Energy-saving and low-noise pre-installed steel structure roof system

Abstract

This utility model discloses an energy-saving and low-noise prefabricated steel structure roofing system, belonging to the field of prefabricated building technology. The roofing system includes roof panels, fixing bases, purlins, thermal insulation blocks, bent plates, and multiple functional layers installed between the fixing bases and the bent plates. The roof panels are fixedly connected to the purlins via the fixing bases, and the purlins are fixedly connected to the bent plates via thermal insulation blocks. The bent plates have a flat bottom surface, two sides perpendicular to the bottom surface and bent in the same direction, and end faces that bend towards each other at the ends of the two sides but do not contact each other, with the bottom surface, sides, and end faces forming an open cavity. The functional layers include at least a thermal insulation layer, a waterproof and breathable layer, and a waterproof and vapor-barrier layer. Adjacent bent plates are arranged side-by-side with gaps, and the sides of two adjacent bent plates are fixed together by bolts. Expanding foam, foam cotton, and sealant are placed in the gaps between the sides. This roofing system can effectively reduce noise caused by structural creaking and reduce heat loss from the building, resulting in excellent energy-saving performance.

Description

Technical Field

[0001] This utility model belongs to the field of prefabricated building technology, specifically relating to an energy-saving and low-noise prefabricated steel structure roofing system. Background Technology

[0002] Prefabricated construction involves manufacturing and assembling a large number of building components in a factory before transporting them to the construction site for assembly. By shifting much of the work to factories, prefabricated construction significantly reduces the amount and intensity of labor during construction and drastically shortens the construction period. Furthermore, it helps conserve energy, reduce construction waste, and minimize other environmental pollution. Compared to traditional construction, it offers significant advantages in energy conservation and environmental protection.

[0003] Prefabricated building components, depending on the building location, can be categorized into walls, floors, columns, roofs, and stairs. Among these, the roofing system is an indispensable and crucial component. Located at the top of the building, the roofing system is essential for achieving functions such as wind and water resistance, thermal insulation, and soundproofing. In existing roofing systems, bent or roll-formed metal sheets are commonly used as the base material connecting purlins and roof panels, as well as supporting functional layers such as insulation and soundproofing layers. For ease of installation, these base materials are connected using a two-sided interlocking method (e.g., ...). Figure 1 (As shown). Adjacent substrates are connected via latching parts IS1 and IIS2 on both sides. While this method offers advantages such as high connection efficiency, the latching points often involve surface-to-surface connections between adjacent substrates. Over time, the metal substrates may experience structural rattling at the contact points due to thermal expansion and contraction, increasing the noise level of prefabricated buildings. This also creates a significant sense of insecurity for building occupants. Furthermore, the structure of these metal substrates is generally complex, often requiring bending, making the processing relatively cumbersome. Utility Model Content

[0004] (a) Technical problems to be solved

[0005] This utility model aims to solve one of the following technical problems existing in the prior art or related technologies:

[0006] Existing prefabricated building roofing systems suffer from complex structures and large metal component foundations, which can easily lead to structural noise, excessive building noise, and safety concerns for users.

[0007] (II) Technical Solution

[0008] To solve the above-mentioned technical problems, this utility model provides an energy-saving and low-noise prefabricated steel structure roofing system, and the specific technical solution adopted is as follows:

[0009] An energy-saving and low-noise prefabricated steel structure roofing system includes a roof panel, a fixing base 2, a purlin 3, a heat insulation pad 5, a bent plate 9, and multiple functional layers installed between the fixing base 2 and the bent plate 9.

[0010] The roof panel 1 is fixedly connected to the upper purlin 3 via the fixing seat 2;

[0011] The upper purlin 3 is fixedly connected to the bending plate 9 by the heat insulation pad 5;

[0012] The bending plate 9 has a flat bottom surface 91, two vertical bottom surfaces 91 bent in the same direction on the side surfaces 92, and end surfaces 93 bent towards each other at the ends of the two side surfaces 92 without contacting each other; the bottom surface 91, side surfaces 92 and end surfaces 93 enclose an open cavity.

[0013] The functional layer includes at least a thermal insulation layer 4 and a waterproof and breathable layer 15;

[0014] Adjacent bent plates 9 are arranged side by side with a gap, and the sides 92 of two adjacent bent plates 9 are fixed by bolts 10; foam 12, foam 13 and sealant 14 are provided in the gap between the sides 92.

