CN101687569B - 具有咬梢的塑料托盘及其制造方法 - Google Patents

具有咬梢的塑料托盘及其制造方法 Download PDF

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CN101687569B
CN101687569B CN2008800104535A CN200880010453A CN101687569B CN 101687569 B CN101687569 B CN 101687569B CN 2008800104535 A CN2008800104535 A CN 2008800104535A CN 200880010453 A CN200880010453 A CN 200880010453A CN 101687569 B CN101687569 B CN 101687569B
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维斯奴·奈杜
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F16B21/086—Releasable fastening devices with snap-action in which the stud, pin, or spigot has a resilient part the shank of the stud, pin or spigot having elevations, ribs, fins or prongs intended for deformation or tilting predominantly in a direction perpendicular to the direction of insertion
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Abstract

一种托盘，其具有一个上层和一个下层。所述上层具有咬梢开口。第一接合构件从所述上层向下凸出，而各个第一接合构件具有一个外套筒环绕各自的咬梢开口。第二接合构件从所述下层向上突出，而各个第二接合构件包括一个内套筒以及定位于其中的一个咬梢接收腔。所述内套筒容纳所述外套筒而定义出接合所述上层和下层的支撑块。咬梢插入到在所述上层的所述咬梢开口中。各个咬梢具有一个头部以卡合一个咬梢开口以及具有通过所述咬梢接收腔延伸的分隔尖端以卡合与其有关的所述内套筒的背面。

Description

具有咬梢的塑料托盘及其制造方法
技术领域
本发明涉及用于材料处理的托盘领域，且进一步为特别设计用在堆高机(forklift)设备的多件塑料托盘。
背景技术
托盘习惯上用于传输与储存货品。典型地，一个托盘包括一个上层和一个下层并由支撑块分开。托盘传统上为木材所制得。尽管在成本条件上为有利，然而木制托盘仍有很多不利条件。例如：它们容易受到破损且因此仅可在短时间内重复使用。况且，木制托盘也难以维持其卫生条件，从而限制了它们在对卫生设施为重要的应用中的可用性，例如在处理食物上的应用。
随着塑料工业的成长，各式各样的塑料已被进行研究以确定它们是否适合用于生产托盘。塑料托盘可以容易被塑模成形且较木制托盘较为牢固且具较轻的重量。况且，它们可以用可循环材料制得。再者，塑料托盘相较于木制托盘更为耐用。
在耐用性上，塑料托盘开始重复接触到起重机的锋利金属尖齿(tine)，其也称为托盘搬运车(pallet jack)。所述支撑块分开所述上层和下层而使该托盘的任何部分遇到最强烈的磨损。此外，如果托盘搬运车的尖齿在所述上层和下层间插的太深，致使所述托盘搬运车的轮子在所述下层静止不动，且当所述托盘搬运车的尖齿被抬起，随后所述上层变得从所述下层分离。从所述下层分离出的所述上层而产生的损坏要求将所述上层替换，且如果损坏太大，接着整个托盘必须要被替换。
