CN104477252A - 冷藏保温车用保温厢板 - Google Patents
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Abstract
本发明公开了一种冷藏保温车用保温厢板,属于保温板生产领域。本发明所述厢板为六面全封闭式结构,由以下工艺生产:(1)底层玻璃纤维材料、保温层材料、面层玻璃纤维材料及侧面玻璃纤维材料根据厢板形状及厢板开口情况下料;(2)将底层玻璃纤维材料、保温层材料及面层玻璃纤维材料自下而上依次铺设在模具内,将侧面玻璃纤维材料铺设在底层玻璃纤维材料、保温层材料及面层玻璃纤维材料的侧面与模具侧壁之间;(3)加温加压的同时进行抽真空操作,一次成型得到六面全封闭式结构保温厢板,成型温度为60—70℃,成型压力为0.8—1.2kg/平方厘米,抽真空至-0.25—-0.15MPa。与现有技术相比,本发明的冷藏保温车用保温厢板具有重量轻、强度高等特点,具有很好的推广应用价值。
Description
技术领域
本发明涉及保温板生产领域,具体地说是一种冷藏保温车用保温厢板。
背景技术
现有技术中,冷藏保温车用保温厢板主要的生产方式包括以下三种:发泡填充式、干湿结合方式、纯干式制板。
发泡填充式:生产工艺是为在上下蒙皮中间放置限高块,内部结构需事先制作并固定于内蒙皮一面,然后送入专用设备,并填充自发泡PU胶,利用设备及限高块决定板材的厚度,本身不使用粘接胶,只利用发泡胶的自粘性连接两侧蒙皮。其内外蒙皮选择种类较多,可选择金属及非金属蒙皮。该生产方式优点是厢板重量轻,蒙皮选择范围广。缺点是,板材与蒙皮粘接强度不高,容易开合,不利于差异化生产,填充要求精确,保温性能差,连接结构复杂,容易产生气泡和空腔。
干湿结合方式:简单来说,以该方法生产的厢板是由蒙皮加保温层构成的(玻纤包裹保温材料后,再利用树脂胶将蒙皮粘接在其外侧)。该方法生产成本低,且不需要过于庞大的生产设备,制作主要由平台及真空床即可完成。其优点在于:投入资金较少,工艺相对成熟,人员环境等外在因素要求较低,外表面较为平整光洁,不必喷漆。缺点在于:一、由于其蒙皮是预制的,所以板材的四周是开放式的,一般为了掩盖其这种缺陷,多数厂家都会在端面进行后期封闭或者利用型材掩盖。二、板材强度较低,修复困难,如遇特殊结构(如肉挂车)只能采用预制板内框架等方法实施,相对而言重量较重,而且设计性不强,后期需维护和维修成本高。
纯干式制板:此种方法跟上面的干湿结合方法有许多相似之处,也是利用平台以及真空床制作的,蒙皮也是预制的。区别在于:一、蒙皮有了较多的选择,可选择金属或者非金属蒙皮;二、保温材料也可以选择聚氨酯或者聚苯泡沫;三、粘接的胶水多采用双组份胶粘接,这样避免了纤维及树脂的使用,所以称之谓纯干式制板。该方式生产的板材重量轻,表面质量高,设计性强,制作难度不高。但是,由于原材料及工艺的限制,此种方法生产的板材强度稍弱,保温性能有所降低,且其生产周期长,成本高,不利于生产大型冷藏保温车的厢板。
发明内容
本发明的技术任务是针对上述现有技术的不足,提供一种重量轻、强度高、设计性强的冷藏保温车用保温厢板。
本发明的技术任务是按以下方式实现的:冷藏保温车用保温厢板,包括保温层,其特征在于,所述厢板为六面全封闭式结构,包括底层玻璃纤维层、保温层、面层玻璃纤维层及侧面玻璃纤维层,由以下工艺生产:
(1)底层玻璃纤维材料、保温层材料、面层玻璃纤维材料及侧面玻璃纤维材料根据厢板形状及厢板开口情况下料;
