Composite wall structure for modular buildings

Abstract

The utility model relates to a kind of composite outer wall structure for modular building, and the composite outer wall structure includes successively from inside to outside: light steel keel wall, vacuum heat insulating board, air gap and BIPV photovoltaic curtain wall.The composite outer wall structure integrates BIPV photovoltaic curtain wall, vacuum heat insulating board insulation layer on modular building envelope structure, utilizes photovoltaic curtain wall to improve the durability of insulation layer, simultaneously, through the air gap formed fluid passage by the air vent and the air gap set behind of BIPV photovoltaic curtain wall set up up and down, the temperature of photovoltaic curtain wall board is reduced by air cooling mode, realizes photovoltaic and insulation integrated application while improving power generation efficiency.

Description

Technical Field

[0001] This utility model relates to the field of building structure technology, and in particular to a composite exterior wall structure for modular buildings. Background Technology

[0002] Modular Construction (MiC) technology is a core construction technology in the current era of prefabricated 4.0, creating three-dimensional integrated building units with functional uses. MiC involves prefabricating hexahedral modules and integrating equipment in a factory, then assembling the modules on the construction site, allowing for building houses "like assembling building blocks." It combines speed, efficiency, and intelligent integration, offering advantages such as rapid construction, short construction cycles, less wet work on site, and less pollution. All building components can be cured in the factory, minimizing seasonal impacts and allowing for year-round construction. It is a typical representative of new industrialized construction and a new type of green construction method.

[0003] In heated buildings, the building envelope accounts for approximately four-fifths of the total heat loss, with the exterior wall system accounting for more than half of that. Modular buildings differ from traditional buildings in design, production, and construction, directly impacting energy conservation and carbon reduction measures during their operation. Therefore, the design of high-performance exterior wall systems suitable for modular buildings is particularly important.

[0004] To achieve energy conservation and carbon reduction in building operations, the construction industry has seen the emergence of a series of new energy-saving and energy-efficient technologies. In terms of building thermal insulation and energy conservation, vacuum insulation panels (VIPs) are a type of vacuum insulation material composed of a core filling material and a protective surface layer. They effectively prevent heat transfer caused by air convection, significantly reducing the thermal conductivity to 1 / 10 that of traditional insulation materials, making them a preferred material for ultra-low energy consumption buildings. Their core performance relies on the vacuum state within the panels. However, during the transportation, construction, or operation of modular buildings, the panels are fragile and easily damaged by external forces (such as tool scratches, nail punctures, or compression), leading to vacuum leakage, a significant decrease in insulation performance, and potential quality issues with the building's exterior walls.

[0005] In terms of reducing carbon emissions in building operations, Building Integrated Photovoltaics (BIPV) is a technology that integrates solar photovoltaics into buildings. BIPV technology meets the requirements of architectural aesthetics, safety performance, energy conservation and emission reduction, and green environmental protection. However, due to limitations in power generation efficiency (heat generation during BIPV power generation leads to a decrease in efficiency), installation structure, installation strength, and installation cost, BIPV technology has not achieved large-scale application. Therefore, overcoming the limitations of construction methods, improving construction efficiency, and increasing power generation efficiency are the key challenges in the development of BIPV technology. Utility Model Content

[0006] In view of the above-mentioned shortcomings of the prior art, this utility model provides a composite exterior wall structure for modular buildings. This composite exterior wall structure integrates a BIPV photovoltaic curtain wall and a vacuum insulation panel into the modular building envelope. The photovoltaic curtain wall enhances the durability of the insulation layer, while the ventilation openings at the top and bottom of the BIPV photovoltaic curtain wall and the air gap layer behind it form a fluid channel, reducing the temperature of the photovoltaic curtain wall panels through air cooling. This improves power generation efficiency while achieving integrated photovoltaic and insulation applications, fully leveraging the advantages of both the vacuum insulation panel and the BIPV photovoltaic curtain wall. Furthermore, this exterior wall structure is particularly suitable for MiC technology systems, facilitating factory prefabrication, integration with MiC modules in the factory, and on-site assembly.

[0007] To achieve the above objectives, this utility model provides a composite exterior wall structure for modular buildings. The composite exterior wall structure, from the inside out, comprises: a light steel frame wall, a vacuum insulation panel, an air gap layer, and a BIPV photovoltaic curtain wall.

