Box-type light steel composite wall panels

Abstract

This utility model belongs to the field of building industrialization technology, and in particular relates to a box-type light steel composite wall panel. Its features include a light steel frame, a set of zigzag keels disposed within the internal cavity of the light steel frame, two integrated decorative cover plates covering the exterior of the light steel frame, and two layers of thermal insulation and soundproofing panels disposed within the internal cavity of the light steel frame. The light steel frame includes two parallel main frames and two parallel secondary frames, which are connected by connectors to form a rectangle. The thermal insulation and soundproofing panels include an inner flange liner and an insulation panel wrapped around this inner flange liner. 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 soundproofing layer inside, achieving 100% factory prefabrication. This wall panel 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 a box-type light steel composite wall panel. Background Technology

[0002] Traditional cast-in-place concrete walls have long construction cycles, high energy consumption, and are difficult to integrate with insulation systems. Adding insulation later reduces floor height and increases construction complexity. While existing lightweight steel walls can reduce structural weight, they still have the following problems:

[0003] 1. Insufficient thermal and sound insulation performance: Traditional light steel walls are prone to forming thermal and acoustic bridges, affecting building energy efficiency and comfort.

[0004] 2. Difficulty in thermal insulation integration: Existing precast walls usually require on-site installation of thermal insulation, which is inefficient and difficult to control in terms of quality.

[0005] 3. Poor adaptability to intelligent manufacturing: Traditional wall structures are complex and difficult to automate, which restricts the efficiency of industrialized construction.

[0006] Chinese patent No. 2018218186600 discloses a wall structure for prefabricated light steel structures. This utility model's main structure is a light steel keel wall structure, integrating insulation and decorative panels, and allowing for the installation of water and electricity pipes. However, this technology uses a large number of screws and square tubular plates for fixing the light steel keel installation, resulting in a cumbersome connection process and difficulty in automating manufacturing. The frame uses a prefabricated cold-formed profile, which forms the frame by setting 45° reverse chamfers at both ends and pre-drilled holes to assemble the panel corners. Due to the unique sheet metal characteristics of thin-walled cold-formed profiles, a process requiring orthogonal cutting of flat plates before forming, and considering stress rebound characteristics, it is difficult to achieve a tight, gapless 45° chamfer assembly. Furthermore, existing prefabricated wall full-fill insulation methods present problems such as difficulties in pipeline pre-embedding and complex on-site construction. Summary of the Invention

[0007] The purpose of this utility model is to provide a modular, intelligently manufactured box-type light steel composite wall panel that integrates structure and insulation prefabrication to meet the needs of building industrialization.

[0008] The objective of this utility model is achieved through the following technical solution:

[0009] The box-type light steel composite wall panel of this utility model is characterized by comprising a light steel frame, a set of Z-shaped keels disposed in the internal cavity of the light steel frame, two integrated decorative cover plates covering the outside of the light steel frame, and thermal insulation and sound insulation boards disposed on the upper and lower layers of the internal cavity of the light steel frame.

[0010] The light steel frame includes two parallel main frames and two parallel secondary frames, which are connected by connectors to form a rectangle.

[0011] 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.

[0012] 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.

[0013] 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.

[0014] The intermediate flange and the outer flange are both located above the outer web.

[0015] 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.

[0016] The two outer flanges of the U-shaped thin sheet cold-formed profile are provided with inward 180-degree hooks.

[0017] 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.

[0018] The integrated decorative cover is fixed to the two outer flanges of the frame to form a closed box.

[0019] The insulation board includes rock wool, phenolic board, aerogel, or polyurethane foam.

[0020] 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.

[0021] Advantages of this utility model:

[0022] (1) The box-type light steel composite wall panel of this utility model has strong intelligent manufacturing adaptability: it adopts standardized modular design, is compatible with automated production lines, and robots can complete cutting, welding, assembly and other processes, which greatly improves production efficiency. The product is fully produced by automated production line.

[0023] Reduce on-site construction volume: The wall panels are prefabricated in the factory as a whole, and only hoisting and splicing are required on site, shortening the construction period by more than 60% and reducing the dependence on labor.

[0024] The box-type light steel composite wall panel of the present utility model adopts a cold-formed steel frame, with a lightweight structure and high bearing capacity: The cross-section design is optimized to reduce the self-weight (40% lighter than the concrete wall surface) while still having excellent bending and shear resistance performance.