[0015] Preferably, a washer 11 is provided on the bolt 10 that passes through the side 92 of the adjacent bent plate 9; the washer 11 is located in the gap and is circumferentially wrapped with foam 12.

[0016] Preferably, the upper purlin 3 is a U-shaped purlin, and the connecting bolts are sequentially passed through the two side flanges of the U-shaped purlin, the heat insulation pad 5 and the end face 93 of the bending plate 9 to achieve a fixed connection between the upper purlin 3 and the bending plate 9.

[0017] Preferably, the insulation layer 4 is installed inside the open cavity of the bent plate 9 or extends from the open cavity to the outside of the end face 93; the waterproof and breathable layer 15 is located on the outdoor side of the roof system.

[0018] Preferably, the functional layer further includes a sound-absorbing layer 7 and a waterproof vapor barrier layer 16; the sound-absorbing layer 7 is disposed inside the open cavity of the bent plate 9; the waterproof breathable layer 15 and the waterproof vapor barrier layer 16 are located on both sides of the insulation layer 4; the waterproof breathable layer 15 is located on the outdoor side, and the waterproof vapor barrier layer 16 is located on the indoor side.

[0019] More preferably, the insulation layer 4 is disposed on the outer side of the end face 93 of the bent plate 9, and there is a cavity between the insulation layer 4 and the sound-absorbing layer 7.

[0020] More preferably, a support plate 6 is fixed on the end face 93 of the bent plate 9, and the separated part of the end face 93 is used to support the insulation layer 4.

[0021] Preferably, a plurality of sound-absorbing holes are provided on the bottom surface 91 of the bent plate 9.

[0022] Preferably, a sound-absorbing and dust-proof layer 17 is provided between the sound-absorbing layer 7 and the open cavity inner wall of the bent plate 9.

[0023] Preferably, the roofing system further includes a purlin 8; the purlin 8 is fixedly installed on the outer side of the bottom surface 91 of the bent plate 9.

[0024] (III) Beneficial Effects

[0025] Compared with the prior art, the beneficial effects obtained by this utility model are as follows:

[0026] I. This utility model's roofing system uses a simplified and regular bent plate as the base plate. Instead of using interlocking fasteners on both sides of the bent plate, adjacent bent plates are connected via a combination of rigid and flexible connections using connecting bolts and foam layers. This connection method transforms the original surface connection of the bent plates into a point connection, significantly reducing the contact area between adjacent bent plates. This helps reduce structural noise, lowers the overall noise level of prefabricated buildings, and improves user safety. Furthermore, the bent plate not only achieves the connection function of existing interlocking base plates but also reduces the amount of sheet material used.

[0027] II. In this utility model's roofing system, gaps are formed between adjacent bent panels by rigid connections using bolts and washers. Simultaneously, expanding foam and cotton foam are added to these gaps, and the joints are sealed with sealant. The expanding foam and cotton foam in the gaps not only reduce the contact area of ​​the metal bent panels, thus reducing noise caused by structural creaking, but also block the transmission of existing noise and buffer against deformation and compression of the bent panels or other components due to stress or thermal expansion and contraction.

[0028] Third, the roofing system of this utility model adopts a double-purlin structure. The upper purlin is used to connect the roof panels, and the lower purlin is used to connect the building's roof truss support structure. Furthermore, the entire roofing system can be pre-assembled and directly hoisted to the construction site for installation, thus significantly reducing the construction period. Simultaneously, by controlling the number and size of the bent panels, the roofing system can be modularized, facilitating loading and transportation while providing greater flexibility and adaptability to a wider range of buildings.

[0029] Fourth, the roofing system of this utility model uses heat-insulating pads to connect the upper purlin and the bent plate, thereby reducing the contact area between hot and cold water vapor and avoiding the formation of linear thermal bridges. Furthermore, wrapping the connection points with insulation layers on both sides can maximize the isolation between hot and cold water vapor, preventing cold air condensation from causing mold and rust at the connection points. Attached Figure Description

[0030] The accompanying drawings, which form part of this utility model, are used to provide a further understanding of the utility model. The illustrative embodiments of the utility model and their descriptions are used to explain the invention and do not constitute an undue limitation of the utility model. In the drawings:

[0031] Figure 1 The diagram schematically illustrates a cross-section of an existing snap-fit ​​bent panel used for prefabricated building roofs.

[0032] Figure 2 The cross-section of a bent plate used in a prefabricated building roofing system is schematically shown in a preferred embodiment of the present invention.

