CN113213000B - 一种拼接式竹木集装箱底板 - Google Patents

一种拼接式竹木集装箱底板 Download PDF

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CN113213000B
CN113213000B CN202110471641.5A CN202110471641A CN113213000B CN 113213000 B CN113213000 B CN 113213000B CN 202110471641 A CN202110471641 A CN 202110471641A CN 113213000 B CN113213000 B CN 113213000B
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CN113213000A (zh
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龙开学
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Shaoyang Bailong Bamboo And Wood Co ltd
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Abstract

本发明公开了一种拼接式竹木集装箱底板，其包括多个板体单元，板体单元包括上面板、芯层材料以及下面板，上面板和下面板均为高密度竹材复合板体，并在下面板上成型有若干贯穿槽，这些贯穿槽内嵌装有与贯穿槽尺寸相匹配的贯穿钢条，位置相邻的贯穿钢条之间的下面板表面成型有一层增强网面作为界面层，所述增强网面表面成型有一层环氧乳化沥青衬层；而在上面板与下面层之间隔出有夹层空间，并在所述夹层空间中成型有芯层材料，所述芯层材料通过封边条进行侧面面封闭，并以该封边条作为插接结构进行拼接。本发明的拼接式竹木集装箱底板结构稳定性好，且在拼接后板体的整体性佳，具有高强度、耐酸、耐碱、耐磨的性能。

Description

一种拼接式竹木集装箱底板
技术领域
本发明涉及集装箱货柜领域中的集装箱垫板技术，具体涉及一种拼接式竹木集装箱底板。
背景技术
集装箱底板是集装箱的三大主要构件之一，主要用于垫装在集装箱的底面上进行货物承载，集装箱底板本身对强度有较高的要求。传统的集装箱底板多采用热带地域的硬质木材作为原料加工生产成型，具有工艺简单，使用加工方便的优点，但是木底板耐磨性差，使用寿命短，且硬木成才时间长，耗用量大，对环境资源消耗较大。
另外，集装箱底板一般都具有底板以及面板，其面板最好为一全尺寸板，且面板的纤维纹理通常与集装箱底架纵向平行以加强底板纵向强度以满足集装箱使用的要求。而随着木材资源的日益紧缺和克隆原木的濒临绝种，不仅是大尺寸的全幅板材越来越少，市面上还是出现3×3、3×2以及其他尺寸的拼接式集装箱底板，这种拼接式集装箱底板便于更换和维护，也逐渐形成一种新的集装箱底板品类，而随着硬质木材在集装箱底板中的使用比例也越来越低，越来越多的材料被应用于集装箱地板的生产过程中，如竹质材料、各种纤维材料、树脂材料、金属材料等都在集装箱地板领域中有应用，而其中作为速生材料的竹质材料成为了新一代的替代材料，越来越多的生产者和研究者都把目光投向了这种生长周期短、价格低廉的材料，但现有技术的复合材料集装箱底板的结构设计不合理，无法解决复合材料内部密度差异所带来的强度问题，导致成型后的集装箱底板物理性能不稳定，在面层承受压力和冲击力的应力作用时，内部结构相比于传统的硬质木材底板稳定性更差，在使用一段时间后容易在集装箱底板的内部形成裂纹，并持续发展导致底板在内部裂纹产生后不久出现断裂失效的情况，而这种缺陷在应用于拼接式集装箱底板中时表现的尤为明显。
