CN103128897A - 一种托盘的制造方法及托盘 - Google Patents

一种托盘的制造方法及托盘 Download PDF

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CN103128897A
CN103128897A CN2011103817720A CN201110381772A CN103128897A CN 103128897 A CN103128897 A CN 103128897A CN 2011103817720 A CN2011103817720 A CN 2011103817720A CN 201110381772 A CN201110381772 A CN 201110381772A CN 103128897 A CN103128897 A CN 103128897A
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drain pan
pallet
upper cover
inner core
manufacture method
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吉永丰弘
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NEW TIMES PACKAGE HONGKONG CO Ltd
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NEW TIMES PACKAGE HONGKONG CO Ltd
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Priority to CN2011103817720A priority Critical patent/CN103128897A/zh
Priority to US13/603,417 priority patent/US20130133557A1/en
Priority to GB1215798.8A priority patent/GB2496940A/en
Publication of CN103128897A publication Critical patent/CN103128897A/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/08—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles using several expanding or moulding steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1228—Joining preformed parts by the expanding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/1228—Joining preformed parts by the expanding material
    • B29C44/1233—Joining preformed parts by the expanding material the preformed parts being supported during expanding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/128—Internally reinforcing constructional elements, e.g. beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
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    • B65D2519/00119—Materials for the construction of the reinforcements
    • B65D2519/00139—Plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00258—Overall construction
    • B65D2519/00263—Overall construction of the pallet
    • B65D2519/00273—Overall construction of the pallet made of more than one piece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00258—Overall construction
    • B65D2519/00283—Overall construction of the load supporting surface
    • B65D2519/00288—Overall construction of the load supporting surface made of one piece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00258—Overall construction
    • B65D2519/00313—Overall construction of the base surface
    • B65D2519/00318—Overall construction of the base surface made of one piece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
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    • B65D2519/00313—Overall construction of the base surface
    • B65D2519/00328—Overall construction of the base surface shape of the contact surface of the base
    • B65D2519/00338—Overall construction of the base surface shape of the contact surface of the base contact surface having a discrete foot-like shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
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    • B65D2519/00402—Integral, e.g. ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2519/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D2519/00004—Details relating to pallets
    • B65D2519/00547—Connections
    • B65D2519/00552—Structures connecting the constitutive elements of the pallet to each other, i.e. load supporting surface, base surface and/or separate spacer
    • B65D2519/00557—Structures connecting the constitutive elements of the pallet to each other, i.e. load supporting surface, base surface and/or separate spacer without separate auxiliary elements
    • B65D2519/00562—Structures connecting the constitutive elements of the pallet to each other, i.e. load supporting surface, base surface and/or separate spacer without separate auxiliary elements chemical connection, e.g. glued, welded, sealed

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Abstract

本发明公开一种托盘的制造方法及托盘，其制造方法包括有如下步骤：a、分别制备底壳和上盖；b、将底壳或上盖定位于EPS泡沫成型机的成型模具中，合模并向成型模具的模腔内填充入EPS珠粒；c、进行加热，以使EPS珠粒发泡膨胀而形成与底壳或上盖熔结的内芯，后进行冷却处理；d、打开成型模具，将上盖或底壳定位组合于底壳或上盖上后合模，进行加热使EPS珠粒再次发泡膨胀而与上盖或底壳熔结，后进行冷却处理；e、脱模而制成托盘。该托盘的外壳和内芯的具有良好的结合强度，有效地避免托盘在使用过程中发生外壳和内芯脱离的情况，保证了托盘的品质。