如果仅有支撑块被所述托盘搬运车损坏，接着他们可能会依其成本远小于替换整个托盘而替换掉支撑块。例如：美国专利第5,413,052号揭示了一种具有上层和下层的塑料托盘，而在其中有可替换的支撑块。所述支撑块包括具有定位于所述上层的加强部分下的支撑构件壁的八角柱子。所述柱子也具有带有平行于所述支撑构件壁的中央螺栓(bolt)孔的套筒。所述上层容纳在嵌壁式口袋中的所述支撑块。塑料托盘偷过所述上层、各个柱子以及所述下层插入。塑料T型螺母(T-nut)用在将螺栓支撑到适当地方。
在美国专利第4,843,976号中，塑料托盘具有由支撑块互相连结的相同的上层和下层。各个支撑块具有由辐条(spoke)互联的中央核心以及周围套筒。所述核心具有延伸到所述套筒的相反端与锁上基底层和载货层的有弹性卷标。揭露在美国专利第5,791,261号中的塑料托盘也是揭示一种具有弹性卷标的用途在一起以支持所述基层和载货层。更特别是，所述塑料托盘包含在所述上层和下层间的支撑块以及从各自的上层和下层所延伸的上弹簧锁(snap-lock)构件和下弹簧锁构件通过所述支撑块以彼此相互锁固。
虽然塑料托盘可以提供超过木制托盘的数个优势，但其仍然具有需求以增加塑料托盘的耐用性与强度。
发明内容
按照上述的背景，本发明的一个目的在于减少或限制由起重机或其它起重装置对塑料托盘所导致的损坏。
根据本发明的这个和其它目的、优势和特色在于提供一种具有一个上层的塑料托盘。所述上层具有咬梢开口以及从所述上层向下凸出的第一接合构件，而各个第一接合构件具有一个外套筒环绕各自的咬梢开口。所述塑料托盘进一步具有一个下层以及从所述下层向上突出的第二接合构件，而各个第二接合构件包括一个内套筒以及定位于其中的一个咬梢接收腔。
所述第二接合构件的内套筒可以容纳所述第一接合构件的外套筒而定义出接合所述上层和下层的支撑块。各个支撑块可以具有圆弧边缘。咬梢插入到在所述上层的所述咬梢开口中。各个咬梢具有一个头部以卡合一个咬梢开口以及具有通过所述咬梢接收腔延伸的分隔尖端以卡合与其有关的所述内套筒的背面。
所述咬梢的一个优点在于它们是作为在事件中的熔线(fusible link)，而在所述托盘的所述上层和下层间施加一个分离力。当一个托盘搬运车的轮子在所述下层上静止不动时，这个分离力可以产生，且从所述托盘搬运车延伸的尖齿被向上举起。这导致所述上层会从所述支撑块中分离。在所述支撑块中，当所述分离力变得太超过时，在所述熔线上的标签将会被折断或破坏。因此，具有破坏的标签的咬梢将被替换，而不是替换整个上层。
各个咬梢进一步具有一个本体，所述本体耦合在所述头部和所述分隔尖端间。在经历过所述咬梢接收腔以卡合与其有关的所述内套筒的背面之后，各个咬梢的所述分隔尖端有弹性地从所述本体向外延伸。各个咬梢的所述分隔尖端可以有角度以协助通过所述咬梢接收腔而插入。各个咬梢的所述分隔尖端包含一个各自的唇部以卡合所述内套筒的背面。各个咬梢的所述各自的唇部基于在所述上层和下层间施加的分离力而被配置为断开(break off)。
各个第二接合构件可以进一步包含在所述内套筒和定位于其中的所述咬梢接收腔间延伸的肋。所述肋沿着所述内套筒的长度以及沿着所述咬梢接收腔的长度径向延伸。因此，所述支撑块的优点在于来自接触所述起重机的尖齿的冲击能量可以沿着下列组件而得到消散：所述外套筒、所述内套筒、所述径向肋、以及由在所述内套筒中的所述咬梢接收腔所定义的圆柱核心。所述叉尖(fork tine)首先会撞击所述外套筒，其可以吸收了大部分的冲击能量。冲击能量可以接着传送到所述内套筒，这也可吸收了一些冲击能量。更多冲击能量的吸收在所述径向肋处发生。剩余的冲击能量会到达所述咬梢接收腔而最后消散。
另一观点针对一种用于制造如前面所描述的托盘的方法。所述方法可以包含将所述第二接合构件的所述内套筒定位为容纳所述第一接合构件的所述外套筒以定义出接合所述上层和所述下层的多个支撑块。所述咬梢可以被插入在所述上层的所述咬梢开口中。各个咬梢可以包含具有一个头部以卡合一个咬梢开口以及具有通过所述咬梢接收腔延伸的分隔尖端以卡合与其有关的所述内套筒的背面。