基于上述原因，市面上需要一种能同时满足整体结构稳定性、强度需求和拼装便利性需求的拼接式竹木集装箱底板。
发明内容
本发明所解决的技术问题在于提供一种拼接式竹木集装箱底板，这种与拼接式竹木集装箱底板将竹材作为基材与其他材料进行复合，并在拼接位置进行结构设计，保证拼装便利性的同时保证集装箱底板拼接后的整体承载强度和结构稳定性，以解决上述技术背景中的缺陷。
本发明所解决的技术问题采用以下技术方案来实现：
一种拼接式竹木集装箱底板，包括能进行拼接的多个板体单元，这些板体单元结构一致，均包括上面板、芯层材料以及下面板；
所述上面板以及所述下面板均为高密度竹材复合板体，所述高密度竹材复合板体由偶数层的高密度竹材薄板经过涂胶后热压复合成型，单层高密度竹材薄板的单层厚度的3~5mm，同层高密度竹材薄板上的竹纤维纹路走向一致，而相邻层的高密度竹材薄板的竹纤维纹路之间相互垂直；
所述下面板的上表面上成型有若干等间距设置的贯穿槽，所述贯穿槽为盲槽，沿下面板中最上层高密度竹材薄板上的竹纤维纹路平行设置，贯穿槽的深度小于下面板的厚度且大于单层高密度竹材薄板的厚度，贯穿槽内嵌装有与贯穿槽尺寸相匹配的贯穿钢条，所述贯穿钢条高出下面板的上表面；相邻的贯穿钢条之间的下面板表面成型有一层增强网面作为界面层，并在所述增强网面表面成型有一层环氧乳化沥青衬层，所述环氧乳化沥青衬层的厚度为3~5mm，且不高于贯穿钢条的上表面；
所述上面板与所述下面层之间隔出有夹层空间，并在所述夹层空间中成型有芯层材料，所述芯层材料在一侧设置有用于对两块板体单元进行拼接的插接结构，并在所述插接结构位置通过封边条进行侧面面封闭，且所述封边条在对应插接结构的内凹部分内侧对应顶靠于所述贯穿钢条的外侧面上，并将所述环氧乳化沥青衬层以及所述芯层材料封装于所述封边条的内侧。
作为进一步限定，所述高密度竹材薄板的获得方式为将竹材经过去黄去青后碱煮，在碱煮完成后通过蒸汽软化后展平后并加工成竹帘，然后用竹帘热压胶合并压制成高密度竹材薄板。
作为进一步限定，所述上面板中的高密度竹材薄板层数优选为两层，而所述下面板中的高密度竹材薄板层数优选为四层。
作为进一步限定，所述上面板中最上层高密度竹材薄板的纤维走向与集装箱的长度方向平行。
作为进一步限定，所述贯穿槽为剖面呈上大下小的倒等腰三角形或者倒等腰梯形槽，而所述贯穿钢条为实心钢条，截面形状与所述贯穿槽相匹配，其下部嵌装于所述贯穿槽中，并通过所述环氧乳化沥青衬层封闭，而上表面为平面，并成型于所述芯层材料中。
作为进一步限定，所述芯层材料为竹木复合材料，由高密度竹材薄板和木质单板交替叠合后上胶、并热压成型，所述木质单板为木质刨花板、橡胶木单板或者热带硬杂木，成型后的芯层材料在贯穿钢条对应位置铣出预留槽，并在预留槽位置压力注胶后硬化后成型。
作为进一步限定，所述芯层材料为高密度纤维浆料填充并硬化成型，且所述高密度纤维浆料填充层的成型密度为680~750kg/m3；而作为优选的技术方案，该高密度纤维浆料填充层以脲醛树脂作为基础材料，并在脲醛树脂中均匀分散有增强纤维，所述增强纤维为尼龙纤维、杂环族聚酰胺纤维与高强度纤维的比例混合物，所述高强度纤维为高强高模聚乙烯纤维与玄武岩纤维的任意比例混合物，且高强度纤维在增强纤维中的质量比不少于30%。
作为进一步限定，所述增强网面为尼龙网面。
作为进一步限定，所述封边条为一整根方管通过折弯机折弯成型后在插接结构位置进行封边。
本发明的优点及有益效果在于：
