Composite wall panel and prefabricated cabin

Abstract

The application belongs to the technical field of power equipment, and particularly relates to a composite wallboard and a prefabricated cabin. The composite wallboard comprises a decorative layer, a structural support layer and a non-metal protective layer arranged in sequence from inside to outside. The protective layer is configured as the outermost surface of the composite wallboard. By arranging the non-metal protective layer as the outermost surface, the corrosion resistance of the non-metal protective layer effectively reduces the problem that the wallboard is easily damaged in a corrosive environment. Meanwhile, the composite structure formed by the non-metal protective layer and the internal structural layer effectively reduces the thermal conductivity of the overall structure, and by blocking the continuous heat bridge path formed by the metal outer wall in the related art, the heat preservation performance of the cabin body is significantly improved.

Description

Technical Field

[0001] This application belongs to the field of power equipment technology, specifically relating to a composite wall panel and a prefabricated cabin. Background Technology

[0002] Prefabricated modules (such as power distribution equipment modules and substation prefabricated modules) are critical facilities in power systems, and their structural reliability directly affects the safe and stable operation of the internal equipment. Currently, these prefabricated modules generally use steel structural wall panels.

[0003] However, steel wall panels face severe challenges in highly corrosive environments such as industrial areas and coastal regions (C5 level). Steel itself is prone to electrochemical reactions with corrosive media in the environment (such as salt spray and humid air), leading to rapid erosion of the wall panels. This corrosion not only affects the appearance but, more seriously, continuously weakens the mechanical properties of the wall panels, resulting in a decrease in the overall structural strength of the compartment and posing a safety hazard to expensive electrical equipment inside. Furthermore, addressing corrosion requires frequent maintenance and replacement of the steel wall panels, significantly increasing the total life-cycle cost and operational burden. Utility Model Content

[0004] The purpose of this application is to provide a composite wall panel and a prefabricated cabin, which can improve the long-term durability and structural safety of the prefabricated cabin wall panel in a highly corrosive environment.

[0005] The first aspect of this application provides a composite wall panel for use in prefabricated cabins, the composite wall panel comprising a decorative layer, a structural support layer, and a non-metallic protective layer arranged sequentially from the inside to the outside, the protective layer being configured as the outermost surface of the composite wall panel.

[0006] In one exemplary embodiment of this application, the protective layer is a dense HPL (High-Pressure Laminate) board.

[0007] In one exemplary embodiment of this application, the protective layer and the structural support layer are slidably connected.

[0008] In an exemplary embodiment of this application, the structural support layer has guide grooves on opposite sides of one side facing the protective layer. The guide grooves extend along a first direction and have openings facing a second direction, which intersect the second direction. The corresponding side of the protective layer is embedded in the guide groove through the opening and can slide in the first direction.

[0009] In one exemplary embodiment of this application, the structural support layer is provided with guide grooves on all four edges, and the protective layer is embedded in the guide grooves.

[0010] In one exemplary embodiment of this application, the structural support layer includes an alternately arranged first portion and a second portion, the first portion being connected to the inner side of the protective layer, and the second portion having a gap with the inner side of the protective layer to form a cavity.

[0011] In one exemplary embodiment of this application, a thermal insulation layer is further provided between the decorative layer and the structural support layer.

[0012] A second aspect of this application provides a prefabricated cabin, comprising: two parallel wall columns; and a composite wall panel as described in any of the preceding claims, wherein the structural support layer, the protective layer, and the decorative layer are disposed between the two wall columns.

[0013] In another exemplary embodiment of this application, the opposite side walls of the two wall columns are formed with a stepped structure, the stepped structure including a first mounting position and a second mounting position distributed from the outside to the inside; the first mounting position is used to accommodate the structural support layer and the protective layer; the second mounting position is used to accommodate the decorative layer.

[0014] In another exemplary embodiment of this application, the wall column includes a groove extending in a first direction, the grooves on two wall columns are disposed opposite to each other to form the second mounting position, and the decorative layer is inserted into the second mounting position.

[0015] The composite wall panel and prefabricated cabin proposed in this application have at least the following beneficial effects: The composite wall panel of this application includes a decorative layer, a structural support layer, and a non-metallic protective layer arranged sequentially from the inside out, with the protective layer configured as the outermost surface of the composite wall panel. By setting the non-metallic protective layer as the outermost surface, its corrosion-resistant properties effectively reduce the problem of the wall panel being easily damaged in corrosive environments. At the same time, the composite structure formed by the non-metallic protective layer and the internal structural layer effectively reduces the thermal conductivity of the overall structure, and by blocking the continuous thermal bridge path formed by the metal outer wall in related technologies, it significantly improves the thermal insulation performance of the cabin.

