CN1248848C - 使用预固化的强化芯层的嵌板及其制造方法 - Google Patents

使用预固化的强化芯层的嵌板及其制造方法 Download PDF

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Publication number
CN1248848C
CN1248848C CNB008140138A CN00814013A CN1248848C CN 1248848 C CN1248848 C CN 1248848C CN B008140138 A CNB008140138 A CN B008140138A CN 00814013 A CN00814013 A CN 00814013A CN 1248848 C CN1248848 C CN 1248848C
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China
Prior art keywords
panel
floor
layer
sandwich layer
top layer
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CNB008140138A
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CN1378504A (zh
Inventor
戴维·M·洛克
约翰·J·托米特
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MILWAUKEE SYNTHETIC COMPOSITES Inc
Milwaukee Composites Inc
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MILWAUKEE SYNTHETIC COMPOSITES Inc
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Abstract

一种公交车辆地板组件，包括多个夹心板。夹心板(30)包括一个顶层(54)，一个底层(58)，一个确定周边的收边(46)，以及一个介于顶层(54)和底层(58)并在收边(46)内的芯层(50)。收边(46)包括配合面用于连接相邻的嵌板。芯层是一种预固化的强化芯层，包括多个酚醛肋条和泡沫条，它们以交替的方式放置。预固化芯层的加工是通过在两个泡沫芯层之间用酚醛树脂浸渍织物层，并以交替的方式堆叠以形成一个泡沫胶块。当泡沫胶块在一个恒定压力和温度下固化并冷却后，沿垂直于各层的平面的一个平面切割泡沫胶块，以提供一个预固化的强化芯层嵌板，用于作为芯层插入在夹心板中。

Description

使用预固化的强化芯层的嵌板及其制造方法
技术领域
本发明涉及夹心板，特别涉及使用预固化的强化芯层的夹心板及其制造方法。
夹心板用于要求结构绝缘和/或热绝缘特性的各种应用中。这些应用包括高速公交车辆中的建构和非建构使用，冷却和非冷却建筑，船只，飞机，休闲车辆，封闭式活动房以及其他。建筑用夹心板是通过将两个通常较薄的表面或表层结合在一个相对较厚的芯层材料上而构成的合成结构。表层通常致密而坚固，经得住压力和拉力，而芯层一般由相对不很坚固并且低密度的材料制成，用以分隔开表层，消除它们的翘曲并且抵抗剪切载荷。
相关的在先技术
用于公交车辆的地板组件是一种简单的夹心板的一个例子。用于构造地板的常用材料是各种木料和不锈钢。通常所知通过提供不锈钢薄层，将其附在由木料，一般是轻木或胶合板制成的支撑框架顶部来构造这种地板组件。钢层提供具有刚性和耐久性的暴露表面，而木质框架为地板提供轻型的刚性支撑结构。组成部件和材料的这一结合在业界作为可取之道广为人知，因为该结构足可满足安全要求，包括所有用于公交车辆的地板组件所必需的烟火试验。
