set inside the insulation layer and is cured and bonded to the insulation layer to form an integral main board. The keel frame includes an outer frame, and a connecting part is provided on the periphery of the outer frame. The prefabricated insulation composite wall panel includes a flat wall panel and a right-angle wall panel: when the outer frame includes only one rectangular frame, it constitutes a flat wall panel; when the outer frame includes two mutually perpendicular rectangular frames, it constitutes a right-angle wall panel.

2. The prefabricated thermal insulation composite wall panel according to claim 1, characterized in that, The keel frame also includes a grid connected inside the outer frame. The grid includes a first support rod vertically arranged inside the outer frame and a second support rod perpendicular to the first support rod.

3. The prefabricated thermal insulation composite wall panel according to claim 1, characterized in that, The connecting part consists of mounting holes evenly distributed around the outer frame.

4. The prefabricated thermal insulation composite wall panel according to claim 1, characterized in that, It also includes a concrete layer, which is disposed on both sides of the integral mainboard.

5. The prefabricated thermal insulation composite wall panel according to claim 4, characterized in that, It also includes a steel mesh and fixing bolts; the steel mesh is set in the concrete layer and fixed to the keel frame by fixing bolts.

6. The prefabricated thermal insulation composite wall panel according to claim 1, characterized in that, It also includes fiberglass layers, which are disposed on both sides of the overall motherboard.

7. The prefabricated thermal insulation composite wall panel according to any one of claims 1 to 6, characterized in that, The joints between the prefabricated thermal insulation composite wall panels are filled with sealant.

8. The prefabricated thermal insulation composite wall panel according to claim 2, characterized in that, The outer frame is formed by welding several rectangular steel pipes, and the grille is also made of rectangular steel pipes and welded to the outer frame.

9. A building insulation structure, characterized in that, It includes a first right-angle wall panel, a second right-angle wall panel, a third right-angle wall panel, and a fourth right-angle wall panel, wherein the first right-angle wall panel, the second right-angle wall panel, the third right-angle wall panel, and the fourth right-angle wall panel are the prefabricated thermal insulation composite wall panels as described in any one of claims 1 to 6. The first right-angle wall panel, the second right-angle wall panel, the third right-angle wall panel, and the fourth right-angle wall panel are sequentially connected by bolts to form a continuous wall structure, and a roof is provided on the top of the wall structure and the bottom is connected to the foundation.

10. The building insulation structure according to claim 9, characterized in that, It also includes several flat wall panels, which are connected as needed between the first right-angle wall panel and the second right-angle wall panel, between the second right-angle wall panel and the third right-angle wall panel, between the third right-angle wall panel and the fourth right-angle wall panel, or between the fourth right-angle wall panel and the first right-angle wall panel.

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