Prefabricated and decorated integrated light steel structure self-supporting integrated box roof panel

Abstract

This utility model belongs to the field of building industrialization technology, and in particular relates to a prefabricated and decorated integrated light steel structure self-supporting integrated box roof panel. Its features include a light steel frame, a set of Z-shaped joists set in the internal cavity of the light steel frame, an upper integrated decorative cover plate covering the upper part of the light steel frame, a lower integrated decorative cover plate covering the lower part of the light steel frame, a thermal insulation and sound insulation board set below the upper integrated decorative cover plate, a thermal insulation and sound insulation board set above the lower integrated decorative cover plate, a steel bearing plate set above the light steel frame, and a waterproof layer set above the upper integrated decorative cover plate. This utility model forms a closed box body through a cold-formed steel frame and double-layer cover plates, with an integrated thermal insulation and sound insulation layer inside, achieving 100% factory prefabrication. This roof is suitable for automated robotic production and has advantages such as lightweight, high strength, energy saving, and rapid installation. It is suitable for prefabricated buildings, green and low-carbon buildings, civil buildings, and industrial buildings.

Description

Technical Field

[0001] This utility model belongs to the field of building industrialization technology, and in particular relates to an integrated box-type roof panel with prefabricated and decorated light steel structure and self-supporting structure. Background Technology

[0002] The current roofing system mainly faces the following technical bottlenecks: the construction cycle of traditional cast-in-place concrete roofing systems is as long as 14-28 days, involving multiple processes such as formwork, reinforcement binding, and pouring. The energy consumption of concrete production is as high as 1.2 GJ / m³-1.8 GJ / m³, resulting in significant carbon emissions. The insulation system is difficult to integrate, and subsequent additions lead to: a loss of 80mm-120mm in floor height, 5-7 additional cross-processes, difficulty in joint treatment, and a 35% increase in the risk of leakage.

[0003] Conventional light steel roofing systems suffer from several performance defects: thermal bridges have a heat transfer coefficient of 1.5 W / (m²·K)-2.5 W / (m²·K), airborne sound insulation is only 35dB-42dB, and the risk level of condensation is Class II. Construction efficiency is also low: on-site insulation installation accounts for over 40% of the total time, and the joint treatment qualification rate is less than 75%.

[0004] The existing technology currently retrieved is patent number 2018218186583, which describes the roof structure of a prefabricated light steel structure building. This technology primarily uses a light steel keel roof structure, integrating insulation and decorative panels, and can accommodate built-in water and electricity pipes. However, the connection structure disclosed in this patent is complex, requiring the use of numerous screws and square tubing for fixing; manufacturing precision is low, with gaps appearing in the 45° chamfered corner assembly; pipe integration is difficult, lacking an independent hollow layer, and pre-embedded pipes are prone to conflict with the structure; automated production is challenging, and the stress rebound of thin-walled profiles affects assembly accuracy. Summary of the Invention

[0005] The purpose of this utility model is to propose a modular, intelligently manufactured, assembled and decorated integrated light steel structure self-supporting integrated box roof panel, which realizes the integrated prefabrication of structure and insulation, and meets the needs of building industrialization.

[0006] The objective of this utility model is achieved through the following technical solution:

[0007] This utility model discloses an integrated, self-supporting, modular box-type roof panel with a light steel frame, characterized in that it comprises a light steel frame, a set of zigzag joists disposed within the internal cavity of the light steel frame, an upper integrated decorative cover covering the upper part of the light steel frame, a lower integrated decorative cover covering the lower part of the light steel frame, a thermal insulation and soundproofing board disposed below the upper integrated decorative cover, a thermal insulation and soundproofing board disposed above the lower integrated decorative cover, a steel support plate disposed above the light steel frame, and a waterproof layer disposed above the upper integrated decorative cover.

[0008] The light steel frame includes two parallel main frames and two parallel secondary frames, which are connected by connectors to form a rectangle.

[0009] The aforementioned thermal insulation and soundproofing board includes a flanged inner lining board and an insulation board wrapped around the outside of this flanged inner lining board.