更为标准的夹心板的常用芯层是刚性的发泡塑料泡沫和蜂窝材料。蜂窝状芯层一般包括一种薄层材料，比如纸张或铝箔，它制成各种空腔构造。发泡塑料泡沫通常比蜂窝材料提供更高的绝热程度，但是蜂窝材料一般比密度相当的绝缘泡沫芯层更加坚固。
为了浸渍空间或增加更高的绝热程度以结构上适应蜂窝式芯层，采用了各种将绝缘泡沫导入蜂窝材料的空腔内的方法。包括诸如将发泡化学剂加到蜂窝空腔内，并且将塑料泡沫板压入空腔内的方法。但是，在厚芯层部分难于进行这些加工方法，或者说需要在加工机器上投入更大的投资。从而，这种合成芯层在许多夹心板应用中很少使用，并且因此许多蜂窝式芯层产品绝缘性不够而使得水易于侵入芯层。
具有金属、木料、玻璃纤维增强塑料和类似的可耐久的材料的表层的夹心板普遍通过三种基本工序加工制造。一种工序中，液态化学试剂，一般具有聚异氰脲酯配方，注入在表层之间，其后它们发生反应并膨胀形成刚性泡沫，该刚性泡沫将其与表层结合而形成夹心板。加工夹心板的第二种方法是利用胶粘压层，其中利用粘合剂将预制的嵌板表层和从膨胀泡沫板坯切割下来的刚性泡沫板的芯层结合。第三种方法，未固化的树脂和强化材料施加到这种泡沫板的表面，或者将树脂导入装有芯层和表层强化物的封闭的或真空的包装好的模子里并且随后固化形成刚性表层。可固化的表层可以是，例如，热固聚酯、乙烯酯、环氧树脂、聚亚安酯或酚醛树脂。也可以使用诸如聚丙烯或聚醚醚酮(PEEK)的热塑树脂，只需要施加足够的热量以使其流动并浸湿强化物。强化物包括诸如玻璃、碳或者合成聚合纤维的材料，它们编织或绑结在织物中或者构成为散乱纤维的致密垫，并通常铺设成平面排列。
夹心板压层使用各种这类预制芯层，包括聚亚安酯、聚异氰脲酯、挤压聚苯乙烯、膨胀聚苯乙烯、聚偏二氯乙烯及泡沫玻璃。结构上需要的夹心板应用，如船体的塑料泡沫芯层通常由线性或交联的聚氯乙烯(PVC)配方制成，其密度为每立方英尺2到16磅。每板英尺(perboard foot)的这种材料的高额花费限制了它在诸如公路活动房和休闲车辆的中高性能应用中的使用。PVC泡沫和诸如聚苯乙烯的其他热塑泡沫的另一个不足是当在运输和其他环境中发生的温度升高时它们的物理属性严重退化。
由于刚性泡沫绝缘芯层的内在结构限制，塑料泡沫芯层夹心板经常会在其设计和成本之间存在严重的折衷。除了因表层中的拉压应力导致的嵌板的变形外，另外的变形是由于刚性泡沫材料的较低的剪切模量。芯层越厚，剪切变形变的越明显，因弯曲而达到过度变形极限。在持续增加的负载作用下，塑料泡沫还易于蠕变，进一步增加了嵌板的变形，结果是夹心板有断裂的危险。
芯层的这些不足要求通过使用相当重且昂贵的表层来提高合成物的强度和硬度。另外，通过将泡沫芯层的厚度或密度增加到高于可接受的限定值而在结构上改进嵌板，这也提高了材料和运输的花费。低密度塑料泡沫芯层的较低压缩模量也使得薄平板表层以相对较低的应力水平发生弯曲，作为补偿还需要表层或较高密度泡沫芯层的保险设计。泡沫芯层的低抗剪强度和其中没有强化材料使得在致裂应力作用下芯层和嵌板表层之间以及芯层自身内部发生延展，结果是嵌板损坏或结构失效。再一个不利是大部分塑料泡沫的低压缩强度，这使得集中载荷或冲击载荷使表层和芯层变形。
金属、木料、玻璃纤维增强塑料和其他材料的加强框架或加强肋用于泡沫芯层夹心板以缓减或克服上述的结构限制。尽管泡沫芯层和加强肋都有助于加大这些嵌板的强度，但是在这种构造中的肋条的结构上的作用基本上并不依赖于泡沫芯层的存在。
