CN108792158A - 一种轻质热塑蜂窝板复合材料托盘及其制作方法 - Google Patents
一种轻质热塑蜂窝板复合材料托盘及其制作方法 Download PDFInfo
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Abstract
本申请涉及一种轻质热塑蜂窝板复合材料托盘及其制作方法，轻质热塑蜂窝板复合材料托盘由蜂窝板面板和塑料托柱通过接触面粘结或焊接构成，所述的蜂窝板面板具有三层夹心结构，上层、下层均为玻璃纤维增强热塑复合材料，中间层为塑料蜂窝，所述玻璃纤维增强热塑复合材料由连续纤维增强的热塑性材料制成。塑料托柱与蜂窝板面板的接触面占蜂窝板面板总面积的20%~30%。本申请还包括上述轻质热塑蜂窝板复合材料托盘的制作方法；材料准备：蜂窝板面板与塑料托柱通过接触面热熔熔接或粘接。本申请结构简洁，强度高，耐腐蚀，成本低，效果好。
Description
技术领域
本申请涉及一种轻质热塑蜂窝板复合材料托盘及其制作方法，主要适用于托盘的设计制作。
背景技术
作为货物存储堆放、搬运用的托盘，目前主要使用木质托盘、金属托盘以及塑料注塑托盘。而通常遍及世界各地用于储运和运输货物的多为木制托盘。这些托盘各自存在很多的缺点。例如:木质托盘，可承载受到限制；易于损坏或破裂；吸收湿气、液体和气味；可受白蚁和昆虫污染；钉子松动等，尤其在当今森林大面积减少的情况下，其使用受限。金属托盘，其制造昂贵，自重较大；在潮湿以及酸碱环境下易于锈蚀等。塑料注塑托盘，强度低、承载能力受限，抗撞击能力较差，使用寿命短等。
发明内容
本申请解决的技术问题是克服现有技术中存在的上述不足，而提供一种结构简洁，强度高，成本低，效果好的轻质热塑蜂窝板复合材料托盘及其制作方法。
本申请解决上述技术问题所采用的技术方案包括：
一种轻质热塑蜂窝板复合材料托盘，其特征在于：由蜂窝板面板和塑料托柱通过接触面粘结或焊接构成。
所述的蜂窝板面板具有三层夹心结构，上层、下层（上下两层为表层）均为玻璃纤维增强热塑复合材料，中间层为塑料蜂窝，所述玻璃纤维增强热塑复合材料由连续纤维增强的热塑性材料制成，所述的热塑性材料（热塑性粒料或片材）中选自PP (聚丙烯)、PE (聚乙烯)、PA6 (尼龙6)或PBT (聚对苯二甲酸丁二醇酯)中的一种或两种以上的组合。所述的连续纤维选自玻璃纤维、碳纤维或玄武岩纤维中的一种或两种以上的组合。
所述的塑料托柱由热塑性材料选自PP (聚丙烯)、PE (聚乙烯)、PA6 (尼龙6)或PBT (聚对苯二甲酸丁二醇酯)中的一种或两种以上原材料或者回收料注塑成型制成。
本申请轻质热塑蜂窝板复合材料托盘从结构上采用热塑蜂窝为芯材，大大减轻了托盘重量，而且增加了其弹性，抗压性能；表层采用连续纤维增强热塑性材料，大大增加了托盘的抗冲击、抗穿刺能力。倒塔型的塑料托柱结构，使塑料托柱端面垂直或向内倾斜，避免了在搬运时经常发生的碰撞，塑料托柱内部采用镂空结构，可以使托盘摞在一起节省空间，塑料托柱与蜂窝板面板的接触面约占蜂窝板面板总面积的20%~30%（见图2），以增强面板的承重能力和抗弯强度。 所述的塑料托柱，用于静载时支撑结构，其两侧、前后端面均呈中心对称，优选为方形、矩形或梯形；塑料托柱端面（包括两侧、前后端面）与塑料托柱底面之间的夹角为90°~110°。塑料托柱内部为加强筋或者镂空结构。 所述的蜂窝板面板厚度为15~50mm ，所述的塑料托柱（底座）高度为40~80mm。
所述的轻质热塑蜂窝板复合材料托盘根据需要，可以制作1000mm*1000mm、1200mm*1400mm、1200mm*2400mm等不同规格（均指长度*宽度）的托盘。
另外，根据承载能力需求的不同，可以调整面板结构以及托柱结构。承载面板，根据承载能力不同，可以调整面板厚度；塑料托柱根据承载能力不同，可以调整塑料托柱高度以及底座截面形状，并选择是否增加加强筋等结构。
所述的蜂窝板面板弯曲强度≥220MPa，动载承重≥2吨；