①本发明的一种拼接式竹木集装箱底板具有工艺简单、强度高的特点，且其结构相对于传统竹木材料集装箱底板也更加合理，对竹材的性能利用率也更高，更好的利用了木材资源，降低了集装箱底板的使用成本。
②通过高密度竹材薄板叠合的高密度竹材复合板体作为上面板以及下面板，能有效利用竹材的纤维纹路的交错贴合提高面层的强度，以提高集装箱底板的纵向强度和抗剪切的能力，更好的保证底板整体性能，而环氧乳化沥青衬层的设置配合贯穿钢条的设置能有效提高夹层空间中的芯层材料的承压性能，用以减缓芯层材料内部出现开裂现象，延长底板使用寿命。
③通过贯穿钢条提高集装箱底板的纵向强度，使得集装箱底板在拼接后具有更好的整体性能。
附图说明
图1为本发明的较佳实施例的结构示意图。
图2为本发明的另一实施例的结构示意图。
其中：1、第一高密度竹材薄板；2、第二高密度竹材薄板；3、高密度纤维浆料层；4、环氧乳化沥青衬层；5、增强网面；6、贯穿钢条；7、封边条；8、第三高密度竹材薄板；9、第四高密度竹材薄板；10、芯层高密度竹材薄板；11、木质单板；12、第五高密度竹材薄板；14、第六高密度竹材薄板。
具体实施方式
为了使本发明实现的技术手段、创作特征、达成目的与功效易于明白了解，下面结合具体图示，进一步阐述本发明。
参见图1的一种拼接式竹木集装箱底板的实施例，在本实施例中，拼接式竹木集装箱底板包括六个板体单元，六个板体单元按照3×2的方式进行排列，其长度方向设置三组，每组包括宽度方向上的两块，位置相邻的板体单元在相邻边上通过方波形状的插接结构进行咬合拼接以拼接形成一块完成的竹木集装箱底板来对集装箱的底面进行垫装。
而在另外的实施例中，板体单元也可以设置为3×3或者3×1等其他规格，以能拼接并形成一块完整的能平铺于集装箱底面的集装箱底板为准。
在本实施例中，每个板体单元均包括第一高密度竹材薄板1、第二高密度竹材薄板2、高密度纤维浆料3、第三高密度竹材薄板8以及第四高密度竹材薄板9，其中，第一高密度竹材薄板1、第二高密度竹材薄板2、第三高密度竹材薄板8以及第四高密度竹材薄板9均以竹材为原料成型制成，制备时，先将竹材经过去黄去青后碱煮，在碱煮完成后通过蒸汽软化后展平后，使竹纤维纹路走向一致并加工成竹帘，竹帘表层剥皮，留中心韧部，然后用竹帘热压胶合并压制成高密度竹材薄板，成型后的高密度竹材薄板的单层厚度控制在4~5mm即得到制备第一高密度竹材薄板1、第二高密度竹材薄板2、第三高密度竹材薄板8以及第四高密度竹材薄板9的原料竹材薄板。其中，第一高密度竹材薄板1、第二高密度竹材薄板2叠合后使两者的竹纤维纹路相互垂直，并在经过涂胶后热压复合成型得到上面板，而第三高密度竹材薄板8以及第四高密度竹材薄板9叠合后使两者的竹纤维纹路相互垂直，并在经过涂胶后热压复合成型得到下面板。
然后调整下面板的朝向，使得第四高密度竹材薄板9的竹纤维走向平行于集装箱的长度方向，并在其下面板的表面铣出若干条剖面为倒梯形的贯穿槽，该贯穿槽沿集装箱的宽度方向设置，且这些贯穿槽等间距设置于下面板上，这些贯穿槽深度小于下面板的厚度且大于单层高密度竹材薄板的厚度，贯穿槽中嵌装成型有与贯穿槽尺寸相匹配的贯穿钢条6，并在贯穿钢条6之间的第三高密度竹材薄板8表面上成型有一层尼龙网面作为增强网面5，而在增强网面5上则成型有一层厚度为3~5mm的环氧乳化沥青衬层4。该贯穿钢条6对应的倒等腰梯形的下底高于环氧乳化沥青衬层4的表面，并在该环氧乳化沥青衬层4与贯穿钢条6的表面上通过压力注浆方式成型有高密度纤维浆料层3，该高密度纤维浆料层3由高密度纤维浆料填充并硬化成型，用于成型高密度纤维浆料层3的浆料以脲醛树脂作为基础材料，其中分散有质量比为4:4:3:1的尼龙纤维、杂环族聚酰胺纤维、高强高模聚乙烯纤维、玄武岩纤维的混合物纤维作为增强纤维，并保证该高密度纤维浆料层3成型后的密度为680~750kg/m3即可，高密度纤维浆料层3为本实施例中的芯层材料。