大间距分开的肋条的一个常见的严重缺陷是在一个通常更为柔性的嵌板中产生过度刚性的结构部分。这会导致在肋条和表面层压板，尤其是和用较高强度的合成材料制成的薄表面层压板的相交处不希望的集中载荷。合成物的结构属性可以通过在表层间组装有大量单独的泡沫挡块或阻条来改善，其中泡沫挡块或阻条由连接表层并浸渍其间的空腔的纤维加强材料缠绕。在该绞合期间，施加浸渍性树脂到表层和芯层强化物中。另外，当处于干燥和疏松的状态时，表层和芯层强化物及泡沫的所有成分可以放置在一个模子里，其后封闭模子并在压力下导入树脂，如同真空辅助树脂传递模塑法一样，从而流入并浸渍强化物。
加工强化泡沫芯层的另一个常用方法采用了将干燥的有吸附性的纤维网粘接到交替的泡沫芯层嵌板上。通过在各层间利用粘合剂交替地堆叠刚性泡沫绝缘板和薄的弹性纤维层，并随后当粘合剂凝固后压紧叠层以形成芯层嵌板或芯层板坯，从而提供强化泡沫芯层。穿经交替各层并沿平行的分隔平面切割板坯来形成强化泡沫芯层嵌板，每条都有由纤维层条带构成的隔网。利用具有干燥纤维网的强化泡沫芯层的方法在业界作为可取之道广为人知，因为干燥网中的多孔性能够通过吸附施加到上覆的嵌板表层的树脂而形成整体结合。
发明概述
在所知的地板组件中存在的困难中，难点在于地板组件的加工、装配和安装。木质和钢制地板必须在车辆本身内加工和安装。这种工序不允许地板部件的节约成本的工厂预制。
所知的地板组件中存在的另一个困难是关联于这种地板的相对较高的保养费用。对于这种情况，公知的地板组件难于防水密封。在诸如客运列车、公共汽车等等的公交车辆的环境中，潮气以水的形式经常被带到地板上，并且渗透进入地板并和木质框架接触。一旦潮湿浸透木质框架，潮湿就积聚在钢层下面。这会导致加速分解或腐烂过程。腐烂的框架使得地板易于损坏，这就必须要更换腐烂的木料或者更换整个地板。
本发明通过提供一种坚固的、轻型的、防水的合成地板而解决了这些问题，这种地板简化了加工和安装。这种设计使用可靠的材料和成分，以酚醛成分材料的高级烟火性能等级为特征。这种设计相比于传统的运输车辆地板还降低了重量。
在一个实施例中，本发明提供一种地板组件，它由具有足够刚度和防水性的合成材料构造，从而适合公交车辆的严格环境。此外，该地板组件的部件由一种通过安全测试要求的合成材料制成。
具体地，本发明提供一种含有酚醛成分的合成地板。该地板组件包括一个具有一个夹心结构合成板。该板通过将两块薄表层或者表面结合到一个相对较厚的芯层材料上而制成。表层由建筑用酚醛成分制成。在用酚醛树脂浸渍两个玻璃纤维增强层后表层被固化。芯层材料包括轻型且刚性闭孔泡沫以及酚醛肋条的组合。酚醛肋条提供了地板中必要的加强。泡沫芯层阻止水分吸收并且还为表层提供优质的结合特性。预制肋条的芯层的其他优点和其他芯层材料的劣势将在以下论述。
酚醛收边模铸到地板棱边以防止水分进入芯层并且为地板提供额外的强度和稳定性。酚醛收边围绕地板的周边并且由同一固化工序结合到上和下表层以防水密封芯层。
酚醛地板组件易于安装到公交车辆中。地板用大量预制好的嵌板现场组装。酚醛收边易于加工，允许在嵌板之间形成高密度的接缝。预制好的嵌板通过将搭接处插入在酚醛收边里可以容易地相互连接。由酚醛收边制成的开孔板和固定件可以固化在地板芯层内以在装配区提供额外的支撑。地板的这些区域可以很容易地现场钻孔和攻丝以将地板机械地固定在车架上。
在一个实施例中，本发明提供一种含有多个嵌板的地板组件。每个嵌板相互连接并且每个嵌板包括一个确定一个顶面的顶层，一个确定一个底面的底层。该组件还包括收边部件，它接触顶层和底层并部分地确定所述地板的周边。该地板组件还包括一个位于顶层和底层之间的芯层。芯层包括一个加肋的芯层，它的一个侧壁接触收边部件。