附图说明
图1为根据本发明的一种组装的托盘的顶部透视图；
图2为显示在图1中的所述托盘的底部透视图；
图3为显示在图1中的所述托盘的上层的底部透视图；
图4为显示在图1中的所述托盘的下层的顶部透视图；
图5为根据本发明在各个支撑块中所使用的咬梢的透视图；
图6为显示在图5中的所述咬梢的顶视图；
图7为根据本发明以表示在一个支撑块中的咬梢的一个托盘的部分剖面侧视图。
具体实施方式
现将参照所附的图示在下文中更充分地描述本发明，其中显示出本发明的较佳实施例。然而，本发明可以用不同形式体现且应该不能解释为限制在此规定的实施例中。反之，这些实施例被提供以使此揭露得以彻底且完整，且将传达本发明的范围给本领域的技术人员。通篇的类似图号涉及类似组件。
图1至图4表示具有上层12和下层14的托盘10的顶部和底部透视图，所述上层12和下层14使用咬梢(snap-pin)16接合在一起。所述上层12也被称为载货层(cargo layer)，而所述下层14也被称为基底层(baselayer)。
所述上层12具有从所述上层12向下突出的多个第一接合构件，且各个第一接合构件具有一个外套筒40。所述下层14具有从所述下层14向上突出的多个第二接合构件，且各个第二接合构件具有一个内套筒42。所述第二接合构件的所述内套筒42容纳所述第一接合构件的所述外套筒40以定义出接合所述上层12和下层14的支撑块18、18a。
所述支撑块18、18a定义出在所述上层12和下层14间的一个空间20以容纳至少一个起重构件(lifting member)，如一个托盘搬运车(palletjack)的尖齿(tine)。所述咬梢16的优点在于它们是作为在以下事件中的熔线(fusible link)，在该事件中一个分离力在所述托盘10的所述上层12和下层14间被施加。当所述托盘搬运车的轮子在所述下层14上静止不动时，这个分离力可以产生，而且从所述托盘搬运车延伸的尖齿被向上举起。这导致所述上层12会从所述支撑块18、18a中分离。当所述分离力变得太超过时，在所述熔线16上的标签(tab)50将会被折断或破坏。因此，具有破坏的标签50的咬梢16将被替换，而不是替换整个上层12。
正如将在下面描述的进一步详细说明的，所述支撑块18、18a通过从各自的上层12和下层14延伸的所述外套筒40和内套筒42所形成。所述外套筒40和内套筒42被塑模成形以作为其各自的上层12和下层14的部分。然而，所述上层12和下层14被个别地塑模成形。
所述上层12包括具有多个延伸通过的孔22的一个基本平坦、平的表面。同样地，所述下层14包括具有多个延伸通过的孔23的一个基本平坦、平的表面。所述孔22、23提供了几个好处，譬如包括：降低所述上层12和下层14的表面区域、增加位于所述上层12中的项目的空气流通、以及降低所述托盘10的重量。一个具有上层和下层的范例的塑料托盘揭示在美国公开专利申请案第2007/0256609号中。此项专利让渡到本发明的目前申请人，且全部合并在这里而做为参考之用。
所述上层12可以包括不包含任何孔22的所述平面表面的外围(outerperimeter)24，而这个区域譬如可以约为3到5英寸宽。所述下层14具有实质上匹配于所述上层12的周边形状的一个周边形状。所述下层14可以包括一个矩形的周边形状，所述矩形的周边形状具有贯穿于所述矩形周边的各侧的中央部分、所述托盘10角落间中间的交叉构件(cross member)26、28。
所述上层12和下层14可以由热塑性或其它聚合物材料中塑模成形，其包括高密度聚乙烯(HDPE)、聚丙烯(PP)、其它聚合物材料等等。由本领域技术人员可以体会到的，所述聚合物材料在其它特征中可以为充填或未充填及/或可以包括微粒或纤维、自然或合成材料。譬如：未充填的高密度聚乙烯可以提供改良的冲击强度、具有助力剂(strengtheners)(即：长玻璃纤维)的聚丙烯可以提供改良的结构性质、以及具有随机共聚物的未充填的聚丙烯可以提供改良的强化能力。