而在每个板体单元的外侧拼接位置均设置有拼接面，在本实施例中，该拼接面为相互啮合的方波形拼接面，在上面板与下面板之间的外缘拼接面位置成型有呈方波形结构的封边条7，该封边条7为一整根方管通过折弯机折弯成型于该拼接面位置，用于将位置相邻的板体单元按照如图中箭头所示方式进行拼接。
本实施例的板体单元具有较佳的拼接性能，且拼接成型后的集装箱底板具有较佳的结构稳定性，其极限承重为整块成型的硬质木材底板的0.8~1.1倍，且由于其内部通过高密度纤维浆料层3进行填充，配合环氧乳化沥青衬层4进行内部减震，使得该集装箱底板在承重条件下连续使用的寿命为整块成型的硬质木材底板0.9~1.2倍，且由于该集装箱底板为拼接结构，因而可以在其中一块板体单元损坏后，其该板体单元进行替换，能有效提高其他板体单元循环使用率，降低使用成本。
而为了追求更为极限的承压性能，可以将板体单元设置为如图2所示的另一实施例形态，在图2所示实施例中，用于成型上面板和下面板的高密度竹材薄板的单层厚度为3~4mm，其上面板与图1所示的实施例保持一致，包括第一高密度竹材薄板1以及第二高密度竹材薄板2，而下面板则包括四块层叠并涂胶热压成型的高密度竹材薄板，即除第三高密度竹材薄板8和第四高密度竹材薄板9之外，在第四高密度竹材薄板9之下还成型有第五高密度竹材薄板12以及第六高密度竹材薄板14，加厚的下面板能有效提高集装箱底板的承压性能，而由于集装箱底板本身的受力特性，其芯层材料上部以及上面层主要承受压应力的作用，而芯层材料下部以及下面板主要承受拉应力的作用，多层结构的上面板和下面板能够通过竹纤维之间的
也能使得第一高密度竹材薄板1的表面承受压应力的作用以及芯层材料以及下面板位置承受拉应力时利用薄板的层间结构进行强度弥补，提高底板的纵向强度和抗剪切的能力，使得上面板以及下面板不容易出现开裂现象，更好的保证底板整体性能。而为了进一步优化这种性能，在图2所示的实施例中，芯层材料也采用竹木复合的多层结构，其包括两层芯层高密度竹材薄板10以及两层木质单板11，芯层高密度竹材薄板10和木质单板11上胶后相互交错层叠，并热压成型，其芯层高密度竹材薄板10的成型方式与包括第一高密度竹材薄板1、第二高密度竹材薄板2、第三高密度竹材薄板8、第四高密度竹材薄板9、第五高密度竹材薄板12以及第六高密度竹材薄板14在内的高密度竹材薄板的单板成型方式一致，而木质单板11则为木质刨花板或者橡胶木单板或者热带硬杂木，而为了方便贯穿钢条6进行装配，可以在热压合成型的芯层材料上对应贯穿钢条6的位置铣出对应的预留槽，并在预留槽对贯穿钢条6进行装配，并在装配并保持热压成型的过程中进行压力注胶保持，并在硬化成型后得到对应的成品板体单元。
以上显示和描述了本发明的基本原理、主要特征和本发明的优点。本行业的技术人员应该了解，本发明不受上述实施例的限制，上述实施例和说明书中描述的只是说明本发明的原理，在不脱离本发明精神和范围的前提下，本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等效物界定。

Claims (9)

1.一种拼接式竹木集装箱底板，其特征在于，包括能进行拼接的多个板体单元，这些板体单元结构一致，均包括上面板、芯层材料以及下面板；
所述上面板以及所述下面板均为高密度竹材复合板体，所述高密度竹材复合板体由偶数层的高密度竹材薄板经过涂胶后热压复合成型，单层高密度竹材薄板的单层厚度的3～5mm，同层高密度竹材薄板上的竹纤维纹路走向一致，而相邻层的高密度竹材薄板的竹纤维纹路之间相互垂直；