Description

一种托盘的制造方法及托盘
技术领域
本发明涉及一种运输容器及其制造方法，尤其是指一种托盘的制造方法及由此方法制造出的托盘。
背景技术
为了更有效地搬运货物，一般使用托盘用于承托货物，以便于使用叉车进行货物的搬运或装卸。传统的托盘为采用木材制备的木质托架，其存在着易受潮、虫蛀、不环保等缺点，而逐步被塑料托盘所取代。常见的塑料托盘为采用塑料材料一次注塑成型而制备，如国家知识产权局于2006年4月5日授权公告的专利号为ZL20052002995.6的实用新型专利即公开了一种采用高密度聚乙烯材料一体注塑而成的塑料托盘，此种材料制备的塑料托盘存在着耐环境应力开裂性不好、耐热老化性差的缺陷。
国家知识产权局于2011年3月9日公布的申请号为201010502168.4的发明专利申请即公开了一种航空托盘及其制造方法，其将EPS泡沫模压一体成型制成带有支撑柱的EPS板，再于该EPS板的表面处固定附着有EVA胶层的PET膜，然后通过真空吸塑机将PET膜与EPS板之间吸成真空，利用大气压力使PET膜与EPS板经EVA胶层紧密粘贴。相比于使用高密度聚乙烯材料一体注塑成型制备的塑料托盘，其作为内芯的EPS板具有质量轻、隔热效果好的特性，而其作为外壳的PET膜具有良好的力学性能，可克服其内的EPS板抗冲击性、抗拉性较差的不足，使得托盘既具备质量轻的优点，又具有耐冲击、耐拉等良好的力学性能。然而，在该托盘的结构中，PET膜为采用EVA胶层经真空吸塑而粘贴于EPS板的外表面，在比较恶劣的环境下，容易造成内芯与外壳两者发生分离，从而降低托盘的耐冲击强度，加大托盘在使用过程中发生断裂、破碎的可能性。
发明内容
本发明所要解决的技术问题为采用现有托盘制造方法所制造出的托盘存在着内芯和外壳容易分离的缺陷，据此提供一种托盘的制造方法及托盘，采用该制造方法所制成的托盘其内芯和外壳可良好结合而不易分离。
为解决上述技术问题，本发明采用如下所述的技术方案：一种托盘的制造方法，包括有如下步骤：a、分别制备底壳和上盖；b、将底壳或上盖定位于EPS泡沫成型机的成型模具中，合模并向成型模具的模腔内填充入EPS珠粒；c、进行加热，以使EPS珠粒发泡膨胀而形成与底壳或上盖熔结的内芯，后进行冷却处理；d、打开成型模具，将上盖或底壳定位组合于底壳或上盖上后合模，进行加热使EPS珠粒再次发泡膨胀而与上盖或底壳熔结，后进行冷却处理；e、脱模而制成托盘。
上述托盘的制造方法中，步骤b中所填充的EPS珠粒为经过预发泡和熟化处理的EPS珠粒。
上述托盘的制造方法中，所述底壳和上盖为选用PVC、HIPS、PET、PC或ABS材料通过吸塑工艺制备。
上述托盘的制造方法中，在步骤c和步骤d中，均采用向成型模具内通入水蒸汽的方式进行加热。
上述托盘的制造方法中，在步骤c和步骤d中，向成型模具内通入100～120℃的水蒸汽，加热1～2分钟。
上述托盘的制造方法中，在步骤c和步骤d中，冷却处理均采用水冷方式。
上述托盘的制造方法中，水冷0.5～1分钟进行冷却。
上述托盘的制造方法中，先将底壳定位于成型模具中而在其上成型内芯，后再盖合上盖与内芯熔结。
一种托盘，包括有一采用HIPS、PVC、PET、PC或ABS材料制备的外壳，所述外壳包括有一底壳及一组合于所述底壳的上盖，所述底壳具有一平板部，自所述平板部向下凹入而形成有多个中空的支撑脚，于所述外壳形成有一采用EPS泡沫热成型制备的与所述底壳和上盖的内表面熔结的内芯。
上述托盘中，所述底壳沿其平板部的周边向上延伸形成有一垂直于所述平板部的底壳侧缘，而所述上盖沿其周边向下延伸形成有一垂直于所述上盖的上盖侧缘，所述内芯凸出于所述底壳的底壳侧缘，所述上盖侧缘内侧的下部与底壳侧缘外侧的上部贴合。
本发明的有益技术效果在于：由于EPS泡沫珠粒在加热条件下膨胀而可熔结于底壳、上盖的内表面，实现外壳与冷却成型后的内芯两者的紧密结合，相比于现有的采用EVA胶层粘合的方式，其可大幅度提高外壳和内芯的结合强度，有效地避免托盘在使用过程中发生外壳和内芯脱离的情况，保证了托盘的品质。
附图说明
图1是本发明托盘的立体结构示意图。
图2是本发明托盘的剖视结构示意图。
图3是本发明托盘的下壳的结构示意图。
图4是本发明托盘的制造工艺流程图。
具体实施方式
为使本领域的普通技术人员更加清楚地理解本发明的目的、技术方案和优点，以下结合附图和实施例对本发明做进一步的阐述。
本发明所公开的托盘为一种塑料托盘，其设计为具有支撑脚的矩形板状结构，参考图1至图3所示，该托盘包括有一采用聚氯乙烯(Polyvinylchloride；PVC)材料制备的外壳10及一采用可发性聚苯乙烯(Expandable Polystyrene；EPS)泡沫材料发泡成型于该外壳10内的内芯20。该外壳10包括有一底壳100及一盖合该底壳100上的上盖101，其中，该底壳100具有一平板部102，自该平板部102向下凹入而形成有多个中空的支撑脚103。多个支撑脚103呈三列分布，而在两列支撑脚103之间形成供于叉车的叉臂插入的插入槽S，便于使用叉车叉起托盘而搬运或装卸固定于托盘上的货物。