[0025] The hanging connection of the channel-shaped parts and the hanging connection of the Great Wall steel decking achieve convenient connection, cost savings, and improved assembly efficiency.

[0026] The hanging holes of the channel-shaped parts and the diamond-shaped hangers are formed by co-punching. When the box-type panels are combined with each other, the box-type panels are connected to each other by the diamond-shaped hangers, and the box-type 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 box-type floors or box-type roofs or box-type walls after installation.

[0027] The combination of the channel-shaped parts can also bear the external forces from the inside and outside of the box-type panel, and then the hooks of the channel-shaped parts are hung on the long rectangular holes of the concave main frame to conduct the external force to the concave main frame. Furthermore, the concave main frame is connected to the single-hole by multiple groups of screws to conduct the external force to the single-hole connector, and the single-hole connector is connected to the steel column and steel beam by bolts to conduct the external force to the beam and column.

[0028] The box-type light steel composite wall panel of the present utility model has excellent heat insulation and sound insulation performance.

[0029] Flange lining + multi-layer insulation: The lining board with a flange wraps rock wool or aerogel to form a continuous insulation layer, effectively blocking the heat bridge; Sound insulation optimization: The composite structure can reduce the impact sound and airborne sound, and the sound insulation amount ≥ 50dB, far exceeding that of ordinary concrete walls; The three-layer insulation (insulation cotton / static air layer / insulation cotton) has reliable functions, and the internal sound insulation cotton is increased to increase the sound insulation index.

[0030] The box-type light steel composite wall panel of the present utility model is green and low-carbon, conforms to the trend of sustainable development, and reduces construction waste; The prefabrication accuracy in the factory is high, and the material waste is less. Compared with cast-in-place concrete, the construction waste can be reduced by 80%; Recyclable: Steel, insulation materials, etc. can be disassembled and recycled, meeting the requirements of circular economy; The modular design is convenient for transportation by car and long-distance packing and shipping by sea.

[0031] This utility model of a box-type light steel composite wall panel offers convenient construction, reduced overall costs, and rapid installation: It utilizes bolt connections or snap-fit ​​splicing, eliminating the need for wet work and significantly shortening the construction cycle; it features self-supporting and load-bearing functions (panel / frame / single-hole connector / beam / column), simplifying construction (connecting beams and columns only with bolts using single-hole connectors), resulting in simple beam-column joints; it boasts a high degree of integration: decoration, structure, and pipelines are prefabricated as a single unit, reducing on-site work by over 30%; it possesses inherent decorative functions (panel decoration) and sealing and waterproofing functions (aluminum alloy / rubber strips); and it offers convenient maintenance: the pipeline system can be quickly inspected via access ports or external systems, and the water, electricity, and heating functions are highly integrated; wiring can be installed within the cavity formed by the wall panel, and the equipment automatically opens and closes the opening holes on both the inner and outer panels, allowing the inner and outer panels to be used directly as wall decorations;

[0032] This utility model of box-type light steel composite wall panel achieves the building industrialization goal of "factory prefabrication, rapid installation, energy saving and comfort" through innovative design of light steel box structure, integrated insulation and intelligent manufacturing. It is suitable for prefabricated buildings such as residences, apartments and hotels, and has significant economic and social benefits. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the structure of this utility model.

[0034] Figure 2 This is a cross-sectional view of the main frame of this utility model.

[0035] Figure 3 This is a cross-sectional view of the secondary frame of this utility model.

[0036] Figure 4 This is a cross-sectional view of the wall surface with flashing when the outer wall panel and the inner wall panel of this utility model are joined.

[0037] Figure 5 This is a top view and cross-sectional view of the junction between the outer wall surface and column of the box panel of this utility model.

[0038] Figure 6 This is a view of the hook node of the zigzag keel and the light steel frame of the present invention. Detailed Implementation

[0039] The specific embodiments of this utility model are further described below with reference to the accompanying drawings.

[0040] like Figure 1-5 As shown, the box-type light steel composite wall panel of this utility model 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, two integrated decorative cover plates 10 covering the outside of the light steel frame, and thermal insulation and sound insulation boards disposed on the upper and lower layers of the internal cavity of the light steel frame.

[0041] 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.