[0016] Other features and advantages of this application will become apparent from the following detailed description, or may be learned in part from practice of this application.

[0017] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0018] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. It is obvious that the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort.

[0019] Figure 1 A cross-sectional structural schematic diagram of a prefabricated cabin provided in some embodiments is shown.

[0020] Figure 2 It shows Figure 1 An enlarged schematic diagram of the structure combining the middle protective layer and the guide groove.

[0021] Figure 3 A cross-sectional structural diagram of a wall column provided in some embodiments is shown.

[0022] Figure 4 A front view schematic diagram of a protective plate disposed in a guide groove according to some embodiments is shown.

[0023] Explanation of reference numerals in the attached figures: 10. Precast cabin; 100. Composite wall panel; 110. Decorative layer; 120. Structural support layer; 121. First part; 122. Second part; 130. Protective layer; 140. Guide channel; 141. Opening; 150. Insulation layer; 200. Wall column; 210. First mounting position; 220. Second mounting position; 230. Groove; 300. Base; 400. Top frame. Detailed Implementation

[0024] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the examples set forth herein; rather, these embodiments are provided to make this application more comprehensive and complete, and to fully convey the concept of the exemplary embodiments to those skilled in the art.

[0025] In this application, 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 technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0026] In this application, unless otherwise expressly specified and limited, the terms "assembly," "connection," 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. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0027] Furthermore, the described features, structures, or characteristics can be combined in any suitable manner in one or more embodiments. Numerous specific details are provided in the following description to give a thorough understanding of embodiments of this application. However, those skilled in the art will recognize that the technical solutions of this application can be practiced without one or more of the specific details, or other methods, components, apparatuses, steps, etc., can be employed. In other instances, well-known methods, apparatuses, implementations, or operations are not shown or described in detail to avoid obscuring various aspects of this application.

[0028] Prefabricated cabins in related technologies generally use steel wall panels, which are easily corroded in the C5 highly corrosive environment, leading to a decrease in cabin strength and requiring frequent maintenance. At the same time, there is a thermal bridging effect between the steel wall panels and the insulation layer, resulting in poor insulation performance, and the appearance is monotonous and poorly integrated with the environment.

[0029] Therefore, see Figure 1 As shown in the figure, this application embodiment provides a composite wall panel 100, which adopts a multi-layer composite structure, including a decorative layer 110, a structural support layer 120, and a non-metallic protective layer 130 from the inside out. By setting the non-metallic protective layer 130 as the outermost surface, its corrosion resistance effectively reduces the problem of the wall panel being easily damaged in corrosive environments; at the same time, the composite structure formed by the non-metallic protective layer 130 and the internal structural layer effectively reduces the thermal conductivity of the overall structure, and significantly improves the thermal insulation performance of the cabin by blocking the continuous thermal bridge path formed by the metal outer wall in related technologies.

[0030] In some embodiments, the decorative layer 110 may be made of antibacterial galvanized steel sheet, color steel sheet, or other special wall panels for computer rooms; it may also be made of rock wool board for both insulation and decoration. The surface of the decorative layer 110 may be treated with antibacterial agents to meet the environmental requirements of the power equipment compartment.

[0031] In some embodiments, the structural support layer 120 may be made of corrugated board, which provides sufficient rigidity and strength through its unique wave-shaped structure. The wave height of the corrugated board can be adjusted according to the load-bearing requirements, and is usually set in the range of 10-50mm.

[0032] In some embodiments, the protective layer 130 can be made of a non-metallic material, such as HPL (High-Pressure Laminate) board, with a thickness of 5 to 10 mm, for example, 8 mm. It is formed by laminating decorative colored paper impregnated with melamine resin with multiple layers of kraft paper impregnated with phenolic resin, and then pressing them under high temperature of 150°C and high pressure of 1430 psi. The thickness can be adjusted from 0.6 mm to 25 mm. By adjusting the number of kraft paper sheets, a thickness variation from 0.6 mm to 25 mm can be achieved to meet the needs of different application scenarios.

[0033] This special manufacturing process gives it a dense surface structure and uniform internal organization, endowing the panels with excellent wear and impact resistance as well as stable weather resistance. Its surface colored paper layer offers a variety of color options, including solid colors, natural colors, and metallic colors, achieving single-sided or double-sided decorative effects, fully meeting the requirements of the prefabricated cabin 10's appearance and environmental harmony, and enhancing its aesthetics.