在附图所示的实施例中，该底壳100上形成有九个支撑脚103，九个支撑脚103呈三行三列分布，而在两列支撑脚103之间及两行支撑脚103之间均形成插入槽S，如此，操作人员在运输/装卸作业时可以操控叉车从托盘的四个方向插入并运输托盘中，而不用太多考虑托盘的放置方式，能够有效地提高货物运输/装卸作业效率。
EPS泡沫先后与底壳100和上盖101一起发泡成型，并在冷却后形成为由该底壳100和上盖101所构成的外壳10所包覆的内芯20，由于EPS泡沫珠粒在加热条件下膨胀而可熔结于底壳100、上盖101的内表面，实现外壳10与冷却成型后的内芯20两者的紧密结合，相比于现有的采用EVA胶层粘合的方式，其可大幅度提高外壳10和内芯20的结合强度，有效地避免托盘在使用过程中发生外壳和内芯脱离的情况，保证了托盘的品质。
为了增强托盘的结构强度，在支撑脚103的至少一外侧面处形成有凹槽104。在此优选的实施例中，每一支撑脚103的四个外侧面均形成有凹槽104，且相对两外侧面上的凹槽104彼此相对称。
优选地，该底壳100的平板部102上表面处位于相邻的二支撑脚103之间形成有直线状的加强筋105，而位于四个支撑脚103之间则形成有环状的加强筋106。藉由上述直线状加强筋105和环状加强筋106的设置，可进一步增加底壳100的结构强度，进而增加托盘的整体结构强度。
参阅图2，该底壳100沿其平板部102的周边向上延伸形成有一垂直于该平板部102的底壳侧缘107，而该上盖101沿其周边向下延伸形成有一垂直于该上盖101的上盖侧缘108，该内芯20凸出于该底壳100的底壳侧缘107，该上盖101盖合于底壳100之上，上盖侧缘108内侧的下部与底壳侧缘107外侧的上部贴合，这样，可增加内芯20与上盖101的熔结面积而增加两者的结合强度，也保证了内芯20完全为外壳10所包覆。一般地，该底壳侧缘107的高度设计为1～3为宜，该内芯20凸出1～3cm为宜，而该上盖侧缘108的高度则设计为3～5cm为宜。
在上述的实施例中，构成外壳10的底壳100和上盖101为采用PVC材料制备，然而，在其他的实施例中，也可采用高抗冲聚苯乙烯(High ImpactPolystyrene；HIPS)、聚对苯二甲酸乙二醇酯(Polyethylene Terephthalate；PET)、聚碳酸酯(Polycarbonate；PC)或丙烯腈-苯乙烯-丁二烯共聚物(AcrylonitrileButadiene Styrene；ABS)材料制备。基于产品刚性、易成型性、成本、环保型等因素综合考虑，优选使用PVC或ABS材料制作本发明的外壳10。
下面结合图4以说明本发明所公开的托盘的制造工艺。
首先，分别制成底壳100和上盖101(步骤S10)。该底壳100和上盖101可选用PVC、HIPS、PET、PC或ABS材料通过吸塑工艺制备，优选使用PVC或ABS材料。
将底壳100定位于EPS泡沫成型机的成型模具中，合模并向成型模具的模腔内填充入EPS珠粒(步骤S11)。在此步骤中，可使用文氏管作用设备(例如灌料枪)将EPS珠粒吹入成型模具的模腔中，以充满该模腔。优选地，EPS珠粒已经经过预发泡和熟化处理。
进行加热，以使EPS珠粒发泡膨胀而形成内芯20，与底壳100的内表面熔结，后进行冷却处理(步骤S12)。在此步骤中，可向成型模具内通入100～120℃的水蒸汽加热1～2分钟，以加热其内的EPS珠粒，使之发泡膨胀至填满彼此间的空隙，并粘接成均匀的内芯20，同时粘接于底壳100的内表面上。成型模具一般采用双层壁模具，其双层壁之间的空间形成蒸汽室，且内壁上形成有气孔，高温的水蒸汽通入双层壁之间的空间，并通过气孔进入模腔中，以对其内的EPS珠粒加热。在热成型内芯20后，水冷0.5～1分钟进行冷却，以使内芯20的形状稳定。
打开成型模具，将上盖101定位组合于底壳100上后合模，再次进行加热使EPS珠粒再次发泡膨胀而与上盖101熔结，后进行冷却处理(步骤S13)。在此步骤中，可向成型模具内通入100～120℃的水蒸汽加热1～2分钟，而在此后的冷却步骤中，水冷0.5～1分钟。
最后，脱模而制成托盘(步骤S14)。
在上述的制备内芯20的步骤S12中，所制成的内芯20凸出于底壳100的底壳侧缘107上端所在平面1～3cm，这样，在步骤S13中，内芯20的凸出部分可与上盖101的上盖侧缘108内侧面形成粘结，以保证上盖101与内芯20的结合强度。
在图5所示的实施例中，先于底壳100上制成内芯20，再于内芯20组合上盖101，本领域普通技术人员可以理解地，在其他的实施例中，也可先于上盖101上制成内芯20，再于该内芯20上组合底壳100。
以上所述仅为本发明的优选实施例，而非对本发明做任何形式上的限制。本领域的技术人员可在上述实施例的基础上施以各种等同的更改和改进，凡在权利要求范围内所做的等同变化或修饰，均应落入本发明的保护范围之内。