[0010] The waterproof layer is a polymer waterproof membrane or a polymer coating.

[0011] The main frame or secondary frame is respectively composed of U-shaped thin plate cold-formed profiles. This U-shaped thin plate cold-formed profile includes a U-shaped main body formed by cold bending four flanges and three web sections. The four flanges include two middle flanges and two outer flanges. The three web sections include a middle web section and two outer web sections located below the two sides of the middle web section.

[0012] The two side edges of the intermediate web are respectively connected to one side edge of the two intermediate flanges, and the other side edge of each intermediate flange is connected to a side edge of an outer web. One side edge of each outer web is connected to an intermediate flange, and the other side edge is connected to an outer flange through a right-angle bend.

[0013] The intermediate flange and the outer flange are both located above the outer web.

[0014] The U-shaped thin sheet cold-formed profile of the main frame has a perforated flange at the connection of both ends of the middle web and above the middle web.

[0015] The two outer flanges of the U-shaped thin sheet cold-formed profile are provided with inward 180-degree hooks.

[0016] The hollow cavity keel is fixed to the two middle flanges on both sides of the concave thin plate cold-formed profile, which are folded inward at 90 degrees.

[0017] The upper integrated decorative cover plate covers the top of the light steel frame as a decorative layer, and the lower integrated decorative cover plate is fixed to the bottom of the light steel frame to form the bottom surface of the closed box.

[0018] The insulation board includes rock wool, phenolic board, aerogel, or polyurethane foam.

[0019] The light steel frame has an internal cavity for integrated water and electricity pipelines, with quick-connect interfaces reserved at the ends of the pipelines.

[0020] Advantages of this utility model:

[0021] (1)The integrated assembly and decoration lightweight steel structure self-bearing integrated cassette roof panel of the present utility model is highly industrialized, achieving complete factory prefabrication, with strong adaptability to intelligent manufacturing. It adopts a standardized module design, adapts to automated production lines, and robots can complete processes such as cutting, welding, and assembly, greatly improving production efficiency. The product is fully produced by automated production lines, reducing on-site construction volume. The entire roof is prefabricated in the factory, and only hoisting and splicing are required on-site, shortening the construction period by more than 60% and reducing dependence on labor.

[0022] (2)The integrated assembly and decoration lightweight steel structure self-bearing integrated cassette roof panel of the present utility model has a lightweight structure and high bearing capacity. It uses a cold-formed steel frame: optimizing the cross-section design, while reducing its own weight (40% lighter than concrete roofs), still having excellent bending and shear resistance; the steel deck enhances stiffness: a steel deck (profiled steel sheet or honeycomb panel) is arranged inside to improve the overall bearing capacity of the roof, and the span can reach more than 6m;

[0023] The hanging connection of the channel-shaped parts and the hanging connection of the Great Wall steel deck achieve convenient connection, cost savings, and improved assembly efficiency.

[0024] The hanging holes of the channel-shaped parts and the diamond-shaped hangers are jointly stamped. When the cassette panels are combined with each other, the cassette panels are connected to each other by the diamond-shaped hangers, and the cassette panels are combined to achieve integral force transmission in the direction perpendicular to the concave main frame by the channel-shaped parts, realizing the integral force of multiple cassette floors or cassette roofs or cassette walls after installation.

[0025] The combination of the channel-shaped parts can also bear the external forces from inside and outside the cassette panel. Thus, the external forces are transmitted to the concave main frame by hanging the hooks of the channel-shaped parts on the oblong holes of the concave main frame. Furthermore, the concave main frame is connected to the single-hole by multiple groups of screws to transmit the external forces to the single-hole connector, and the single-hole connector is connected to the steel column and steel beam by bolts to transmit the external forces to the beam-column.