所述的轻质热塑蜂窝板复合材料托盘规格为1200mm*2400mm，面板厚度20mm时，面板弯曲强度≥300MPa，动载承重≥3吨。
本申请解决上述技术问题所采用的技术方案还包括：
一种轻质热塑蜂窝板复合材料托盘制作方法；
材料准备（蜂窝板面板的准备或蜂窝板面板、塑料托柱的准备，可以自己制作或采购蜂窝板面板、塑料托柱）：
蜂窝板面板与塑料托柱通过接触面热熔熔接或粘接。
所述材料准备步骤的一种特例仅包括蜂窝板面板制作：蜂窝板面板通过特氟龙皮带复合机或者钢带机热压成型，将上下两层玻璃纤维增强热塑复合材料与塑料蜂窝置于成型模具中加热加压制成蜂窝板面板。整个成型过程全靠热熔粘接，无需胶水，可连续生产，生产效率高，生产速度可达到3m/min，每天的单班产能可以达到3000平方。
所述蜂窝板面板与塑料托柱通过接触面热熔熔接或粘接包括两种熔接方法和一种粘接方法，当蜂窝板面板与塑料托柱通过接触面热熔熔接时，一种方法是蜂窝板面板加热至高于轻质热塑蜂窝板复合材料中树脂基体（蜂窝板面板和塑料托柱的树脂基体相同）熔点20~40°C的温度，采用包覆注射的方法，将直接注射成型的塑料托柱与蜂窝板面板背部进行热熔粘接，制成轻质热塑蜂窝板复合材料托盘。另一种熔接方法是：首先用高于轻质热塑蜂窝板复合材料中树脂基体熔点20~40°C的温度加热蜂窝板面板、塑料托柱，然后将塑料托柱与蜂窝板面板背部进行热熔粘接并保温、保压；保温、保压时间到后进行冷却定型，制得轻质热塑蜂窝板复合材料托盘。当蜂窝板面板与塑料托柱通过接触面粘接时，首先将塑料托柱、蜂窝板面板在工装上固定好；用热熔胶枪将塑料托柱与蜂窝板面板焊接成型，制得轻质热塑蜂窝板复合材料托盘。
本申请复合材料托盘易于成型、工艺简单、承载能力强。此结构设计、成型更大的优势在于它能充分利用热塑增强蜂窝板复合材料的特点：
1、采用连续纤维增强热塑复合材料，质量轻、强度高、结构稳定性好；
2、抗撞击，不易损坏，有效的弥补误操作带来的损失；
3、抗酸碱腐蚀，不腐烂，不吸水，易冲洗，易晾干，不受虫蛀和细菌侵蚀；
4、可适用各种恶劣的工作环境（-40℃~80℃下可以正常使用），适用于冷库周转及寒冷地区使用；
5、托盘采用分体成型，如有损坏可对单独部件进行或更换，大大降低了使用成本；
6、使用寿命长，材料环保，可再回收利用。
附图说明
图1是本申请轻质热塑蜂窝板复合材料托盘实施例1的结构示意图。
图2是图1的仰视示意图。
图3是本申请轻质热塑蜂窝板复合材料托盘实施例2及其工装的安装示意图。
图4是图3去掉蜂窝板面板的俯视示意图。
图5是本申请轻质热塑蜂窝板复合材料托盘实施例1的制作方法示意图。
具体实施方式
下面结合附图并通过实施例对本申请作进一步的详细说明，以下实施例是对本申请的解释而本申请并不局限于以下实施例。
参见图1～图5，轻质热塑蜂窝板复合材料托盘由（热塑）蜂窝板面板1和塑料托柱2通过接触面热熔粘结或焊接构成。
所述的蜂窝板面板1采用三层夹心结构，上层、下层均为玻璃纤维增强热塑复合材料（CFT），中间的夹心层为塑料蜂窝，其中：所述的玻璃纤维增强热塑复合材料采用热塑性材料（粒料或片材）与连续纤维混合制成，热塑性材料选自PP (聚丙烯)、PE (聚乙烯)、PA6(尼龙6)或PBT (聚对苯二甲酸丁二醇酯)中的一种或一种以上。所述的连续纤维选自玻璃纤维、碳纤维或玄武岩纤维中的一种或一种以上。
所述的塑料托柱2由热塑性材料选自PP (聚丙烯)、PE (聚乙烯)、PA6 (尼龙6)或PBT (聚对苯二甲酸丁二醇酯)中的一种或一种以上原材料或者回收料注塑成型。
所述的塑料托柱2用于静载时支撑结构，塑料托柱2呈倒塔型，塑料托柱2端面21（包括图1侧面的两个端面和图1前后方向的两个端面）21与水平面垂直或向内倾斜（通常塑料托柱端面21与塑料托柱底面22之间的夹角θ为90°~110°），避免了在搬运时经常发生的碰撞；塑料托柱2内部为加强筋和或镂空结构。
轻质热塑蜂窝板复合材料托盘的制备方法包括:
制作方法一：如图5，
(1)将裁切好尺寸的蜂窝板面板1放置在定位模具4中，参见图5上部；