[0033] Figure 3 A schematic cross-sectional structural diagram of the roofing system in Embodiment 1 of this utility model is shown.

[0034] Figure 4 for Figure 3 A magnified view of the area within box A in the middle.

[0035] Figure 5 for Figure 3 A magnified view of the area within box B in the middle.

[0036] Figure 6 for Figure 3 A magnified view of the area within the box in the middle (C).

[0037] Figure 7 This is a longitudinal section structural diagram of the roof system shown in Example 1.

[0038] Figure 8 A schematic cross-sectional structural diagram of the roofing system in Embodiment 2 of this utility model is shown.

[0039] Figure 9 This is a longitudinal section structural diagram of the roof system shown in Example 2.

[0040] The reference numerals used in the above figures are as follows:

[0041] 1. Roof panel; 2. Mounting bracket; 3. Top purlin; 4. Insulation layer; 5. Thermal insulation pad; 6. Support plate; 7. Sound-absorbing layer; 8. Bottom purlin; 9. Bent plate; 10. Bolt; 11. Washer; 12. Expanding foam; 13. Foam; 14. Sealant; 15. Waterproof and breathable layer; 16. Waterproof and vapor barrier layer; 17. Sound-absorbing and dustproof layer;

[0042] 91, bottom surface; 92, side surface; 93, end surface;

[0043] S1, Fastening part I; S2, Fastening part II. Detailed Implementation

[0044] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings. However, the present invention can be implemented in many different ways as defined and covered by the claims.

[0045] In the following description of this utility model, it should be noted that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer" and "vertical" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0046] In the following description of this utility model, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood according to the specific circumstances.

[0047] Furthermore, in the following description of this utility model, unless otherwise stated, "multiple", "multiple groups", or "multiple roots" means two or more.

[0048] The roof panel and fixing bracket used in this utility model are existing commercially available products. The roof panel has arc-shaped fastening parts at both ends, allowing adjacent roof panels to be fastened together as a whole. The fixing bracket used is a T-shaped fixing connection bracket. An expansion part is provided on the upper part of the vertical surface of the fixing bracket, which can be installed in the arc-shaped space of the roof panel to lock the roof panel and prevent it from loosening. A passage is provided on the bottom horizontal surface of the fixing bracket to facilitate fixed connection with the top of the upper purlin 3 by bolts.

[0049] Compared to Figure 1 The existing known bent plate with a fastening part shown is used in the following embodiments. Figure 2 The bent plate 9 shown has a flat bottom surface 91, with two side surfaces 92 formed by bending in the same direction on both sides of the bottom surface 91. The ends of the side surfaces 92 are bent in opposite directions to form non-contact end faces 93. Thus, the bent plate 9 forms an open cavity with an opening through the bottom surface 91, side surfaces 92, and end faces 93, facilitating the accommodation and installation of functional layers. Because the bent plate 9 eliminates the need for snap-fit ​​connections on the side surfaces, its overall structure is simpler and more regular, reducing the number of processing steps.

[0050] Example 1

[0051] like Figure 2 , 3 As shown in Figures 4, 5, 6, and 7, this embodiment provides a pre-installed steel structure roofing system with a sound-absorbing layer. From Figure 3 As can be seen, the roofing system, from top to bottom, mainly consists of roof panel 1, fixing base 2, upper purlin 4, insulation layer 4, heat insulation pad 5, support plate 6, bent plate 9, sound-absorbing layer 7, and lower purlin 8. The bottom of the fixing base 2 is fixedly connected to the upper part of the upper purlin 3 by bolts, and the upper part of the heat insulation pad 5 is connected to the lower part of the upper purlin 3 by bolts. The bottom of the heat insulation pad 5 is fixedly connected to the end face 93 of the bent plate 9. The support plate 6 is laid on top of the end face 93 to fill the gap between the end faces 93, thereby supporting the insulation layer 4 above it. At the bottom of the roofing system, the bent plate 9 is fixedly connected to the lower purlin 8 by bolts. The sound-absorbing layer 7 is installed within the cavity formed by the bent plate 9, but is not fully filled, thus forming a cavity structure to improve sound absorption.