在另一个实施例中，本发明提供一种用于客运列车的地板组件，其中客运列车包括一个车厢组件，车厢组件包括隔开的侧壁、隔开的端壁、以及一个地板支撑组件。地板组件包括相互连接以覆盖地板支撑组件的多块地板，每一块地板都包括一个顶层，该顶层具有两个侧边、两个端边、一个内表面、以及一个确定所述地板上表面的外露表面。每一块地板还包括一个底层，该底层具有两个侧边、两个端边、一个内表面、以及一个确定所述地板下表面的外露表面。每一块地板还包括两个侧收边，每一个侧收边包括一个内表面、一个外露在地板的侧面上的外表面、一个接触顶层的内表面的顶面、一个接触底层的内表面的底面、以及两个确定侧收边的长度的端面。每一块地板还包括两个端收边，该端收边包括一个内表面，内表面与侧收边的端面接触并与侧收边一起确定所述底板的外周边。地板组件还包括一个位于侧收边和端收边内的芯层，芯层包括与侧收边和端收边的内壁接触的侧壁。芯层还包括一个与顶层内表面接触的上表面、以及一个与底层内表面接触的下表面。
用于夹心板的常见芯层材料具有许多劣势。带有干网的强化泡沫芯层所具有的难点中，用于将干网和泡沫芯层结合在一起的粘合剂防碍其用在有严格的安全标准的行业。例如，公交行业受各种安全要求的限制，包括对用于公交应用中的所有地板组件的烟火测试。最为普遍地用于粘接的氨基甲酸酯粘合剂燃烧时产生一种气体，不符合规定所设的标准。因此，这类强化芯层对于用在公交行业的嵌板来说是不可取的。
肋条中未经破坏性实验的酚醛结合质量的目测也是困难或不可能的。干网开始局部饱和于用于浸渍顶和底层玻璃纤维的液态酚醛树脂。因为干网是和顶层及底层同时固化的，发生在干网内的固化的完整性和程度是目测不了的。为了确定干网固化的质量，某种程度上干网必须作成可以目测。例如，嵌板需要切成横截面。
粘接的干网泡沫芯层具有的其他困难是由于干网中的粘合剂和空腔导致的酚醛结合的不一致和不均匀。理想地，干网材料应当完全浸渍有液态酚醛树脂以在固化后形成一致而均匀的酚醛结合。然而，起初氨基甲酸酯粘合剂浸渍干网，随后，不能进行酚醛树脂的适当浸渍。结果是，氨基甲酸酯区域比酚醛树脂区域具有不牢靠的结合。还有，粘合剂是从一个滴棒涂敷的，该滴棒在纤维表面上的一个中间位置滴落粘合剂。因为粘合剂不是均匀并完全地涂敷在干网上，所以在树脂浸渍阶段会产生气泡和空腔。干网中的这些空腔增加了干网性能的不可靠度。充分的酚醛结合形成结构上更加刚性和坚固的结合，这就导致一致性和可靠性。
带有干网的强化泡沫芯层所具有的另一个难点是由于在泡沫芯层和干网之间的脆弱的结合而带来的处理困难。强化泡沫芯层是用于加工酚醛嵌板因此经常被处理和移动。这种移动经常会导致干网和泡沫芯层之间的结合断裂。这就导致浪费或者实施减少损坏的系统的额外花费。
本发明通过提供一种加工预固化强化泡沫芯层的方法解决了这些问题，该方法可以超过公交行业的安全标准，并且能够提供一种在整个肋条中的可目测的、坚固的、以及均匀的酚醛结合。
具体地，预固化强化芯层优于公交行业要求的安全测试。泡沫板和玻璃纤维利用液态酚醛树脂结合在一起。固化的酚醛，以及其他材料一起，通过必要的安全测试。不使用不符合烟火测试安全标准的粘合剂。
此外，在芯层掩藏在嵌板表层内以前，酚醛结合的质量可以目测。泡沫胶块在恒定温度和压力下固化后，泡沫胶块沿垂直于泡沫层平面的平面切割。从该有利位置可以目测酚醛结合的质量。另外，玻璃纤维不含任何防止液态酚醛树脂均匀浸渍的粘合剂。因为可以目测酚醛结合的质量以及可以获得液态酚醛树脂的均匀浸渍，所以地板的整体性能和质量将保持一致。
通过以下的详细说明、权利要求书和附图，本领域技术人员会更加清楚本发明的其他特征和优点。
附图简述
图1是本发明第一实施例的车厢组件的平面图；
图2是图1所示的组件的局部正视图；
图3是图2所示的地板组件中包含的地板的透视图；
图4是图3所示的地板的分解透视图；
图5是沿图3中线5-5的横截面图；
图6是沿图3中线6-6的横截面图；