[0008] The light steel keel wall is installed between the upper beam and the floor slab corresponding to the lower beam in the modular building;

[0009] The vacuum insulation panel is attached to the outer side of the light steel keel wall;

[0010] The BIPV photovoltaic curtain wall is installed on the outside of the vacuum insulation panel via upper and lower embedded parts fixed to the outer sides of the upper and lower beams, respectively. Upper and lower vents are respectively located near the upper and lower embedded parts. Both the upper and lower vents can be opened and closed. When the upper and lower vents are open, the air gap layer communicates with the outside through the vents, forming a fluid channel. When the upper and lower vents are closed, the air gap layer forms a sealed cavity. This sealed cavity improves the overall thermal insulation effect of the composite exterior wall structure.

[0011] Furthermore, the light steel keel wall comprises, from the inside out: a first cement fiberboard, a light steel keel main body, a waterproof and breathable membrane, and a second cement fiberboard; wherein, the light steel keel main body is filled with insulation material, and the waterproof and breathable membrane is located between the insulation material and the second cement fiberboard. Through the above arrangement, the light steel keel wall itself possesses certain waterproof, heat-insulating, and fire-resistant functions. The insulation material can be rock wool or other building insulation materials; there are no restrictions on this.

[0012] Furthermore, the light steel keel wall comprises 1 to 3 sets of light steel keel main bodies, and the waterproof and breathable membrane is located between the insulation material filled within the outermost light steel keel main body and the second cement fiberboard. Through the above arrangement, while meeting the structural and strength requirements of modular buildings, the waterproof, thermal insulation, and fireproof functions of the light steel keel wall are further improved.

[0013] Furthermore, the vacuum insulation panel is bonded to the outer surface of the second cement fiberboard with adhesive mortar, and the joints are treated with insulating grout. The purpose of caulking the joints with insulating grout is to weaken the thermal bridging effect at the joints of the vacuum insulation panel, further reducing the thermal bridging in the light steel keel wall.

[0014] Furthermore, the outer surface of the vacuum insulation panel is coated with plastering mortar and covered with fiberglass mesh.

[0015] As one implementation, the upper and lower embedded parts have corresponding grooves on their opposite surfaces, and the BIPV photovoltaic curtain wall is installed and fixed between the upper and lower embedded parts through the corresponding grooves.

[0016] As one implementation, a vertical metal frame is installed between the upper and lower embedded parts, and a horizontal metal frame is installed on the vertical metal frame. The BIPV photovoltaic curtain wall is divided into multiple components, all of which are installed on the horizontal metal frame.

[0017] Furthermore, the upper and lower embedded parts are made of metal and are fixed to the outer surfaces of the upper and lower beams by welding, threaded connection, or detachable buckles.

[0018] Furthermore, when the upper and lower vents are open, the upper vent faces downwards and the lower vent faces upwards. This orientation of the vents facilitates the entry and exit of hot and cold air into the air gap layer. The thermal pressure generated by the heat transfer within the BIPV photovoltaic curtain wall further enhances airflow circulation, thereby reducing the heat generation phenomenon of the BIPV photovoltaic curtain wall and improving its power generation efficiency. Simultaneously, when the upper and lower vents are closed, the air gap layer forms a sealed cavity, which improves the overall thermal insulation effect of the composite exterior wall structure.

[0019] Furthermore, the upper and lower ventilation openings are opened and closed via remote control; and / or a temperature sensor is installed on the inner side of the BIPV photovoltaic curtain wall, and the opening and closing of the upper and lower ventilation openings are automatically controlled by the signal from the temperature sensor.

[0020] The beneficial effects of this utility model include:

[0021] 1. Regarding the overall building envelope, a prefabricated exterior wall that integrates energy conservation and production capacity for modular buildings is proposed, which solves the problem of high heat loss in modular building envelope systems.

[0022] 2. In the application of high-performance thermal insulation material vacuum insulation panels, they are assembled with prefabricated finished exterior walls in the factory with high precision, and external BIPV photovoltaic curtain walls are installed to form a protective function. This solves the problems of easy damage and hollowing of VIP (vacuum insulation panel) thermal insulation materials during on-site construction, easy damage during transportation of prefabricated exterior walls, and easy detachment due to environmental factors during operation and use.