[0052] from Figure 4 It is known that a gap exists at the connection point of the sides 92 of adjacent bent plates 9, and the sides 92 of the two bent plates 9 are connected by through bolts 10. Simultaneously, a gasket 11 is provided in the gap, which increases the stability of the connection and facilitates control of the gap thickness. The gasket 11 is surrounded by expanding foam 12, and foam 13 is installed on the outer side of the expanding foam 12 near the gap. The outermost edge of the gap is sealed with sealant 14. This connection method of adjacent bent plates 9 greatly reduces the contact area of ​​the metal sheets at the connection point, effectively reducing structural noise caused by stress deformation, thermal expansion and contraction, etc., at the connection point. This connection method, combining rigid and flexible connections, ensures connection strength while allowing the connection point to act as an isolation point for noise transmission and a buffer point for compression deformation.

[0053] from Figure 5 It can be seen that a waterproof and breathable layer 15, composed of a waterproof and breathable membrane, is provided on the outer side of the upper purlin 3 above the insulation layer 4 to prevent external water from entering the insulation layer 4 and to allow gas to escape from the insulation layer 4. This waterproof and breathable layer 15 can also be installed between the upper purlin 3 and the upper part of the insulation layer 4, depending on the situation. At the lower part of the insulation layer 4, between the upper part of the support plate 6, a waterproof and vapor barrier layer 16, composed of a waterproof and vapor-barrier membrane, is also provided to prevent indoor moisture from entering the insulation layer 4.

[0054] from Figure 6 It is known that a sound-insulating and dust-proof layer 17, made of sound-insulating paper or non-woven fabric, is provided between the bent plate 9 and the sound insulation layer 7 to improve the sound insulation effect and prevent indoor dust from entering the sound insulation layer 7. At the same time, to improve the sound insulation effect, sound-absorbing holes can be made on the bottom surface of the bent plate 9 as needed.

[0055] from Figure 7 It can be seen that both the upper purlin 3 and the lower purlin 8 used in this roofing system are U-shaped purlins. The difference is that the upper purlin 3 is installed facing forward, with its two side flanges located at the bottom and connected to the heat insulation pad 5 and the bent plate 9 by bolts, while the upper part is fixedly connected to the fixing seat 2. The lower purlin 8 is installed in the opposite direction, with its two side flanges facing upward and fixedly connected to the bent plate 9 by bolts, while the middle part of the lower purlin 8 can be connected to other structural components of the prefabricated building.

[0056] Example 2

[0057] like Figure 2 , 8 As shown in Figures 9 and 1, this embodiment provides a pre-installed steel structure roofing system without a sound-absorbing layer. From Figure 8 and Figure 9 It can be seen that, in cases where there is no or low sound absorption requirement, a thick insulation layer 4 can be installed inside and outside the open cavity of the bent plate 9. The insulation layer 4 extends from the bottom surface 91 of the bent plate 9 to a position flush with the upper surface of the upper purlin 3. A waterproof and breathable layer is laid on the upper part of the upper purlin 3 to prevent water from entering the upper part of the insulation layer and to facilitate ventilation. Since the insulation layer 4 can be directly attached to the inner wall of the bent plate 9, and the metal bent plate 9 itself has excellent vapor barrier function, a waterproof and vapor barrier layer is not required between the insulation layer 4 and the bent plate 9. In addition, since the insulation layer 4 is laid continuously from the bottom, a support plate 6 is not required at the end face 93 of the bent plate 9. The insulation layer 4 can be installed in a staggered manner.

[0058] The manufacturing and construction process of the above roofing system is as follows:

[0059] First, determine the specifications and dimensions of the roofing system and its components based on the specific building's design and construction requirements. Manufacture custom-made components, such as bent panels. Procure other common components, such as connecting bolts, insulation pads, functional layers like insulation layers, and roof panels.

[0060] Secondly, components are adapted to design and construction requirements. For example, holes are drilled in specific locations on the bent plate to facilitate bolt connection. Depending on specific working conditions, functional layers that cannot be installed later, such as waterproof and vapor-proof membranes, are added to the bent plate.

[0061] Third, connect adjacent bent plates. First, apply expanding foam to the side of the bent plate as needed, then attach the foam. Next, thread in the gaskets and bolts and tighten them. The two sides of the bent plate will press the foam together to create a space for applying the foam. Then, apply expanding foam into the space, and after it solidifies, apply a layer of sealant to the outside of the foam to seal it.

[0062] Fourth, according to specific design requirements, lay various functional layers. During the laying process, install components such as purlins and support plates as needed. After the functional layers are laid, install fixing seats on the purlins. After the fixing installation is completed, lay the roof panels.

[0063] Fifth, after erecting the roof panel modules, install the lower purlins on the outer back of the bent panels. After installation, seal the roof system and transport it to the construction site.