图7是本发明另一个实施例的第二车厢组件的平面图；
图8是本发明所述预固化强化芯层的加工方法的流程图；
图9是按照图8的流程图加工的预固化强化芯层的泡沫胶块的分解透视图；
图10是从图9所示的泡沫胶块切割下来的预固化强化芯层的嵌板的透视图。
在详细说明本发明的一个实施例之前，应当理解本发明的应用不限制于以下说明或附图示例指出的结构和部件安排。本发明可有其他实施例并且可以以各种方式实施或实现。另外，应当理解这里所用的措辞和术语出于说明的目的而不应认为是限制。
优选实施例详述
图1-6表示了实施本发明的一个第一车厢组件10。参考图1，车厢组件10是一个客运列车车厢，它包括隔开的侧壁14和隔开的端壁18。两个相对的的侧壁14和两个相对的端壁18相连接，它们一起确定了组件10的周边。车厢组件10还包括一个地板支撑组件22(如图1的虚线所示)。地板支撑组件22围绕车厢组件10的周边延展，各部件垂直于长度间隔分开。
车厢组件10还包括一个固定在地板支撑上并由侧壁14和端壁18包围的地板组件26(图1和2)。
参考图2，地板组件26包括多块地板30以及两个端板34。地板组件26为公交车厢10内的乘客、座椅提供支撑。地板30和端板34相互连接覆盖车厢10内的整个区域。
地板组件26，包括地板30和端板34，可以以各种方式构造以提供公交车辆地板。例如，图7表示了本发明的另一个实施例的一个第二车厢地板组件38。地板组件38适于用做位于公共汽车内并在汽车车架上的驾驶室的地板。地板38具有与地板26显著不同的周边，但是由同样的基本部件构造而成。
地板30，34具有类似的结构。每一个的各自形状取决于嵌板的位置以及围绕地板组件26的车厢组件10的侧壁14和端壁18的构形。因此，为了易于理解，只详细描述一个地板30。
参考图3和4，每个地板30包括两个侧收边42、以及两个端收边46。该两个端收边46隔开一定距离并连接于侧收边42的端部。地板30还包括一个芯层50。芯层50占据了由相连的一对收边42、46确定的空间。芯层材料可以包括轻木、胶合板、泡沫、强化材料、或者它们的任何组合。地板30还包括一个顶层54和一个底层58。顶层54位于芯层50、端收边46和侧收边42上面而底层58位于芯层50、端收边46和侧收边42下面。表层54、58和收边42、46用于防止水分进入地板30的内部。
顶层54在地板30的上表面提供一个耐久的表面。顶层54提供一个内表面62，该内表面与芯层50、侧收边42和端收边46的顶侧接触。顶层54还提供一个外露表面66，该外露表面确定了地板30的上表面。
底层58在地板34的下侧提供一个耐久的表面，为了稳定和安装的目的。底层58还包括一个内表面70和一个外露表面74。内表面70与芯层50、侧收边42和端收边46的底侧接触。外露表面74确定了地板30的下表面。
每个侧收边42包括一个内表面78和一个外表面82。侧收边42的内表面78接触芯层50而侧收边42的外表面82外露在地板30的侧部。侧收边42还包括一个上表面86和一个下表面90。侧收边42的上表面86与顶层54的内表面62接触而侧收边42的下表面90与底层58的内表面70接触。侧收边42还包括两个端面94(示出一个)。端面94确定了侧收边42的长度。
每个端收边46也包括一个内表面98和一个外表面102。端收边46的内表面98接触侧收边42的端面94，二者一起确定了地板30的外周边。在侧收边42之间的区域内，端收边46的内表面98接触芯层50。端收边46的外表面102外露在地板30的侧部。端收边46还包括一个上表面106和一个下表面110。端收边46的上表面106与顶层54的内表面62接触而端收边46的下表面110与底层58的内表面70接触。端收边46还包括两个端面114(示出一个)。端收边46的端面114外露于地板的侧面。