[0026] (3)The integrated assembly and decoration lightweight steel structure self-bearing integrated cassette roof panel of the present utility model has excellent heat insulation and sound insulation performance;

[0027] Flange lining and multi-layer insulation structure: The lining board with a flange wraps rock wool or aerogel to form a continuous insulation layer;

[0028] Sound insulation optimization: The composite structure can reduce impact sound and airborne sound, and the sound insulation amount ≥ 50dB, far exceeding that of ordinary concrete roofs;

[0029] The three-layer insulation (insulating cotton\static air layer\insulating cotton) has reliable functions, and adding sound insulation cotton inside increases the sound insulation index;

[0030] (4) The assembled and decorated integrated light steel structure self-supporting integrated box roof panel of this utility model is green and low-carbon, conforms to the trend of sustainable development, and reduces construction waste; the factory prefabrication has high precision and less material waste, which can reduce construction waste by 80% compared with cast-in-place concrete; steel, insulation materials, etc. can be disassembled and recycled, which meets the requirements of circular economy; the modular design facilitates automobile transportation and long-distance container shipping.

[0031] (5) The assembled and decorated integrated light steel structure self-supporting integrated box roof panel of this utility model is easy to construct and reduces the overall cost; it is quick to install: it adopts bolt connection or snap-on splicing, which eliminates the need for wet work and greatly shortens the construction cycle. It has self-supporting and force transmission functions (plate / frame / single hole connector / beam and column), and is easy to construct (it is connected to the beam and column by bolts using only a single hole connector), and the beam and column nodes are simple;

[0032] High degree of integration: Decoration, structure and pipeline are prefabricated in one piece, reducing on-site work by more than 30%, with its own decorative function (panel decoration) and sealing and waterproof function;

[0033] Easy maintenance: The pipeline system can be quickly inspected and maintained through the access panel or external system, and the water, electricity and heating functions are highly integrated;

[0034] (6) The prefabricated and decorated integrated light steel structure self-supporting integrated box roof panel of this utility model, through the innovative design of light steel box structure + integrated insulation + intelligent manufacturing, realizes the building industrialization goal of "factory prefabrication, rapid installation, energy saving and comfort", and is suitable for prefabricated buildings such as residences, apartments and hotels, with significant economic and social benefits. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the structure of this utility model.

[0036] Figure 2 This is a cross-sectional view of the present invention.

[0037] Figure 3 This is a cross-sectional view of the main frame of this utility model.

[0038] Figure 4 This is a cross-sectional view of the secondary frame of this utility model.

[0039] Figure 5 This is a top view and cross-sectional view of the box-type roof panel and column joint of this utility model.

[0040] Figure 6 This is a view of the hook node of the zigzag keel, steel bearing plate and light steel frame of the present invention. Detailed Implementation

[0041] The specific embodiments of this utility model are further described below with reference to the accompanying drawings.

[0042] like Figure 1-5 As shown, the self-supporting integrated box-type roof panel of this utility model, which is an integrated light steel structure with prefabricated decoration, is characterized by comprising a light steel frame, a set of Z-shaped keels 9 disposed in the internal cavity of the light steel frame, an upper integrated decorative cover plate 10 covering the upper part of the light steel frame, a lower integrated decorative cover plate 18 covering the lower part of the light steel frame, a thermal insulation and sound insulation board disposed below the upper integrated decorative cover plate 10, a thermal insulation and sound insulation board disposed above the lower integrated decorative cover plate 18, a steel bearing plate 19 disposed above the light steel frame, and a waterproof layer 20 disposed above the upper integrated decorative cover plate 10.

[0043] The light steel frame includes two parallel main frames 12 and two parallel secondary frames 13. The two main frames 12 and the two secondary frames 13 are connected by connectors to form a rectangle.

[0044] The aforementioned thermal insulation and soundproofing board includes a flanged inner lining board 14 and an insulation board 11 wrapped around the outside of this flanged inner lining board.

[0045] The waterproof layer 20 is a polymer waterproof membrane or a polymer coating.

[0046] The main frame 12 or the secondary frame 13 is respectively composed of U-shaped thin plate cold-formed profiles. This U-shaped thin plate cold-formed profile includes a U-shaped main body formed by cold bending four flanges and three web sections. The four flanges include two middle flanges 3 and two outer flanges 4. The three web sections include a middle web 1 and two outer web sections 2 disposed on both sides below the middle web 1.