[0042] The thermal insulation and sound insulation board includes a flanged inner lining board 14 and an insulation board 11 wrapped around the flanged inner lining board 14.

[0043] 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.

[0044] 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.

[0045] The intermediate flange plate 3 and the outer flange plate 4 are both located above the outer web plate 2.

[0046] The U-shaped thin plate cold-formed profile of the main frame 12 has a perforated flange 8 at the connection of the two ends of the intermediate web 1 and above the intermediate web 1.

[0047] The two outer flanges 4 of the U-shaped thin sheet cold-formed profile are provided with inward 180-degree hooks 6.

[0048] 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.

[0049] The integrated decorative cover plate 10 is fixed to the two outer flange plates 4 of the frame to form a closed box.

[0050] The insulation board 11 includes rock wool, phenolic board, aerogel or polyurethane foam.

[0051] 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.

[0052] When the exterior wall panel and the interior wall panel are joined, a decorative flashing structure 18 is installed at the joint.

[0053] This utility model provides a box-type lightweight steel composite wall panel, the core of which lies in its modular design, facilitating intelligent manufacturing in factories and rapid on-site assembly. The specific structure includes:

[0054] 1. Light steel frame: A rectangular frame is formed by welding or bolting U-shaped thin plate cold-formed profiles with connecting fittings, serving as the main load-bearing structure of the wall. The cross-sectional shape is optimized to improve bending stiffness. Single-hole connector 15 can be selected as the connector. The design of single-hole connector 15 allows for rapid installation and wall laying with the square tube beams of the building's steel structure frame.

[0055] 2. Integrated Decorative Cover Plate 10: The wall surface is designed with an integrated decorative cover plate 10 fixed to the flanges on both sides of the frame, forming the bottom surface of a closed box. OSB board, fiber cement board, or thin steel plate with wallpaper or other decorative surfaces can be used. Interior and exterior walls are not limited to color-coated steel sheets, galvanized sheets, steel strips, and aluminum sheets; other materials include decorative carbon crystal panels, decorative flooring, OSB boards, cement boards, magnesium crystal boards, calcium silicate boards, gypsum boards, and more.

[0056] 3. Functional layer structure: Thermal insulation and sound insulation layer: The thermal insulation and sound insulation layer is located inside the integrated decorative cover plate 10. It is made of rock wool, phenolic board, aerogel or polyurethane foam wrapped with a flanged inner lining plate 14 (such as galvanized steel plate or aluminum plate) to form a continuous thermal insulation and sound insulation barrier, reducing thermal bridge and sound bridge effects.

[0057] 4. Hollow enclosed cavity design: This provides sound and heat insulation while reducing the need for additional insulation and soundproofing materials. For higher sound insulation requirements, soundproofing cotton panels can be installed on one or both sides of the inner cavity.

[0058] 5. Hollow cavity rib 9: 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 provide stable support.

[0059] 6. Smart Manufacturing Adaptability

[0060] Standardized production: All components (frame, cover, insulation layer) are designed according to a uniform module, which facilitates automated cutting, welding and assembly.

[0061] Robot assembly: The use of robotic arms to automatically lay the insulation layer improves production precision.

[0062] Digital management: By combining BIM technology, we can achieve full-process information management of wall surfaces from design and production to construction.

[0063] Preferred solution:

[0064] The frame of the U-shaped thin sheet cold-formed profile is made of galvanized carbon steel of Q235 or above with a thickness of 0.7mm-3.0mm.

[0065] 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.

[0066] The manufacturing process of integrated wall panel modules:

[0067] 1. Packaging film: Brand-printed thin film packaging (to be removed on-site after installation).

[0068] 2. The inner surface is a 0.5mm thick color steel plate channel. This plate can be made of materials such as carbon crystal plate or honeycomb aluminum plate. Wallpaper can also be applied to this plate on-site or at the factory. Switch and socket holes are set on the plate surface according to the design.

[0069] 3. Black and white glue: The factory uses an automatic glue-applying machine to apply the glue.

[0070] 4. 50mm thick rock wool: cut into strips and laid out, with a density of over 150 kg, and the cotton fibers perpendicular to the board surface. The cotton fixing nails pass through the groove board and are fixed to the 30mm Z-shaped keel 9, and the spacing between the surfaces along the Z-shaped keel 9 should not exceed 400mm.