[0023] 3. In the application of building-integrated photovoltaics (BIPV), it is assembled with prefabricated finished exterior walls that integrate VIPs in the factory with high precision. Openable ventilation openings are set at the top and bottom of the BIPV photovoltaic curtain wall, and a heat dissipation air gap layer is reserved in combination with the metal frame system. This solves the problems of poor heat dissipation and low power generation efficiency of BIPV photovoltaic curtain walls when the temperature is high, as well as the difficulties and low precision of on-site installation. Attached Figure Description

[0024] Figure 1 This is a vertical sectional view of a composite exterior wall structure for modular buildings in one embodiment of the present invention.

[0025] Figure 2 This is a cross-sectional schematic diagram of a composite exterior wall structure for modular buildings in one embodiment of the present invention.

[0026] [Explanation of Labels in the Attached Image]

[0027] 1-Modular building upper beam; 2-Modular building roof; 3-Modular building lower beam; 4-Modular building floor slab; 5-Light steel keel main body; 6-First cement fiberboard and second cement fiberboard; 7-Light steel keel wall; 8-Vacuum insulation board; 9-Air gap layer; 10-BIPV photovoltaic curtain wall; 11-Upper ventilation opening; 12-Lower ventilation opening; 13-Upper embedded part; 14-Lower embedded part. Detailed Implementation

[0028] To better understand the above technical solutions, exemplary embodiments of the present invention will be described in more detail below with reference to the accompanying drawings.

[0029] While exemplary embodiments of the present invention are shown in the accompanying drawings, it should be understood that the present invention may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the present invention can be understood more clearly and thoroughly, and that the scope of the present invention can be fully conveyed to those skilled in the art.

[0030] In the description of this utility model, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0031] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction 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.

[0032] In this utility model, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "beneath" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0033] In the description of this specification, the terms "one embodiment," "some embodiments," "embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0034] Example 1

[0035] like Figure 1 and Figure 2 The diagram shows a cross-sectional view of a composite exterior wall structure for modular buildings in one embodiment of the present invention.

[0036] Based on a hexahedral modular building, the composite exterior wall structure consists of, from the inside out: a light steel keel wall 7, a vacuum insulation panel 8, an air gap layer 9, and a BIPV photovoltaic curtain wall 10.

[0037] The light steel keel wall 7 is installed between the upper beam 1 and the floor slab 4 corresponding to the lower beam 3 in the modular building;

[0038] Vacuum insulation panel 8 is attached to the outer side of light steel keel wall 7;

[0039] The BIPV photovoltaic curtain wall 10 is installed on the outside of the vacuum insulation panel 8 by upper embedded parts 13 and lower embedded parts 14, which are respectively fixed to the outer side of the upper beam 1 and the lower beam 3. Upper vents 11 and lower vents 12 are respectively provided near the upper embedded parts 13 and the lower embedded parts 14. Both the upper vents 11 and the lower vents 12 can be opened and closed. When the upper vents 11 and the lower vents 12 are open, the air gap layer 9 is connected to the outside through the upper vents 11 and the lower vents 12 to form a fluid channel. When the upper vents 11 and the lower vents 12 are closed, the air gap layer 9 forms a sealed cavity.

[0040] Example 2

[0041] Based on Example 1, the preparation of this exterior wall structure includes the following aspects.

[0042] (1) The hexahedral modular building consists of structural beams, columns, and enclosures, all integrated in the factory. The factory first completes the casting or installation of beams and columns, followed by the installation of light steel keel wall panels. On-site, it is connected to surrounding modules via bolts, shear cones, and connecting plates. This hexahedral modular building can be a steel structure modular building or a concrete modular building. In this embodiment, the modular building is a steel structure.

[0043] (2) The light steel keel wall 7 (from the inside to the outside) includes the first cement fiber board 6, the light steel keel body 5 (filled with rock wool), the waterproof and breathable membrane (with self-adhesive backing), and the second cement fiber board 6 assembled in sequence. Through the above structure, the light steel keel wall itself can achieve the functions of waterproof, heat preservation and fireproof.

[0044] (3) The vacuum insulation board 8 is bonded to the uncoated surface of the light steel keel wall 7 with adhesive mortar, and the board joints are treated with thermal insulation mortar. The outer side is coated with plastering mortar (with fiberglass mesh attached) to reduce the thermal bridging effect of the light steel keel wall 7.