(2)将底层玻璃纤维材料、保温层材料及面层玻璃纤维材料自下而上依次铺设在模具内,将侧面玻璃纤维材料铺设在底层玻璃纤维材料、保温层材料及面层玻璃纤维材料的侧面与模具侧壁之间,并且在各结构层之间铺设热固性树脂胶粘剂;厢板开口处放置成型模胎;
(3)将模具移入热压机,加温加压的同时进行抽真空操作,一次成型得到六面全封闭式结构保温厢板,成型温度为60—70℃,成型压力为0.8—1.2kg/平方厘米,抽真空至-0.25—-0.15MPa。
上述厢板可用作冷藏车保温箱的顶板及侧板,当用作底板时,为了增加其强度,可以在保温层材料与面层玻璃纤维材料之间依次铺设有复合毡与胶合板层,保温层材料、复合毡、胶合板层及面层玻璃纤维材料之间均铺设有热固性树脂胶粘剂。
为了进一步增加板材强度,可以在保温层内置加强筋,加强筋的密度优选为1.5—2.5件/平方米。所述加强筋为不带预埋件木梁、带预埋件木梁、Z字型加强筋和/或加强立筋(由聚氨酯条加胶合板组成(包裹纤维))。
为了进一步提升厢板的表面性能,可以在底层玻璃纤维层、面层玻璃纤维层及侧面玻璃纤维层与模具之间涂覆不饱和胶衣树脂,加温加压处理后在厢板表面形成胶衣层。
为了使厢板开口位置具有与其它位置一样的结构性能,可以在厢板结构层与成型模胎之间铺设侧面玻璃纤维材料,并涂覆不饱和胶衣树脂。
底层玻璃纤维层、面层玻璃纤维层及侧面玻璃纤维层均优选表面毡、短切毡及复合毡构成,复合毡、短切毡及表面毡自内而外依次铺设,且复合毡、短切毡之间,以及短切毡及表面毡之间均铺设有热固性树脂胶粘剂。
本发明的冷藏保温车用保温厢板与现有技术相比具有以下突出的有益效果:
(一)利用玻璃纤维材料+热固性树脂胶粘剂+保温材料+加强筋的结构形式,在保证板材厚度的前提下加温加压,并且抽真空,各结构层粘接强度高,强度高,保温性能好,从根本上保证了产品的强度及质量;
(二)厢板六面是一体成型全封闭式结构,而且内部结构设计性极强,能够调整不同结构适应不同的客户需求;
(三)厢板重量轻,强度高,无需内置框架,即可以3吨/米的刚性适应肉挂要求,同时由于其出色的保温性能及多变的产品结构,能够适应移动通讯车、炸药车、海鲜运输车等诸多领域厢式车辆的要求,适用范围广;
(四) 由于厢板本身强度高,一体式结构,所以在连接成厢体时可采用最简单的胶粘式连接,不仅重量轻,连接强度高,而且避免了95%以上的热桥的传导,提高了保温性能。
附图说明
附图1是本发明冷藏保温车用保温厢板顶板(侧板)结构层示意图;
附图2是本发明冷藏保温车用保温厢板底板结构层示意图;
附图3是加强立筋结构示意图。
具体实施方式
参照说明书附图以具体实施例对本发明的冷藏保温车用保温厢板作以下详细地说明。
实施例:
本发明的冷藏保温车用保温厢板为六面全封闭式结构,由大幅面聚酯三明治板热压机加温加压的同时进行抽真空操作,一次成型得到。
如附图1所示,本发明的厢板用作冷藏车顶板或侧板时,其结构层包括底层玻璃纤维层1、保温层2、面层玻璃纤维层3及侧面玻璃纤维层4。
其中,底层玻璃纤维层1由表面毡1.1、短切毡1.2及复合毡1.3构成;面层玻璃纤维层3由表面毡3.1、短切毡3.2及复合毡3.3构成;侧面玻璃纤维层4由表面毡4.1、短切毡4.2及复合毡4.3构成。
生产工艺如下:
(1)底层玻璃纤维材料、保温层材料、面层玻璃纤维材料及侧面玻璃纤维材料根据厢板形状及厢板开口情况下料;
(2)在模具底面涂覆一层不饱和胶衣树脂材料(待其固化后进行制板),然后将表面毡1.1铺设在模具内,之后自下而上依次铺设热固性树脂胶粘剂、短切毡1.2、热固性树脂胶粘剂、复合毡1.3、热固性树脂胶粘剂、保温层2、热固性树脂胶粘剂、复合毡3.3、热固性树脂胶粘剂、短切毡3.2、热固性树脂胶粘剂及表面毡3.1,并在表面毡3.1上侧涂覆一层不饱和胶衣树脂材料,