[0034] In terms of physical properties, HPL (High-Pressure Laminate) sheets possess high elastic modulus, tensile strength, and flexural strength, giving them excellent impact resistance. The high-density core material provides the sheets with high anchor pull-out strength, making them particularly suitable for applications using bolts or inserts. Thanks to their dense structure, the sheets can be directly machined using standard carbon steel alloy tools for drilling, hammering, sanding, and cutting. They can also be processed into any shape using CNC machines, allowing for precision operations such as chamfering and drilling.

[0035] In practical applications, HPL (High-Pressure Laminate) boards exhibit exceptional durability. Their weather resistance allows them to maintain stable performance even after prolonged exposure to sunlight, rain, and temperature variations, without fading, deformation, or cracking. Regarding fire safety, the boards possess excellent fire resistance; they will not melt, drip, or explode when exposed to fire, achieving the highest fire rating among organic materials, and do not release toxic or corrosive gases.

[0036] In terms of maintenance, HPL (High-Pressure Laminate) panels, with their self-cleaning properties and dense surface that does not easily attract dust, require cleaning only once every 3-4 years, unlike typical curtain walls which need annual cleaning. This significantly reduces maintenance costs. Cleaning only requires rainwater or organic solvents and has no impact on the color.

[0037] In some embodiments, see Figure 1 and Figure 2As shown, the structural support layer 120 has guide grooves 140 extending along a first direction on opposite sides facing the protective layer 130. Each guide groove 140 has an opening 141 facing a second direction. The corresponding side of the protective layer 130 is embedded in the guide groove 140 through the opening 141 and can slide along the first direction. The first and second directions intersect, with the first direction being the height direction (i.e., longitudinal direction) of the composite wall panel 100 and the second direction being the length direction (i.e., transverse direction) of the composite wall panel 100. By setting longitudinal guide grooves 140 with lateral openings 141 on both sides of the structural support layer 120, the protective layer 130 can be accurately positioned and firmly installed through simple operation of lateral embedding and longitudinal sliding. This not only greatly improves construction efficiency, but also effectively ensures the flatness of the exterior wall and the integrity of the structure through continuous mechanical interlocking. At the same time, its tightly matched groove rail structure forms a physical barrier, which significantly enhances the corrosion resistance and sealing performance of the joints. Furthermore, by reserving sliding allowance, it adapts to thermal expansion and contraction and supports quick disassembly of single panels, achieving multiple advantages such as convenient installation, efficient maintenance and long-term reliability.

[0038] It should be noted that, see Figure 2 As shown, the cross-sectional shape of the guide groove 140 can be designed as C-shaped, U-shaped or L-shaped, with a depth of 5-20mm and a width of 3-15mm.

[0039] In some embodiments, for further reinforcement of the fixation, see [link to documentation]. Figure 4 As shown, guide grooves 140 can be provided on all four edges of the structural support layer 120, so that the protective layer 130 is embedded therein, forming a complete circumferential positioning. The guide grooves 140 can be made of aluminum alloy, stainless steel or engineering plastic, and are fixed to the structural support layer 120 by riveting, welding or bonding.

[0040] In some embodiments, see Figure 1 As shown, in terms of structural design, the structural support layer 120 may include alternating first parts 121 and second parts 122. The first part 121 is directly connected to the inner side of the protective layer 130, providing the main support; the second part 122 maintains a certain gap with the inner side of the protective layer 130, forming a thermal break cavity. These cavities are filled with still air, which can effectively block the thermal bridging effect. In addition, this continuous cavity structure also physically constitutes a barrier layer, which can effectively delay the intrusion path of external moisture or humidity, and reduce the accumulation of liquid water in the cavity through reasonable flow guidance design. It can be combined with the sealing measures of the guide grooves 140 around the protective layer 130 to further enhance the water tightness of the overall wall panel, forming a dual guarantee of thermal management and waterproof sealing.

[0041] In some embodiments, the height of the cavity can be 5-30mm, which can be adjusted according to the insulation requirements.

[0042] In some embodiments, see Figure 1 As shown, an insulation layer 150 can also be installed between the decorative layer 110 and the structural support layer 120. The low thermal conductivity of the insulation layer 150 effectively blocks the heat transfer path between the interior and exterior of the cabin, significantly improving the cabin's thermal insulation performance. This insulation layer 150 can be made of materials such as polyurethane or rock wool, which possess both thermal insulation and flame-retardant properties. It not only forms a continuous and complete insulation barrier, reducing localized thermal bridging, but its dense structure also acts as a physical barrier, blocking the spread of external fire. Simultaneously, the composite structure formed by the insulation layer 150 and the metal structural layer further improves the fire resistance limit of the wall, providing multiple layers of safety protection for the prefabricated cabin 10 while achieving high energy efficiency.