所述上层12和下层14可以由不同的热塑性或其它聚合物材料而塑模成形。譬如：所述上层12可以由第一类型的热塑性或聚合物材料塑模成形，而所述下层可以由第二类型的热塑性或聚合物材料塑模成形。依据替换的实施例，所述上层12和下层14的全部或一部分可以由其它材料像例如木材及/或金属所构成而非为由塑料构成。
所述表示的托盘10实质上是正方形。所述托盘10的范例尺寸可以譬如是48英寸乘上48英寸大小。如同本领域的技术人员可以体会到的，所述托盘10也可以用其它的矩形形状所形成，像譬如为40英寸乘上48英寸大小。所述托盘10顺着其周边而具有圆角/边缘30。所述圆角/边缘30会在冲击起重机(forklift)的尖齿期间帮助降低及/或转移损坏以及提供一个改良的美观。
所述表示的托盘10包括多个支撑块18、18a，多个支撑块18、18a提供来将所述上层12和下层14接合在一起以及提供分离，所以托盘搬运车的尖齿可以插在里面。例如：所述表示的托盘10具有九个支撑块18、18a，九个支撑块18、18a位于所述托盘10的角落以及沿着所述托盘10的外边缘的所述托盘10的角落间。支撑块18a也可以在所述下层14中的交叉构件26、28的交叉点处的所述托盘10的中心。
各个支撑块18、18a由从所述上层12向下突出的外套筒40以及从所述下层14向上突出的内套筒42所定义出。所述外套筒40和内套筒42由其各自的上层12和下层14而塑模成形。所述外套筒40和内套筒42具有差不多的尺寸所以当接合在一起时它们可以彼此重叠。所述外套筒40和内套筒42的形状并不限制在任何特定形状。例如：所述外套筒40和内套筒42可以是正方形、三角形、椭圆形或十字形。所述外套筒40的边缘可以是圆形的。
所述上层12具有多个咬梢开口以容纳所述咬梢16。各个外套筒40环绕各自的咬梢开口。所述下层14包括定位于各个内套筒内的咬梢接收腔44。多个径向肋(radial rib)43在所述咬梢接收腔44和所述内套筒42间延伸。
支撑块18、18a的优点在于来自接触所述起重机的尖齿的冲击能量可以沿着下列组件而得到消散：所述外套筒40、所述内套筒42、所述径向肋43、以及由在所述内套筒42中的所述咬梢接收腔44所定义出的圆柱核心。所述叉尖(fork tine)首先会撞击所述外套筒40，因此这可以吸收大部分的冲击能量。冲击能量可以接着传送到所述内套筒42，这也可吸收一些冲击能量。冲击能量的过多吸收发生在所述径向肋43处。剩余的冲击能量到达所述咬梢接收腔44而最后会消散。
如在图5中的最佳表示，各个咬梢16具有一个头部46、一个本体48以及分隔尖端50。所述头部46用来卡合在所述上层12中的咬梢开口。各个咬梢16的头部46可以如图6所表示的形成为具有分隔的直边(spacedapart straight edge)49。在所述上层12中的各个咬梢开口具有相应的相同形状。这会帮助在适当地方支撑住所述咬梢16。在所述上层12和下层14已经接合在一起而形成所述支撑块18、18a之后，所述咬梢16典型地插在所述托盘16中。
即如图7为最佳的说明，所述分隔尖端50通过所述咬梢接收腔44延伸以卡合所述内套筒42的背面60。所述咬梢接收腔44不会从所述内套筒42的顶部一路延伸到所述下层14的底部。这就让在所述咬梢16上的标签50去通过(clear)和卡合所述内套筒42的背面60的地方。
即使所述上层12和下层14在图3和图4中被分离，然而所述咬梢16为了说明目的而被相应地定位。如图3所示，所述咬梢16在所述外套筒40内延伸以及在超过所述外套筒40延伸。如图4所示，所述咬梢16的头部46在所述下层14没有到位的情况下被提升到所述内套筒42和所述咬梢接收腔46上面。这会让各个咬梢16的头部46的间隙(clearance)去卡合在所述下层12的一个咬梢开口，而所述分隔尖端50通过所述咬梢接收腔44延伸以卡合与其有关的所述内套筒42的背面60。