[0047] The two side edges of the intermediate web 1 are respectively connected to one side edge of the two intermediate flange plates 3, and the other side edge of each intermediate flange plate 3 is connected to one side edge of an outer web 2. One side edge of each outer web 2 is connected to an intermediate flange plate 3, and the other side edge is connected to an outer flange plate 4 through a right-angle bend 5.

[0048] The intermediate flange plate 3 and the outer flange plate 4 are both located above the outer web plate 2.

[0049] The U-shaped thin plate cold-formed profile of the main frame has a perforated flange 8 at the connection of the two ends of the middle web 1 and above the middle web 1.

[0050] The two outer flanges 4 of the U-shaped thin sheet cold-formed profile are provided with inward 180-degree hooks 6.

[0051] The hollow zigzag keel 9 is fixed to the two middle flange plates 3 on both sides of the concave thin plate cold-formed profile, which are folded inward at 90 degrees.

[0052] The upper integrated decorative cover plate 10 covers the top of the light steel frame as a decorative layer, and the lower integrated decorative cover plate 18 is fixed to the bottom of the light steel frame to form the bottom surface of the closed box.

[0053] The insulation board 11 includes rock wool, phenolic board, aerogel or polyurethane foam.

[0054] The light steel frame has an internal cavity for integrated water and electricity pipelines, with quick-connect interfaces reserved at the ends of the pipelines.

[0055] This utility model provides a modular box-type light steel composite prefabricated roofing system. Its core innovation lies in adopting a standardized and integrated design concept, enabling intelligent and efficient factory production and rapid on-site assembly. By optimizing structural combinations and connection methods, this system significantly improves the overall performance and construction efficiency of the roof. The specific structural components are as follows:

[0056] 1. Light steel main load-bearing frame

[0057] Frame structure: High-strength concave cold-formed steel and modular connecting parts (welded or bolted) are used to form a rigid rectangular frame, which serves as the core load-bearing unit of the roof system.

[0058] Section optimization: Improve bending stiffness through profile section geometry design to ensure structural stability.

[0059] Quick installation: The connector is designed with a plug-in interface, which can be seamlessly connected to the main steel structure (square tube beam) of the building, greatly simplifying the on-site installation process.

[0060] 2. Multifunctional composite surface layer system

[0061] The lower integrated decorative cover plate 18 is fixed to the bottom of the frame to form a sealed box structure. It can be made of high-strength OSB board, fiber cement board or metal composite board, and the surface can be laminated with decorative materials (such as wallpaper, fireproof coating, etc.).

[0062] Upper integrated decorative cover plate 10: Covers the top of the frame as a roof decoration layer, supporting a variety of high-durability finishing materials such as composite floor tiles, SPC flooring, and metal carved panels.

[0063] Surface scalability: The system is compatible with a variety of decorative surface materials, including but not limited to color-coated steel sheets, galvanized sheets, aluminum sheets, carbon crystal sheets, calcium silicate boards, etc., to meet diverse architectural aesthetic needs.

[0064] High-performance functional layer structure

[0065] Thermal insulation and sound insulation system: Rock wool, aerogel or polyurethane foam are wrapped with a flanged inner lining plate 14 (galvanized steel plate / aluminum plate) to form a continuous thermal insulation and sound insulation barrier, effectively blocking thermal bridge and sound bridge effects.

[0066] Optional sound insulation enhancement solution: Install high-density sound insulation cotton panels inside the hollow cavity to further improve acoustic performance.

[0067] 4. Hollow cavity design:

[0068] Passive thermal insulation and sound wave attenuation are achieved through a closed cavity structure, while reducing the amount of traditional insulation materials used.

[0069] 5. Pre-installed pipeline channels (φ40 standard interface) within the cavity facilitate integrated layout of water and electricity pipelines.

[0070] 6. Enhance the support system:

[0071] The cavity is equipped with a zigzag keel 9 (or honeycomb panel square tube beam), which is fixed to the two middle flange plates 3 on both sides of the U-shaped thin plate cold-formed profile, which are folded inward at 90 degrees, to ensure the roof load-bearing stability.

[0072] The spacing and cross-section of the keel are optimized according to mechanical calculations, taking into account both lightweight and high strength requirements.