端收边46还包括一个配合面118。配合面118允许在公交车辆中简单装配预加工好的地板30。典型地，该表面是一个搭接面。配合面118和相邻的地板30的另一个配合面118接触。
参考图6，配合面118包括孔122、以及锥形扩孔126。沿配合面118的孔以及锥形扩孔122、126允许机械地将相邻的地板30、34端对端地固定在一起并且将地板30固定在地板支撑组件22上。
参考图4，芯层50占据了地板30的内部。芯层50的侧边与端收边46和侧收边42的内表面98、78接触。芯层50包括一个上表面和一个下表面。芯层50的上表面与顶层54的内表面62接触而芯层50的下表面与底层58的内表面70接触。芯层50包括一个预固化强化芯层130、一个安装件134(未示出)、以及一个开孔块138。
参考图4和5，预固化强化芯层130为地板30提供支撑，包括多个泡沫条142和多个肋条146。肋条146和泡沫条142按交替层布置。预固化强化芯层130及其加工方法将在下面进一步详述。
更具体地，参照图5，预固化强化芯层130内的肋条146包括一个上边和一个下边。肋条146的上边与顶层54的内表面62接触而肋条146的下边与底层58的内表面70接触。肋条146还包括两个外露边。肋条的外露边位于预固化强化芯层130分层的端部上，并且如优选实施例所示，与端收边46的内表面98接触。肋条146还包括两个配合面。肋条的配合面或者与两个内部泡沫条142接触或者与一个内部泡沫条142和一个端部泡沫条142接触。
此外，泡沫条142包括一个上表面和一个下表面。泡沫条的上表面与顶层54的内表面62接触而内部泡沫条的下表面与底层58的内表面70接触。泡沫条142还包括两个外露端。外露端位于预固化强化芯层130分层的端部上，并且如优选实施例所示，与端收边46的内表面98接触。泡沫条142还包括两个配合面。泡沫条的配合面与相邻的肋条146的配合面接触。
预固化强化芯层130还包括支撑切块150。支撑切块150为其他部件，例如安装件134或开孔块138，提供空间，以便在芯层50内固化。支撑切块150通过从预固化强化芯层130取走材料而形成。支撑切块150可以在预固化强化芯层130内的任何位置，并且可以改变尺寸和形状。
安装件134包括一个上表面和一个下表面并用于在地板组件26的集中区域提供增大的强度，例如，用于将诸如座椅固定装置等的物体安装到地板组件26上。安装件134的上表面与顶层54的内表面62接触而安装件134的下表面与底层58的内表面70接触。安装件134装在支撑切块150里，一般由酚醛材料制成，不局限于任何特定的二维几何形状。
开孔块138包括一个上表面和一个下表面并提供一个用于在地板组件10中提供集中强度的装置，例如，用于机械固定件。开孔块138装在预固化强化芯层130里的支撑切块150内。开孔块138还包括一个开孔板154。开孔板154在开孔块138的中央固化。开孔块138不局限于任何特定的二维几何形状。开孔板154优选地由钢材制成，并提供在地板内切制螺纹和使用带螺纹的机械固定件所必须的机械特性。
建筑用酚醛合成表层因其优良的烟火性能而优选。表层还优选地按照双向布置，例如，按照0和90度，以提供结构刚性。收边材料是一种强化酚醛合成材料，嵌板装配好后收边加工成需要的构形。
酚醛表层、肋条、收边材料以及闭孔泡沫芯层材料的组合导致一种轻型的、高强度的地板和地板组件。层压结构不会受到水分或其他腐蚀性物质的渗透，并且提供与合成表层非常好的结合。使用所述结构的地板组件重量大约为1.3磅每平方英尺，并且提供了极好的强度、吸声性、以及热特性。