在通过所述咬梢接收腔44以卡合与其有关的所述内套筒42的背面60之后，各个咬梢16的所述分隔尖端50有弹性地从所述主体48向外延伸。各个咬梢16的所述分隔尖端50可以有角度以协助通过所述咬梢接收腔44的插入。各个咬梢16的所述分隔尖端50包含一个各自的唇部51以卡合所述内套筒42的背面60。所述各自的唇部51基于在所述上层12和下层14间施加的过度分离力而被配置为断开(break off)。所述咬梢16也可以由塑料所形成。或者，所述咬梢16也可以由在如前面所具体描述用在所述上层12和下层14中的任何材料所形成。
另一观点是针对一种制造如上所描述的托盘10。所述方法包含将所述多个第二接合构件的所述内套筒42定位以容纳所述多个第一接合构件的所述外套筒40以定义出接合所述上层12和下层14的多个支撑块18、18a。多个咬梢16被插入到所述上层12的所述多个咬梢开口中。各个咬梢16包含具有一个头部46以卡合一个咬梢开口以及具有通过所述咬梢接收腔44延伸的分隔尖端50以卡合与其有关的所述内套筒42的背面。
本发明的诸多改良与其它实施例将会经由此领域的技术人员的精神达成而具有在前述描述和相关图示中所表达出的教导的好处。因此，其应了解到本发明并非限制在所揭示的特定实施例中而是根据由此领域的技术人员容易理解因此可以被预期到而包含到其它改良与实施例。

Claims (31)

1.一种托盘，其包括：
上层，其具有多个咬梢开口；
从所述上层向下突出的多个第一接合构件，每个第一接合构件与该上一层塑模为一体且具有环绕相应的咬梢开口的一个外套筒；
下层；
从所述下层向上突出的多个第二接合构件，每个第二接合构件与该下层塑模为一体且包括内套筒以及定位其中的咬梢接收腔；
多个所述第二接合构件的所述内套筒直接容纳多个所述第一接合构件的所述外套筒，以定义接合所述上层和所述下层的多个支撑块；以及
多个咬梢，多个所述咬梢插入在所述上层中的多个所述咬梢开口，每个咬梢具有卡合咬梢开口的头部且具有分隔尖端，所述分隔尖端延伸通过所述咬梢接收腔，以卡合与其有关的所述内套筒的背面。
2.如权利要求1所述的托盘，其中每个咬梢进一步具有耦合在所述头部和所述分隔尖端间的本体；且其中在通过所述咬梢接收腔以卡合与其有关的所述内套筒的背面之后，每个咬梢的所述分隔尖端有弹性地从所述本体向外延伸。
3.如权利要求2所述的托盘，其中每个咬梢的所述分隔尖端有协助通过所述咬梢接收腔而插入的角度。
4.如权利要求1所述的托盘，其中每个咬梢的所述分隔尖端包含相应的唇部，以卡合所述内套筒的背面。
5.如权利要求4所述的托盘，其中每个咬梢的所述相应的唇部，基于在所述上层和下层间施加的分离力而被配置为断开。
6.如权利要求1所述的托盘，其中每个咬梢的所述头部被形成为具有分隔的直边；且其中在所述上层中的每个咬梢开口具有相同的形状。
7.如权利要求1所述的托盘，其中每个第二接合构件进一步包含在所述内套筒和定位于其中的所述咬梢接收腔间延伸的肋。
8.如权利要求7所述的托盘，其中所述肋沿着所述内套筒的长度以及沿着所述咬梢接收腔的长度径向延伸。
9.如权利要求1所述的托盘，其中多个所述第一接合构件和多个所述第二接合构件在所述相应的上层和下层上的匹配位置处定位；且其中所述匹配位置包括所述相应的上层和下层的角落、在所述相应的上层和下层的角落间的周边以及所述相应的上层和下层的中心。
10.如权利要求9所述的托盘，其中所述上层具有九个所述第一接合构件；以及其中所述下层具有九个所述第二接合构件。
11.如权利要求1所述的托盘，其中每个支撑块具有圆形边缘。
12.如权利要求1所述的托盘，其中所述上层和下层、多个所述第一和第二接合构件以及多个所述咬梢包含塑料。
13.一种托盘，其包括：
上层，其具有多个咬梢开口；
多个第一接合构件，其从所述上层向下突出，每个第一接合构件与该上层塑模为一体且具有一个外套筒，所述外套筒环绕相应的咬梢开口；
下层；