[0045] (4) The dimensions of the upper and lower embedded metal parts 13 and 14 are determined by structural calculations to determine the thickness of the air gap 9 between the vacuum insulation board 8 and the BIPV photovoltaic curtain wall 10.

[0046] (5) The BIPV photovoltaic curtain wall 10 is fixed to the upper and lower beams of the modular building by embedded parts and vertical metal frame, and the installation of the entire BIPV photovoltaic curtain wall is achieved by using horizontal metal frame (when the BIPV photovoltaic curtain wall includes multiple components).

[0047] The BIPV photovoltaic (PV) curtain wall is equipped with openable ventilation holes at the top and bottom, utilizing thermal pressure to dissipate heat during power generation. The entire BIPV photovoltaic curtain wall can be integrated with MiC in the factory, or it can be installed and modified later in the operation period according to project needs.

[0048] When the upper and lower vents are open, the upper vent faces downward and the lower vent faces upward, which facilitates the entry and exit of hot and cold air into the air gap layer and achieves better airflow circulation. At the same time, when the upper and lower vents are closed, the air gap layer forms a sealed cavity, which can improve the overall thermal insulation effect of the composite exterior wall structure.

[0049] The upper and lower ventilation openings can be opened and closed remotely, for example, by actively controlling the opening and closing through the building structure control center, and by using devices such as cylinders or electric cylinders installed on the metal frame; or, the BIPV photovoltaic curtain wall is equipped with a temperature sensor on the inside, and the opening and closing of the upper and lower ventilation openings is automatically controlled by the signal emitted by the temperature sensor when the curtain wall temperature reaches a set threshold.

[0050] Example 3

[0051] In this embodiment, a single-story steel structure modular building is used as the basis, and the light steel keel wall, VIP, and BIPV factory are integrated into one unit, which can be used immediately after construction.

[0052] The structural layers (from the inside out) are as follows: 9mm cement fiberboard, 50mm light steel keel main body (filled with 50mm thick rock wool), 75mm light steel keel main body (filled with 50mm thick rock wool), waterproof and breathable membrane (with self-adhesive backing), 9mm cement fiberboard, 5mm adhesive mortar, 40mm VIP insulation board, 5mm plastering mortar composite fiberglass mesh, air heat dissipation layer (built-in metal frame system), and BIPV photovoltaic curtain wall (including upper and lower ventilation openings).

[0053] On sunny days, the BIPV curtain wall opens its upper and lower ventilation openings to cool the BIPV curtain wall and improve power generation efficiency; on cloudy days and at night, the upper and lower ventilation openings are closed to seal the air gap and improve the thermal insulation effect. The overall thermal performance of the exterior wall is improved by 60%, and the high-performance energy-saving integrated building envelope structure enables modular buildings to achieve 100% energy self-sufficiency.

[0054] The following beneficial effects can be achieved through the practical application of this technical solution:

[0055] (1) Prefabricated rapid installation: 100% of the exterior wall cladding structure of single-story buildings is integrated in the factory and can be used immediately on site; 95% of the exterior wall cladding structure of multi-story buildings is integrated in the factory and only simple curtain wall splicing treatment is required on site.

[0056] (2) Fireproof, heat preservation and energy saving: The application of Class A fireproof rock wool inside the light steel keel wall and Class A fireproof VIP vacuum insulation board outside improves the fireproof performance of the whole wall; at the same time, the rock wool, vacuum insulation board and air gap layer work together to improve the thermal performance of the whole wall by 60% compared with the energy saving standard, greatly improving the energy saving benefits.

[0057] (3) Low-carbon building: By applying BIPV photovoltaic curtain walls on all four sides of the exterior walls, and taking into account the differences in solar radiation in different regions and building types, the building's energy consumption can be covered, creating a low-carbon building;

[0058] (4) High-efficiency sound insulation: The air gap in the closed state plays the role of sound wave reflection and dissipation; the wall panel is filled with porous sound-absorbing rock wool, and the sound waves enter the material through the micropores; the interior causes the air in the gap to vibrate, and due to its viscous resistance, the friction between the air and the pore wall and the heat conduction, the sound energy is consumed, and the wall achieves high-efficiency sound insulation.