[0073] 7. Smart Manufacturing Adaptability

[0074] Standardized production: All components (profiles, panels, functional layers) adopt a unified building module, supporting automated material cutting, laser cutting and robotic welding.

[0075] Intelligent assembly: The application of a robotic arm automatic installation system accurately completes processes such as insulation layer positioning and steel deck installation, with product tolerances controlled within ±0.5mm.

[0076] Full-process digitalization: Based on the BIM collaborative platform, it realizes the integration of information across the entire chain, from parametric design modeling and production data traceability to construction progress management.

[0077] Preferred solution:

[0078] The frame of the U-shaped thin sheet cold-formed profile is made of Q235 or higher galvanized carbon steel with a thickness of 0.7mm-3.0mm.

[0079] The box is molded with a thickness of 150 mm - 300 mm, a width of 600 mm - 1220 mm, and a length of 250 mm - 12000 mm.

[0080] Structure and manufacturing process:

[0081] I. Roof Panel Integrated Module

[0082] Modular prefabricated composite roofing panel system with layered structure (from outside to inside)

[0083] 1. External protective layer

[0084] Waterproof layer 20: The surface is covered with a polymer waterproof membrane (TPO / EPDM / PVC optional).

[0085] Temporary protective film: Protective film (to be peeled off after installation).

[0086] 2. Upper structural layer

[0087] Support panel: 0.6mm thick aluminum-zinc coated steel channel plate as upper integrated decorative cover plate 10.

[0088] Structural adhesive layer: Robotically sprayed two-component polyurethane adhesive (black and white adhesive).

[0089] Insulation layer A: 50mm thick vertical fiber rock wool (density ≥150kg / m³), anchored to Ω30 keel with self-tapping screws (spacing ≤400mm).

[0090] 3. Cavity functional layer

[0091] Pipeline passage: Pre-embedded φ40 conduit integration interface (space for water and electricity pipelines to pass through).

[0092] The height of the hollow layer is adjustable (150mm-300mm).

[0093] Keel system: Main keel: Ω30 type cold-bent keel (spacing ≤1m).

[0094] Vertical connection: C-shaped vertical keel with a width of 28mm is used to connect the upper and lower structural layers in both directions.

[0095] Quick-installation node: The keel hanging point has a pre-drilled diamond-shaped positioning hole (error ±0.5mm).

[0096] 4. Lower structural layer

[0097] Reinforced connector: L-shaped ten-hole connector 17 (Q355 material, 4mm thick, temporary fixation with double-sided adhesive).

[0098] Single-hole connector 15 (Q355, M5 / M6 high-strength screw final tightening).

[0099] Base plate: 0.25mm thick galvanized steel channel plate as flange inner lining plate 14 (lined with fireproof rock wool).

[0100] 5. Bottom decorative layer

[0101] Composite decorative panel: 0.6mm thick galvanized aluminum sheet as the lower integrated decorative cover 18 (optional carbon crystal sheet / honeycomb aluminum sheet).

[0102] Pre-drilled holes: Factory-prefabricated mounting holes for lighting fixtures / equipment.

[0103] 6. Border System

[0104] Main frame: concave cross-section light steel frame, standard model: 150 mm - 300 mm (corresponding to different load-bearing capacities).

[0105] Modular connection: Quick-release connectors are provided at the four corners (mechanically locked with 10×M5 / M6 screws).

[0106] Key process description

[0107] Insulation layer construction: Rock wool strips are laid in a staggered pattern, with the fiber direction perpendicular to the board surface, and the cotton pressing nails penetrate the groove board and are rigidly connected to the keel.

[0108] Cavity optimization design: The space for integrated pipeline routing and acoustic cavity are combined and utilized, and the corrugated steel bearing plate with aligned crests ensures flatness.

[0109] Intelligent production control: laser positioning of connectors (accuracy 0.1mm), AI dynamic control of glue application amount (±5% error band).

[0110] This solution, through standardized hierarchical descriptions and terminology upgrades, retains the essence of the original process while better conforming to the technical language system of modern prefabricated buildings.