加工实施本发明的预固化强化芯层130的方法表示在图8的流程图中。首先，提供一个一般为长方形板的刚性闭孔泡沫芯层158，用做基体(210)。该泡沫芯层基体158的周边尺寸应便于加工，并且由固化机和固化炉的尺寸限定。在本发明的一个实施例中，泡沫芯层基体158平放在预处理台上。预处理台必须足够大以适应基体158的尺寸。预处理台的表面设置有三个竖直止挡用于将相邻各层与基体层158排列在同一位置。第一竖直止挡设置在预处理台的较短的侧边而第二和第三止挡隔开一定距离并设置在预处理台的较长的侧边。当泡沫芯层基体158定位在预处理台上后，侧边压靠在第一止挡上。在仍然保持与第一止挡接触期间，移动泡沫芯层基体158从而纵边靠在第二和第三止挡上。泡沫芯层的优选厚度为0.80”并且厚度在整个堆叠过程中优选地保持一致。芯层厚度可以针对不同的地板改变，并取决于所要求的强度-重量特性。
接着，泡沫芯层基体158涂敷酚醛液态树脂薄层(214)。泡沫芯层中间层166也涂敷酚醛液态树脂薄层，如下文将说明。树脂可以用刷子或其他常用工具涂敷。推进芯层158后，双向的玻璃纤维织物162放置在泡沫芯层158和液态酚醛树脂顶部(218)。在优选实施例中，玻璃纤维织物162的绳股相对由泡沫芯层158的纵边和横边确定的轴线偏移45度角以获得最佳强度。另外，玻璃纤维织物162应当切割成与泡沫芯层158的表面大致相等的尺寸，并定位为覆盖泡沫芯层158的表面。随后，另外一层液态酚醛树脂浸渍玻璃纤维织物162(222)。这可以以类似上述的方式涂敷。在其他实施例中，可以在现有的玻璃纤维织物162层上放置多层玻璃纤维织物162。如果导入一层以上的玻璃纤维织物162，当已经将酚醛树脂涂敷在第一层后，第二层玻璃纤维织物162直接放置在第一层玻璃纤维织物162上面。当第二层玻璃纤维织物162覆盖第一层玻璃纤维织物162后，第二层必须用液态酚醛树脂涂层以类似的方式浸湿。也就是说，重复步骤(218)和(222)以获得所需要的玻璃纤维织物162厚度。
得到所需要的厚度后，泡沫芯层中间层166放置在玻璃纤维织物162上面(226)。类似于步骤(214)中的泡沫芯层基体158的涂层，接着将中间层涂敷液态酚醛树脂薄层。在优选实施例中，三个预处理台止挡用做导引件。从而，泡沫芯层基体158的上表面和泡沫芯层中间层166的下表面夹住了由液态酚醛树脂浸渍的玻璃纤维织物162。接着可以将多层玻璃纤维织物162放置在泡沫芯层中间层166的上面，由液态酚醛树脂浸渍，以及随后由另一个泡沫芯层中间层166覆盖，以和步骤(218)、(222)和(226)一样的方式。也就是说，如图8所示，可以使用多层泡沫芯层中间层166，而多层被浸渍的玻璃纤维织物162放置在泡沫芯层中间层166之间。
以这些不同的方式连续堆叠形成一个泡沫胶块170。一旦泡沫胶块170达到所需要的高度，一个泡沫芯层顶面174就放置在泡沫胶块170上面(226)。该泡沫芯层顶面174类似于泡沫芯层中间层166和泡沫芯层基体158，不同之处在于它完成了堆叠并且有一个干燥的顶面。所需要的泡沫胶块厚度取决于外部因素并不由加工过程本身限制。因为泡沫胶块170最终将被切割成预固化强化芯层嵌板178，所以泡沫胶块170的厚度往往是由可用来确定泡沫胶块170厚度的方便的切割深度来确定。
在优选实施例中，另一个泡沫胶块170预制在同一个预处理台上的前一个泡沫胶块上面。不粘接的纸张或层放置在两个泡沫胶块170之间以形成泡沫胶块的堆栈。泡沫胶块的堆栈的高度由固化机可用尺寸限定。
当泡沫胶块170或泡沫胶块的堆栈堆放到其所需高度后，泡沫胶块170或泡沫胶块的堆栈在一个必需的温度和压力下固化(234)。固化前，泡沫胶块170或泡沫胶块的堆栈必须加载到固化机内。固化机的一个例子包括一个上平面和一个下平面，它对泡沫胶块的堆栈的表面区域施压。泡沫胶块170或泡沫胶块的堆栈必须要以防止各层位置扰乱的方式从预处理台转移到固化机。例如，预处理台可以被辊送到固化机并定位在一个允许泡沫胶块170或泡沫胶块的堆栈容易地从预处理台转移到固化机的下平面的高度。