所述保温层2中平行设置有若干Z字型加强筋,Z字型加强筋的间隔为500mm(车辆行进方向);
(3)在步骤(2)中铺设的板材结构层侧面与模具侧板之间,自内向外依次铺设热固性树脂胶粘剂、复合毡4.3、热固性树脂胶粘剂、短切毡4.2、热固性树脂胶粘剂及表面毡4.1,并在表面毡4.1外侧涂覆一层不饱和胶衣树脂材料;
板材有开口部位时,板材结构层与成型模胎侧壁之间各层的铺设方法同上。
(4)将模具顶板、侧板分别配置到位,将模具移入热压机,加温加压的同时进行抽真空操作,一次成型得到六面全封闭式结构保温厢板,成型温度为65℃,成型压力为1kg/平方厘米,抽真空至-0.2MPa。
如附图2所示,本发明的厢板用作冷藏车底板时,其结构层包括底层玻璃纤维层1、保温层2、面层玻璃纤维层3、复合毡5与胶合板层6及侧面玻璃纤维层4。
底层玻璃纤维层1、保温层2、面层玻璃纤维层3及侧面玻璃纤维层4的结构关系与用作冷藏车顶板时各结构层的结构关系相同,生产工艺也相同。只是在面层玻璃纤维层3与保温层2之间增加了复合毡5与胶合板层6。在复合毡5与保温层2之间、复合毡5与胶合板层6之间、以及胶合板层6与复合毡3.3之间均铺设有热固性树脂胶粘剂。
所述保温层2内平行设置有木梁和加强立筋,木梁间隔为1074mm(车辆行进方向),两木梁之间设1个加强立筋。
所述Z字型加强筋、木梁均为现有技术中公知的加强筋结构。
如附图3所示,所述加强立筋为复合垫7包裹的胶合板立筋8与聚氨酯立筋9的复合结构。所述复合垫7为浸润树脂的玻璃纤维材料(复合毡)。
Claims (6)
1.冷藏保温车用保温厢板,包括保温层,其特征在于,所述厢板为六面全封闭式结构,包括底层玻璃纤维层、保温层、面层玻璃纤维层及侧面玻璃纤维层,由以下工艺生产:
(1)底层玻璃纤维材料、保温层材料、面层玻璃纤维材料及侧面玻璃纤维材料根据厢板形状及厢板开口情况下料;
(2)将底层玻璃纤维材料、保温层材料及面层玻璃纤维材料自下而上依次铺设在模具内,将侧面玻璃纤维材料铺设在底层玻璃纤维材料、保温层材料及面层玻璃纤维材料的侧面与模具侧壁之间,并且在各结构层之间铺设热固性树脂胶粘剂;厢板开口处放置成型模胎;
(3)将模具移入热压机,在保证板材厚度的前提下,加温加压的同时进行抽真空操作,一次成型得到六面全封闭式结构保温厢板,成型温度为60—70℃,成型压力为0.8—1.2kg/平方厘米,抽真空至-0.25—-0.15MPa。
2.根据权利要求1所述的冷藏保温车用保温厢板,其特征在于:保温层材料与面层玻璃纤维材料之间依次铺设有复合毡与胶合板层,保温层材料、复合毡、胶合板层及面层玻璃纤维材料之间均铺设有热固性树脂胶粘剂。
3.根据权利要求1或2所述的冷藏保温车用保温厢板,其特征在于:保温层内置有加强筋,加强筋的密度为1.5—2.5件/平方米。
4.根据权利要求1或2所述的冷藏保温车用保温厢板,其特征在于:底层玻璃纤维层、面层玻璃纤维层及侧面玻璃纤维层与模具之间涂覆有不饱和胶衣树脂,加温加压处理后在厢板表面形成胶衣层。
5.根据权利要求4所述的冷藏保温车用保温厢板,其特征在于:厢板开口位置,厢板结构层与成型模胎之间铺设有侧面玻璃纤维材料,并涂覆有不饱和胶衣树脂。
6.根据权利要求4所述的冷藏保温车用保温厢板,其特征在于:底层玻璃纤维层、面层玻璃纤维层及侧面玻璃纤维层均由表面毡、短切毡及复合毡构成,复合毡、短切毡及表面毡自内而外依次铺设,且复合毡、短切毡之间,以及短切毡及表面毡之间均铺设有热固性树脂胶粘剂。
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