[0064] Sixth, after removing the roof system enclosure at the construction site, the roof is hoisted to the designated location for installation. During installation, it can be directly connected to the building's keel or truss components via the lower purlins.

[0065] The aforementioned roofing system can be pre-assembled in the manufacturing plant before being transported to the construction site for installation, thereby significantly reducing the construction period and the labor intensity of workers. When the roof is sloping, the roofing system can be connected to the building's joists or trusses via its purlins. When the roof is flat, the purlins can be connected to the beams. In this case, the pre-set connection points on the purlins can also serve as installation locations for interior hanging components.

[0066] The above description is merely a preferred embodiment of this utility model and is not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this invention should be included within the protection scope of this invention.

Claims

1. An energy-saving and low-noise pre-installed steel structure roof system, comprising a roof panel (1) and a fixing base (2); characterized in that, It also includes a top purlin (3), a heat insulation pad (5), a bent plate (9), and multiple functional layers installed between the fixed base (2) and the bent plate (9); The roof panel (1) is fixedly connected to the upper purlin (3) via a fixing seat (2); The upper purlin (3) is fixedly connected to the bending plate (9) by heat insulation pad (5); The bent plate (9) has a flat bottom surface (91), two side surfaces (92) that are perpendicular to the bottom surface (91) and bent in the same direction, and end surfaces (93) that are bent towards each other and do not contact each other at the ends of the two side surfaces (92); the bottom surface (91), side surfaces (92) and end surfaces (93) enclose an open cavity. The functional layer includes at least a thermal insulation layer (4) and a waterproof and breathable layer (15). Adjacent bent plates (9) are arranged side by side with gaps, and the sides (92) of two adjacent bent plates (9) are fixed by bolts (10); foam (12), foam (13) and sealant (14) are provided in the gap between the sides (92).

2. The energy efficient low noise pre-fabricated steel structural roofing system as claimed in claim 1, wherein, A washer (11) is also provided on the bolt (10) that passes through the side (92) of the adjacent bent plate (9); the washer (11) is located in the gap and is circumferentially wrapped with foam (12).

3. The energy efficient and low noise pre-fabricated steel roof system as claimed in claim 1, wherein, The upper purlin (3) is a zigzag purlin, and the connecting bolts are sequentially passed through the flanges on both sides of the zigzag purlin, the heat insulation pad (5) and the end face (93) of the bent plate (9) to achieve a fixed connection between the upper purlin (3) and the bent plate (9).

4. The energy efficient and low noise pre-fabricated steel roof system as claimed in claim 1, wherein, The insulation layer (4) is installed inside the open cavity of the bent plate (9) or extends from the open cavity to the outside of the end face (93); the waterproof and breathable layer (15) is located on the outdoor side of the roof system.

5. The energy efficient and low noise pre-fabricated steel roof system as claimed in claim 1, wherein, The functional layer also includes a sound-absorbing layer (7) and a waterproof vapor barrier layer (16); the sound-absorbing layer (7) is disposed inside the open cavity of the bent plate (9); the waterproof breathable layer (15) and the waterproof vapor barrier layer (16) are located on both sides of the insulation layer (4); the waterproof breathable layer (15) is located on the outdoor side, and the waterproof vapor barrier layer (16) is located on the indoor side.

6. The energy-saving and low-noise prefabricated steel structure roofing system according to claim 5, characterized in that, The insulation layer (4) is located on the outside of the end face (93) of the bent plate (9), and there is a cavity between the insulation layer (4) and the sound-absorbing layer (7).

7. The energy-saving and low-noise prefabricated steel structure roofing system according to claim 6, characterized in that, A support plate (6) is fixed on the end face (93) of the bent plate (9) and the separated part of the end face (93) is connected to support the insulation layer (4).

8. The energy efficient and low noise pre-fabricated steel roof system as claimed in claim 5, wherein, Multiple sound-absorbing holes are provided on the bottom surface (91) of the bent plate (9).

9. The energy efficient and low noise pre-fabricated steel structural roofing system as claimed in claim 8, wherein, A sound-absorbing and dust-proof layer (17) is provided between the sound-absorbing layer (7) and the open cavity inner wall of the bent plate (9).

10. The energy efficient and low noise pre-fabricated steel roof system as claimed in claim 1, wherein, It also includes a lower purlin (8); the lower purlin (8) is fixedly installed on the outside of the bottom surface (91) of the bent plate (9).

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