[0043] In some embodiments, the thickness of the insulation layer 150 can be 20-80 mm. It can be laminated with adjacent layers by foaming, bonding or mechanical fixing.

[0044] It should be noted that the second part 122 of the structural support layer 120 is embedded inside the insulation layer 150, so that the insulation material can play the dual functions of filling support and high-efficiency heat insulation at the same time. It not only enhances the structural integrity and deformation resistance of the wall panel by tightly wrapping it, but also reduces the thermal bridge path formed by the metal frame, thereby achieving synergistic optimization of structural strength and thermal insulation performance.

[0045] See Figure 1 and Figure 3 As shown in the illustration, this application embodiment also provides a prefabricated cabin 10 including the composite wall panel 100. The prefabricated cabin 10 further includes two parallel wall columns 200, with the composite wall panel 100 disposed between the two wall columns 200. The two parallel wall columns 200 provide a stable installation boundary and load-bearing frame for the composite wall panel 100, ensuring accurate positioning of the wall panel in the cabin and overall structural rigidity.

[0046] In some embodiments, the wall column 200 may be made of cold-formed steel, square tubing, or C-shaped steel, and its inner sidewalls form a stepped structure. The stepped structure includes a first mounting position 210 and a second mounting position 220 distributed from the outside to the inside. The first mounting position 210 is narrower and is used to accommodate the structural support layer 120, the insulation layer 150, and the protective layer 130. The second mounting position 220 is wider and is used to accommodate the decorative layer 110.

[0047] By dividing the space into first installation position 210 and second installation position 220, the exterior wall protection unit and the interior wall decoration unit are completely decoupled during installation. The narrow first installation position 210 provides a compact fitting space for the structural support layer 120, insulation layer 150, and protective layer 130, ensuring the stable positioning and sealing of the external modules; the wide second installation position 220 provides an independent installation channel for the decorative layer 110, effectively reducing mutual interference during the construction of the inner and outer layers. This layered positioning design not only significantly improves the efficiency of wall panel assembly, but also blocks the thermal bridge transmission path through physical isolation, while reserving concealed space for pipeline layout, enabling the prefabricated cabin 10 to achieve synergistic optimization in terms of structural strength, thermal performance, and space utilization.

[0048] Among them, see Figure 3 As shown, a groove 230 extending along the first direction can be provided on the wall column 200 (i.e., the groove 230 extends longitudinally). The depth of the groove 230 is generally 10-30mm. The grooves 230 of the two wall columns 200 are arranged opposite to each other to form the second mounting position 220, and the decorative layer 110 is fixed therein by plugging.

[0049] Understandably, the second mounting position 220, formed by the relatively arranged longitudinal grooves 230, provides a precise positioning reference and a concealed insertion channel for the decorative layer 110. This not only enables rapid screwless installation of the interior decorative panel, but also effectively absorbs component processing and installation errors through the enclosing space formed by the depth of the grooves 230. At the same time, it hides the seams and enhances the integrity and flatness of the interior system, and forms a physical barrier in the structure to help block the transmission path of sound bridges and thermal bridges.

[0050] In addition, the structural support layer 120 can be fixed to the wall column 200 by welding, bolting or riveting to ensure the overall strength and airtightness of the cabin.

[0051] In actual installation, the structural support layer 120 can be first fixed to the wall column 200 by welding. Then, the guide groove 140 is installed on the outside of the structural support layer 120, and the protective layer 130 is slid into the guide groove 140 from the side. The decorative layer 110 can be installed quickly using a male-female groove structure, that is, the side of the decorative layer 110 is inserted into the groove 230 of the wall column 200, and fixed by plugging and connecting. This installation method not only ensures installation accuracy but also greatly improves construction efficiency.

[0052] It's worth noting that the total thickness of this composite wall panel 100 structure is no less than 120mm, for example, 128mm. Through a four-layer composite wall design, both the strength of the wall panel and its corrosion resistance and aesthetics are significantly improved. The protective layer 130, made of HPL (High-Pressure Laminate) board, has excellent weather resistance; its appearance and properties are unaffected by sunlight, rain, wind erosion, or rapid temperature changes. This wall panel has a service life of over 20 years in a C5 environment and is self-cleaning, generally requiring cleaning only once every 3-4 years, significantly reducing maintenance costs.