[0059] (5) Easy installation of BIPV curtain wall: The entire BIPV curtain wall can be integrated with MiC in the factory, or it can be installed and modified in accordance with the project requirements and the zero carbon requirements in the later stage of operation without affecting the normal use of the main body of the building envelope.

[0060] In addition, the modular building in this solution can be customized according to the actual project requirements, choosing a steel / concrete structure system; the number of layers of light steel keel walls, keel main body, and rock wool can be stacked according to the building's sound insulation requirements; the thickness of the vacuum insulation panels can be set according to the energy-saving requirements of the building's thermal zone; the installation stage of the BIPV curtain wall can be adjusted according to the actual needs of the project, and it can be integrated with the MiC main body during the production stage, or it can be retrofitted later according to zero-carbon requirements during operation; the style of the BIPV curtain wall can be selected and replaced according to the customer's requirements for appearance and power generation; the thickness of the air gap layer can be adjusted according to the requirements of the BIPV curtain wall installation structure, and the size of the embedded parts can be adjusted.

[0061] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make modifications, alterations, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A composite exterior wall structure for modular buildings, characterized in that, The composite exterior wall structure, from the inside out, comprises: a light steel keel wall, vacuum insulation panels, an air gap layer, and a BIPV photovoltaic curtain wall. The light steel keel wall is installed between the upper beam and the floor slab corresponding to the lower beam in the modular building; The vacuum insulation panel is attached to the outer side of the light steel keel wall; The BIPV photovoltaic curtain wall is installed on the outside of the vacuum insulation panel through upper and lower embedded parts fixed to the outer sides of the upper and lower beams, respectively. Upper and lower vents are provided near the upper and lower embedded parts, respectively. The upper and lower vents can be opened and closed. When the upper and lower vents are open, the air gap layer is connected to the outside through the upper and lower vents to form a fluid channel. When the upper and lower vents are closed, the air gap layer forms a sealed cavity.

2. The composite exterior wall structure for modular buildings according to claim 1, characterized in that, The light steel keel wall comprises, from the inside out: a first cement fiberboard, a light steel keel body, a waterproof and breathable membrane, and a second cement fiberboard; wherein, the light steel keel body is filled with thermal insulation material, and the waterproof and breathable membrane is located between the thermal insulation material and the second cement fiberboard.

3. The composite exterior wall structure for modular buildings according to claim 2, characterized in that, The light steel keel wall includes 1 to 3 sets of light steel keel main bodies, and the waterproof and breathable membrane is located between the insulation material filled in the outermost light steel keel main body and the second cement fiberboard.

4. The composite exterior wall structure for modular buildings according to claim 1, characterized in that, The vacuum insulation board is bonded to the outer side of the second cement fiberboard with adhesive mortar, and the joints are treated with thermal insulation grout.

5. The composite exterior wall structure for modular buildings according to claim 4, characterized in that, The outer surface of the vacuum insulation panel is coated with plastering mortar and covered with fiberglass mesh.

6. The composite exterior wall structure for modular buildings according to claim 1, characterized in that, The upper and lower embedded parts have corresponding grooves on their opposite surfaces, and the BIPV photovoltaic curtain wall is installed and fixed between the upper and lower embedded parts through the corresponding grooves.

7. The composite exterior wall structure for modular buildings according to claim 1, characterized in that, A vertical metal frame is installed between the upper and lower embedded parts, and a horizontal metal frame is installed on the vertical metal frame. The BIPV photovoltaic curtain wall is divided into multiple components, all of which are installed on the horizontal metal frame.

8. The composite exterior wall structure for modular buildings according to claim 1, characterized in that, The upper and lower embedded parts are made of metal and are fixed to the outer sides of the upper and lower beams by welding, threaded connection or detachable buckles.

9. The composite exterior wall structure for modular buildings according to claim 1, characterized in that, When the upper and lower vents are opened, the upper vent faces downwards and the lower vent faces upwards.

10. The composite exterior wall structure for modular buildings according to claim 1, characterized in that, The upper and lower ventilation openings are opened and closed remotely; and / or a temperature sensor is installed on the inside of the BIPV photovoltaic curtain wall, and the opening and closing of the upper and lower ventilation openings are automatically controlled by the signal from the temperature sensor.

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