[0111] Roofing construction and combined applications:

[0112] Diamond hook holes 7 can be provided on two adjacent frame sides. When splicing roof panels, the diamond hook holes 7 on the two adjacent frame sides are aligned with the hooks and inserted into the holes. Then, the roof panels are moved horizontally, and the hooks and holes form a tight hook structure, so that the adjacent frame sides of the two box-type roof panels fit tightly together to share the load. There will be no misalignment of the two box-type roof panels or loose gaps at the roof joint.

[0113] The box-type roof uses pre-drilled holes (or connecting plates or tapping holes) on the load-bearing structural columns or steel beams of the building to connect to the four corners of the concave frame of the prefabricated connector 15. This allows for quick and easy bolt installation, and the installed roof structure is safe and reliable.

[0114] Prefabricated geothermal pipes between roofs with geothermal heating can be connected using special geothermal pipe sliding fittings.

Claims

1. A self-supporting integrated box-type roof panel with prefabricated and decorative light steel structure, characterized in that, The system includes a light steel frame, a set of Z-shaped joists disposed within the internal cavity of the light steel frame, an upper integrated decorative cover covering the upper part of the light steel frame, a lower integrated decorative cover covering the lower part of the light steel frame, a thermal insulation and soundproofing board disposed below the upper integrated decorative cover, a thermal insulation and soundproofing board disposed above the lower integrated decorative cover, a steel support plate disposed above the light steel frame, and a waterproof layer disposed above the upper integrated decorative cover. The light steel frame includes two parallel main frames and two parallel secondary frames, which are connected by connectors to form a rectangle. The aforementioned thermal insulation and soundproofing board includes a flanged inner lining board and an insulation board wrapped around the outside of this flanged inner lining board.

2. The integrated self-supporting box-type roof panel of the assembled and decorated light steel structure according to claim 1, characterized in that, The waterproof layer is a polymer waterproof membrane or a polymer coating.

3. The integrated self-supporting box-type roof panel of the assembled and decorated light steel structure according to claim 1, characterized in that, The main frame or secondary frame is respectively composed of U-shaped thin plate cold-formed profiles. This U-shaped thin plate cold-formed profile includes a U-shaped main body formed by cold bending four flanges and three web sections. The four flanges include two middle flanges and two outer flanges. The three web sections include a middle web section and two outer web sections located below the two sides of the middle web section. The two side edges of the intermediate web are respectively connected to one side edge of the two intermediate flanges, and the other side edge of each intermediate flange is connected to a side edge of an outer web. One side edge of each outer web is connected to an intermediate flange, and the other side edge is connected to an outer flange through a right-angle bend. The intermediate flange and the outer flange are both located above the outer web.

4. The integrated self-supporting box-type roof panel of the assembled and decorated light steel structure according to claim 3, characterized in that, The U-shaped thin sheet cold-formed profile of the main frame has a perforated flange at the connection of both ends of the middle web and above the middle web.

5. The integrated self-supporting box-type roof panel with prefabricated and decorative light steel structure according to claim 3, characterized in that, The two outer flanges of the U-shaped thin sheet cold-formed profile are provided with inward 180-degree hooks.

6. The integrated self-supporting box-type roof panel of the assembled and decorated light steel structure according to claim 3, characterized in that, The hollow cavity keel is fixed to the two middle flanges on both sides of the concave thin plate cold-formed profile, which are folded inward at 90 degrees.

7. The integrated self-supporting box-type roof panel of the assembled and decorated light steel structure according to claim 1, characterized in that, The upper integrated decorative cover plate covers the top of the light steel frame as a decorative layer, and the lower integrated decorative cover plate is fixed to the bottom of the light steel frame to form the bottom surface of the closed box.

8. The self-supporting integrated box-type roof panel of the assembled and decorated light steel structure according to claim 1, characterized in that, The insulation board includes rock wool, phenolic board, aerogel, or polyurethane foam.

9. The prefabricated and decorative integrated light steel structure self-supporting integrated box roof panel according to claim 1, characterized in that, The light steel frame has an internal cavity for integrated water and electricity pipelines, with quick-connect interfaces reserved at the ends of the pipelines.

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