所述下面板的上表面上成型有若干等间距设置的贯穿槽，所述贯穿槽为盲槽，沿下面板中最上层高密度竹材薄板上的竹纤维纹路平行设置，贯穿槽的深度小于下面板的厚度且大于单层高密度竹材薄板的厚度，贯穿槽内嵌装有与贯穿槽尺寸相匹配的贯穿钢条，所述贯穿钢条高出下面板的上表面；
相邻的贯穿钢条之间的下面板表面成型有一层增强网面作为界面层，所述增强网面表面成型有一层环氧乳化沥青衬层；
所述环氧乳化沥青衬层的厚度为3～5mm，且不高于贯穿钢条的上表面；
所述上面板与所述下面板之间隔出有夹层空间，并在所述夹层空间中成型有芯层材料，所述芯层材料在一侧设置有用于对两块板体单元进行拼接的插接结构，并在所述插接结构位置通过封边条进行侧面面封闭，所述封边条在对应插接结构的内凹部分内侧对应顶靠于所述贯穿钢条的外侧面上，并将所述环氧乳化沥青衬层以及所述芯层材料封装于所述封边条的内侧。
2.根据权利要求1所述的拼接式竹木集装箱底板，其特征在于，所述高密度竹材薄板的获得方式为：
将竹材经过去黄去青后碱煮，在碱煮完成后通过蒸汽软化后展平后并加工成竹帘，然后用竹帘热压胶合并压制成高密度竹材薄板。
3.根据权利要求1所述的拼接式竹木集装箱底板，其特征在于，所述上面板中的高密度竹材薄板层数为两层，而所述下面板中的高密度竹材薄板层数为四层。
4.根据权利要求1所述的拼接式竹木集装箱底板，其特征在于，所述上面板中最上层高密度竹材薄板的纤维走向与集装箱的长度方向平行。
5.根据权利要求1所述的拼接式竹木集装箱底板，其特征在于，所述贯穿槽为剖面呈上大下小的倒等腰三角形或者倒等腰梯形槽，而所述贯穿钢条为实心钢条，截面形状与所述贯穿槽相匹配，其下部嵌装于所述贯穿槽中，并通过所述环氧乳化沥青衬层封闭，而贯穿钢条上表面为平面，并成型于所述芯层材料中。
6.根据权利要求1所述的拼接式竹木集装箱底板，其特征在于，所述芯层材料为竹木复合材料，由高密度竹材薄板和木质单板交替叠合后上胶、并热压成型，所述木质单板为木质刨花板或者橡胶木单板或者热带硬杂木；成型后的芯层材料在贯穿钢条对应位置铣出预留槽，并在预留槽位置压力注胶后硬化后成型。
7.根据权利要求1所述的拼接式竹木集装箱底板，其特征在于，所述芯层材料为高密度纤维浆料填充并硬化成型，且所述高密度纤维浆料填充层的成型密度为680～750kg/m3。
8.根据权利要求7所述的拼接式竹木集装箱底板，其特征在于，所述高密度纤维浆料填充层以脲醛树脂作为基础材料，并在脲醛树脂中均匀分散有增强纤维，所述增强纤维为尼龙纤维、杂环族聚酰胺纤维与高强度纤维的比例混合物，所述高强度纤维为高强高模聚乙烯纤维与玄武岩纤维的任意比例混合物，且高强度纤维在增强纤维中的质量比不少于30％。
9.根据权利要求1所述的拼接式竹木集装箱底板，其特征在于，所述增强网面为尼龙网面。
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CN212173219U (zh) * 2020-02-24 2020-12-18 湖南中集新材料科技有限公司 集装箱底板及具有其的集装箱
CN211640275U (zh) * 2020-03-05 2020-10-09 福建省闽清双棱竹业有限公司 一种对称拼接式集装箱底板竹木材质胶合板
JP3230850U (ja) * 2020-12-04 2021-02-25 信和自動車工業株式会社 貨物自動車荷台用の竹床板

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