Claims (10)

1.一种托盘的制造方法，其特征在于，包括有如下步骤：
a、分别制备底壳和上盖；
b、将底壳或上盖定位于EPS泡沫成型机的成型模具中，合模并向成型模具的模腔内填充入EPS珠粒；
c、进行加热，以使EPS珠粒发泡膨胀而形成与底壳或上盖熔结的内芯，后进行冷却处理；
d、打开成型模具，将上盖或底壳定位组合于底壳或上盖上后合模，进行加热使EPS珠粒再次发泡膨胀而与上盖或底壳熔结，后进行冷却处理；
e、脱模而制成托盘。
2.如权利要求1所述的托盘的制造方法，其特征在于，步骤b中所填充的EPS珠粒为经过预发泡和熟化处理的EPS珠粒。
3.如权利要求1所述的托盘的制造方法，其特征在于，所述底壳和上盖为选用PVC、HIPS、PET、PC或ABS材料通过吸塑工艺制备。
4.如权利要求1所述的托盘的制造方法，其特征在于，在步骤c和步骤d中，均采用向成型模具内通入水蒸汽的方式进行加热。
5.如权利要求4所述的托盘的制造方法，其特征在于，在步骤c和步骤d中，向成型模具内通入100～120℃的水蒸汽，加热1～2分钟。
6.如权利要求1所述的托盘的制造方法，其特征在于，在步骤c和步骤d中，冷却处理均采用水冷方式。
7.如权利要求6所述的托盘的制造方法，其特征在于，水冷0.5～1分钟进行冷却。
8.如权利要求1所述的托盘的制造方法，其特征在于，先将底壳定位于成型模具中而在其上成型内芯，后再盖合上盖与内芯熔结。
9.一种托盘，其特征在于，所述托盘包括有一采用HIPS、PVC、PET、PC或ABS材料制备的外壳(10)，所述外壳(10)包括有一底壳(100)及一组合于所述底壳(100)的上盖(101)，所述底壳(100)具有一平板部(102)，自所述平板部(102)向下凹入而形成有多个中空的支撑脚(103)，于所述外壳(10)形成有一采用EPS泡沫热成型制备的与所述底壳(100)和上盖(101)的内表面熔结的内芯(20)。
10.如权利要求9所述的托盘，其特征在于，所述底壳(100)沿其平板部(102)的周边向上延伸形成有一垂直于所述平板部(102)的底壳侧缘(107)，而所述上盖(101)沿其周边向下延伸形成有一垂直于所述上盖(101)的上盖侧缘(108)，所述内芯(20)凸出于所述底壳(100)的底壳侧缘(107)，所述上盖侧缘(108)内侧的下部与底壳侧缘(107)外侧的上部贴合。
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