多个第二接合构件，其从所述下层向上突出，每个第二接合构件与该下层塑模为一体且包括内套筒、定位其中的咬梢接收腔以及在所述内套筒与所述咬梢接收腔间延伸的多个肋；
多个所述第二接合构件的所述内套筒直接容纳多个所述第一接合构件的所述外套筒，以定义接合所述上层和所述下层的多个支撑块；以及
多个咬梢，多个所述咬梢插入在所述上层中的多个所述咬梢开口，每个咬梢延伸通过所述咬梢接收腔，以卡合与其有关的所述内套筒的背面。
14.如权利要求13所述的托盘，其中每个咬梢在其一端包含用以卡合咬梢开口的头部以及在其相反端有延伸通过所述咬梢接收腔的分隔尖端，以卡合与其有关的所述内套筒的背面。
15.如权利要求14所述的托盘，其中所述分隔尖端在通过所述咬梢接收腔后有弹性地从所述咬梢接收腔向外延伸。
16.如权利要求14所述的托盘，其中每个咬梢的所述分隔尖端有协助通过所述咬梢接收腔而插入的角度。
17.如权利要求14所述的托盘，其中每个咬梢的所述分隔尖端包含相应的唇部，以卡合所述内套筒的背面。
18.如权利要求17所述的托盘，其中每个咬梢的所述相应的唇部基于在所述上层和下层间施加的分离力而被配置为断开。
19.如权利要求13所述的托盘，其中所述肋沿着所述内套筒的长度以及沿着所述咬梢接收腔的长度径向延伸。
20.如权利要求13所述的托盘，其中多个所述第一接合构件和多个所述第二接合构件在所述相应的上层和下层上的匹配位置处定位；且其中所述匹配位置包括所述相应的上层和下层的角落、在所述相应的上层和下层的角落间的周边以及所述相应的上层和下层的中心。
21.如权利要求13所述的托盘，其中所述上层和下层、多个所述第一和第二接合构件以及多个所述咬梢包含塑料。
22.一种制造托盘的方法，所述托盘包含上层和下层，所述上层具有多个咬梢开口、从所述上层向下突出的多个第一接合构件以及从所述下层向上突出的多个第二接合构件，而每个第一接合构件与该上层塑模为一体且具有环绕相应的咬梢开口的一个外套筒，而每个第二接合构件与该下层塑模为一体且包括内套筒以及定位其中的咬梢接收腔，所述方法包含：
将多个所述第二接合构件的所述内套筒定位为直接容纳所述第一接合构件的所述外套筒，以定义接合所述上层和所述下层的多个支撑块；以及
将多个咬梢插入在所述上层的多个所述咬梢开口中，每个咬梢具有用以卡合一个咬梢开口的一个头部且具有分隔尖端，所述分隔尖端延伸通过所述咬梢接收腔而卡合与其有关的所述内套筒的背面。
23.如权利要求22所述的方法，其中每个咬梢进一步包含耦合在所述头部和所述分隔尖端间的本体；且其中在通过所述咬梢接收腔以卡合与其有关的所述内套筒的背面之后，每个咬梢的所述分隔尖端有弹性地从所述本体向外延伸。
24.如权利要求23所述的方法，其中每个咬梢的所述分隔尖端有协助通过所述咬梢接收腔而插入的角度。
25.如权利要求22所述的方法，其中每个咬梢的所述分隔尖端包含相应的唇部，以卡合所述内套筒的背面。
26.如权利要求25所述的方法，其中每个咬梢的所述相应的唇部基于在所述上层和下层间施加的分离力而被配置为断开。
27.如权利要求22所述的方法，其中每个咬梢的所述头部形成为具有分隔的直边；且其中在所述上层中的每个咬梢开口具有相同形状。
28.如权利要求22所述的方法，其中每个第二接合构件进一步包含在所述内套筒和定位于其中的所述咬梢接收腔间延伸的肋。
29.如权利要求28所述的方法，其中所述肋沿着所述内套筒的长度以及沿着所述咬梢接收腔的长度径向延伸。
30.如权利要求22所述的方法，其中多个所述第一接合构件和多个所述第二接合构件在所述相应的上层和下层上的匹配位置处定位；且其中所述匹配位置包括所述相应的上层和下层的角落、在所述相应的上层和下层的角落间的周边以及所述相应的上层和下层的中心。
31.如权利要求22所述的方法，其中所述上层和下层、多个所述第一和第二接合构件以及多个所述咬梢包含塑料。
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