(2)用高于所选轻质热塑蜂窝板复合材料中树脂基体熔点20~40°C的温度加热定位模具4、注射模具5，注射模具5置于定位模具4上，采用包覆注射的方法，将注射成型的塑料托柱2与蜂窝板面板1背部进行热熔粘接，同时进行保温、保压，参见图5中部； (3)保温、保压结束后进行冷却定型；然后脱模取件，得到所述轻质热塑蜂窝板复合材料托盘，参见图5下部。
所述的步骤(2)中的加热温度为190~255°C，保压时间为1~3min ；所述的步骤(3)中冷却定型的时间为10~15min。
制作方法二，如图3、图4：
(1)将塑料托柱2与蜂窝板面板1在工装3上固定好；
直接用热熔胶枪将塑料托柱2与蜂窝板面板1焊接成型。
制作方法三：
蜂窝板面板放置在面板定位模具中，塑料托柱放在托柱固定模具中；
用高于轻质热塑蜂窝板复合材料中树脂基体熔点20~40°C的温度加热蜂窝板面板、塑料托柱，然后将塑料托柱与蜂窝板面板背部进行热熔粘接并保温、保压；保温、保压时间到后进行冷却定型，制得轻质热塑蜂窝板复合材料托盘。
和现有技术相比，本申请的有益效果如下:
1.托盘采用包覆注射成型的方式一次性将蜂窝板面板1和塑料托柱2粘接在一起或用热熔胶枪焊接在一起，生产效率高，该托盘因其特定结构，可以堆叠存放、运输，可以节省存储、运输空间。
2.该托盘蜂窝板面板1和塑料托柱2通过热熔完全粘接，结合良好，粘接过程无需胶水，具有承载能力强、耐腐蚀、使用寿命长的优点。
3.该托盘面板采用轻质高强蜂窝板结构，重量轻，抗冲击能力强，防腐蚀，环保可回收。
凡是本申请技术特征和技术方案的简单变形或者组合，应认为落入本申请的保护范围。
Claims (10)
1.一种轻质热塑蜂窝板复合材料托盘，其特征在于：所述由蜂窝板面板和塑料托柱通过接触面粘结或焊接构成，所述的蜂窝板面板具有三层夹心结构，上层、下层均为玻璃纤维增强热塑复合材料，中间层为塑料蜂窝，所述玻璃纤维增强热塑复合材料由连续纤维增强的热塑性材料制成。
2.根据权利要求1所述轻质热塑蜂窝板复合材料托盘，其特征是：所述塑料托柱与蜂窝板面板的接触面占蜂窝板面板总面积的20%~30%。
3.根据权利要求1所述轻质热塑蜂窝板复合材料托盘，其特征是：所述塑料托柱呈倒塔型，塑料托柱端面与塑料托柱底面之间的夹角为90°~110°。
4.根据权利要求1所述轻质热塑蜂窝板复合材料托盘，其特征是：所述塑料托柱内部采用镂空结构。
5.根据权利要求4所述轻质热塑蜂窝板复合材料托盘，其特征是：所述塑料托柱内部设置有加强筋。
6.一种轻质热塑蜂窝板复合材料托盘的制作方法，其特征是包括以下步骤：
材料准备：
蜂窝板面板与塑料托柱通过接触面热熔熔接或粘接。
7.根据权利要求6所述轻质热塑蜂窝板复合材料托盘的制作方法，其特征是：所述材料准备步骤仅包括蜂窝板面板制作；蜂窝板面板通过特氟龙皮带复合机或者钢带机热压成型。
8.根据权利要求7所述轻质热塑蜂窝板复合材料托盘的制作方法，其特征是：所述蜂窝板面板与塑料托柱通过接触面热熔熔接或粘接步骤为：蜂窝板面板加热至高于轻质热塑蜂窝板复合材料中树脂基体熔点20~40°C的温度，采用包覆注射的方法，将直接注射成型的塑料托柱与蜂窝板面板背部进行热熔粘接，制成轻质热塑蜂窝板复合材料托盘。
9.根据权利要求6所述轻质热塑蜂窝板复合材料托盘的制作方法，其特征是：所述蜂窝板面板与塑料托柱通过接触面热熔熔接或粘接步骤为：用高于轻质热塑蜂窝板复合材料中树脂基体熔点20~40°C的温度加热蜂窝板面板、塑料托柱，然后将塑料托柱与蜂窝板面板背部进行热熔粘接并保温、保压；保温、保压时间到后进行冷却定型，制得轻质热塑蜂窝板复合材料托盘。
10.根据权利要求6所述轻质热塑蜂窝板复合材料托盘的制作方法，其特征是：当蜂窝板面板与塑料托柱通过接触面粘接时，首先将塑料托柱、蜂窝板面板在工装上固定好；用热熔胶枪将塑料托柱与蜂窝板面板焊接成型，制得轻质热塑蜂窝板复合材料托盘。
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