[0071] 5. Black and white glue: Apply glue manually.

[0072] 6. 0.25mm thick flanged inner lining plate 14: On the concave shoulder plane. Place an L-shaped ten-hole piece 17 at each of the four corners of the shoulder.

[0073] 7. One side concave shoulder inner zigzag keel 9: The spacing density of the 30mm zigzag keels 9 on one side is not greater than 1 meter. The inner plane of the keel is level with the concave shoulder. The 30mm zigzag keel 9 on one side is connected to the other 30mm zigzag keel 9 by a vertical keel 16 with a C-shaped cross section and a width of 28mm.

[0074] 8. Hollow layer: Water pipes and electrical wiring are installed in the middle, with integrated connectors through φ40 conduit openings.

[0075] 9. The spacing of the 30mm Z-shaped keel on the other side of the concave shoulder should not exceed 1 meter. The outer plane of the keel should be flush with the concave shoulder on the other side.

[0076] 10. 0.25mm thick galvanized channel plate flange inner lining plate 14: Place a 4mm thick L-shaped ten-hole piece 17 in each of the four corners of the channel plate. The material of this piece is Q355.

[0077] 11. Black and white glue: Glue is applied by an automatic glue-applying machine in the factory.

[0078] 12. 50mm thick rock wool: cut into strips and laid out, with a density of over 100 kg, and the cotton fibers perpendicular to the board surface. The cotton fixing nails pass through the galvanized channel plate and connect to the 30mm Z-shaped keel 9, with a spacing of no more than 400mm between nails on the 30mm Z-shaped keel 9.

[0079] 13. Black and white glue: Glue is applied by an automatic glue-applying machine in the factory.

[0080] 14. 0.6mm thick galvanized aluminum sheet as integrated decorative cover plate 10: Light holes are provided, pre-drilled at the factory. Carbon crystal sheet, honeycomb aluminum sheet, or color-coated sheet with wall covering are available options. Switch and socket holes are provided according to the design.

[0081] 15. Packaging film: Brand-printed film packaging is used.

[0082] 16. Concave frame: The four sides are made of concave-shaped thin plate cold-formed profile. The parameters and materials of the concave frame can be selected according to the preferred scheme based on the stress model.

[0083] 17. Connectors: The connectors are made of Q355 steel. Single-hole connectors 15 can be installed at the four corner shoulders outside the thin-walled steel frame as needed. The single-hole connectors 15 are connected to the concave frame, inner groove plate, and L-shaped ten-hole connectors 17 with 10 M5 or M6 screws.

[0084] Wall construction and combined applications:

[0085] Diamond hook holes 7 can be provided on two adjacent frame sides. When the wall panels are spliced ​​together, the diamond hook holes 7 on the two adjacent frame sides are aligned with the hooks and inserted into the holes. Then, the wall 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 wall panels fit tightly together and share the load. There will be no misalignment or loose gaps between the two box-type wall panels at the joint.

[0086] The box-type wall panel connects to the pre-drilled holes (or connecting plates or tapping holes) on the load-bearing structural columns or steel beams of the building through the single-hole connector 15 connected at the four corners of the concave frame, enabling quick bolt installation. The installation is simple and the wall structure after installation is safe and reliable.

Claims

1. A box-type light steel composite wall panel, characterized in that, It includes a light steel frame, a set of Z-shaped keels set in the internal cavity of the light steel frame, two integrated decorative cover plates covering the outside of the light steel frame, and two layers of thermal insulation and sound insulation panels set in the internal cavity of the light steel frame. 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 box-type light gauge steel composite wall panel according to claim 1, wherein, 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.

3. The box-type light gauge steel composite wall panel according to claim 2, wherein, 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.

4. The box-type light steel composite wall panel according to claim 2, characterized in that, The two outer flanges of the U-shaped thin sheet cold-formed profile are provided with inward 180-degree hooks.

5. The box-type light gauge steel composite wall panel according to claim 2, wherein, 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.

6. The box-type light gauge steel composite wall panel according to claim 2, wherein, The integrated decorative cover is fixed to the two outer flanges of the frame to form a closed box.

7. The box-type light gauge steel composite wall panel according to claim 1, wherein The insulation board includes rock wool, phenolic board, aerogel, or polyurethane foam.

8. The box-type light gauge steel composite wall panel according to claim 1, wherein, 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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