[0053] In addition, the composite wall panel 100 can be provided with other functional layers as needed, such as adding a self-cleaning coating to the outside of the protective layer 130, adding a vapor barrier to the inside of the insulation layer 150, and adding an electromagnetic shielding layer to the surface of the decorative layer 110.

[0054] In some embodiments, see Figure 4 As shown, the prefabricated cabin 10 may also include structures such as a base 300 and a top frame 400. The composite wall panel 100 is set between two wall columns 200. The bottom of the wall column 200 is fixedly connected to the base 300, and the top is connected to the top frame 400, together forming a complete load-bearing system of the prefabricated cabin 10.

[0055] The base 300 can be a frame structure made of welded or cold-formed steel, providing a stable installation foundation for the wall column 200 and fixing it to the foundation through embedded parts or anchors. The top frame 400 can be a rectangular frame structure corresponding to the wall column 200, connected to the top of the wall column 200 by welding or bolts to form a complete box structure. This frame system of base 300, wall column 200, and top frame 400 not only provides a reliable installation boundary for the composite wall panel 100, but also effectively transfers roof loads and wind loads to the foundation through overall stress design, ensuring the overall structural stability of the prefabricated cabin 10.

[0056] During actual installation, the base 300 is first positioned and leveled, followed by the installation of the wall columns 200, ensuring their verticality. The pre-installed composite wall panel 100 is then embedded between the two wall columns 200. The structural support layer 120 is fixed to the wall columns 200 by welding, the protective layer 130 is installed via the guide channel 140 system, and the decorative layer 110 is fixed via the mounting positions on the inner side of the wall columns 200. Finally, the top frame 400 is installed to complete the overall structural enclosure. This modular construction method significantly improves installation efficiency and facilitates rapid on-site assembly.

[0057] The prefabricated cabin 10 structure, through the synergistic effect of the base 300, wall column 200 and top frame 400, provides the composite wall panel 100 with the optimal working environment, which not only ensures the full performance of the wall panel, but also ensures the overall structural strength and safety of the prefabricated cabin 10. It is particularly suitable for application scenarios with high requirements for structural reliability and environmental adaptability, such as power equipment and data centers.

[0058] In the description of this specification, references to terms such as "some embodiments," "exemplarily," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. The illustrative expressions of the above terms in this specification do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in a suitable manner in any 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.

[0059] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application. Therefore, any changes or modifications made in accordance with the claims and description of this application should fall within the scope of this patent application.

Claims

1. A composite wall panel for use in prefabricated cabins, characterized in that, The composite wall panel includes a decorative layer, a structural support layer, and a non-metallic protective layer arranged sequentially from the inside to the outside, with the protective layer configured as the outermost surface of the composite wall panel; The protective layer is a dense HPL (High-Pressure Laminate) board; The protective layer and the structural support layer are slidably connected; The structural support layer has guide grooves on opposite sides of the side facing the protective layer. The guide grooves extend along a first direction and have openings facing a second direction. The first direction and the second direction intersect. The corresponding side of the protective layer is embedded in the guide groove through the opening and can slide in the first direction.

2. The composite wall panel according to claim 1, characterized in that, The structural support layer is provided with guide grooves on all four edges, and the protective layer is embedded in the guide grooves.

3. The composite wall panel according to any one of claims 1 to 2, characterized in that, The structural support layer includes an alternately arranged first part and a second part, the first part being connected to the inner side of the protective layer, and the second part having a gap with the inner side of the protective layer to form a cavity.

4. The composite wall panel according to any one of claims 1 to 2, characterized in that, An insulation layer is also provided between the decorative layer and the structural support layer.

5. A prefabricated cabin, characterized in that, include: Two wall columns arranged parallel to each other; as well as The composite wall panel according to any one of claims 1 to 4, wherein the structural support layer, the protective layer and the decorative layer are disposed between the two wall columns.

6. The prefabricated cabin according to claim 5, characterized in that, The two wall columns have a stepped structure formed on their opposite side walls, and the stepped structure includes a first mounting position and a second mounting position distributed from the outside to the inside. The first mounting position is used to accommodate the structural support layer and the protective layer; the second mounting position is used to accommodate the decorative layer.

7. The prefabricated cabin according to claim 6, characterized in that, The wall column includes a groove extending in a first direction, and the grooves on two wall columns are arranged opposite to each other to form the second mounting position, and the decorative layer is inserted into the second mounting position.

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