固化机通过施加必需的压力和热量固化泡沫胶块170或泡沫胶块的堆栈(234)。当泡沫胶块的堆栈放置在固化机内后，上平面强制向下到泡沫胶块的堆栈的顶面以施加所需的恒定压力。特别地，优选的压力是在每平方英寸25到40磅之间，但是最佳的压力取决于泡沫胶块的堆栈各层的厚度。当压力施加于泡沫胶块170或泡沫胶块的堆栈后，泡沫胶块170或泡沫胶块的堆栈被放置在一个恒定的环境温度中。优选地，环境温度高于室温。更优选地，环境温度在大约华氏160-180度。这可以通过将固化机移动到大的现有固化炉内而实现。当泡沫胶块170或泡沫胶块的堆栈放置在固化炉内后，它将优选地在一个恒定温度和在一个恒定压力下固化一个特定时间周期。固化时间取决于肋条和芯层的厚度以及泡沫胶块170或泡沫胶块的堆栈的整体周边尺寸。通常固化时间在2到3个小时之间。
随后，泡沫胶块170或泡沫胶块的堆栈被冷却(238)。固化机从固化炉内取出并且泡沫胶块的堆栈在室温下或更冷的温度下冷却大约2小时。当冷却固化机和泡沫胶块的堆栈时，上平面上移以释放施加于泡沫胶块的堆栈上的压力。随后泡沫胶块的堆栈以现有方式从固化机取出。这可以通过将泡沫胶块170各个地从泡沫胶块的堆栈中移开并将其放置在一个方便的位置以准备切割操作而完成。
泡沫胶块170被切割成条块以提供预固化强化芯层嵌板178(242)。优选地，使用带有金刚石刀片的镶板锯来进行切割操作。将泡沫胶块切割成预固化强化芯层嵌板178的其他方法包括使用带有金刚石刀片的条形锯以及本领域技术人员所知的其他类似切割方法。特别地，端部被修整和刮研以除去过度固化的酚醛树脂并得到围绕泡沫胶块170的周边的清洁和直角的棱边。接着，根据需要的地板厚度从泡沫胶块170切割所需厚度的预固化强化芯层嵌板178。最后，可以使用一个精磨机来形成一个在0.020”公差范围内的厚度，以形成预固化强化芯层嵌板178的更高的精确度。切割并打磨预固化强化芯层嵌板178后，它们就可以装配在一起并在地板30中结合。
通常，预固化强化芯层嵌板178在地板30内包括整个芯层50。更具体地，预固化强化芯层嵌板178必须浸渍顶层54和底层58之间的空腔，并在由收边42、46确定的周边内。装配过程开始于底层58的内表面70，其中底层58放置在一个钢架装配台上。首先，预固化强化芯层嵌板178的长度切割为匹配地板30的第一方向上的必要尺寸。接着，预固化强化芯层嵌板178放置成并排以满足在另一个方向上的第二尺寸。可以用两种方法形成相邻芯层之间的肋条。首先，在相邻芯层之间什么也不放以留出将被液态酚醛树脂浸渍的空间。另外，可以在其间放置将被酚醛树脂浸渍的干燥的连接玻璃纤维织物条。因为不必需要粘合剂，液态酚醛树脂的均匀浸渍是可能的。预固化强化芯层嵌板178的宽度取决于泡沫胶块170的高度，因此为了更大的地板30，将的高度作的与允许的高度一样高更为有效。较大尺寸的泡沫胶块170将提高地板装配速度，因为需要连接较少的预固化强化芯层嵌板178。在优选实施例中，利用关于相邻芯层的上述任何方法可以在相邻的预固化强化芯层嵌板178和收边42、46之间形成肋条。当全部区域浸渍了预固化强化芯层嵌板178和诸如安装件134和开孔块138的芯层50的其他部件后，贴上顶层54并且固化整个地板30。固化后，具有预固化强化芯层的酚醛地板可以进行任何进一步的必要加工。
在以下的权利要求书中提出了本发明的各种特征。

Claims (36)

1.一种嵌板，包括：
一个顶层；
一个底层；
一个位于顶层和底层之间的芯层；以及
收边，它接触顶层和底层，其特征在于，收边围绕芯层并基本确定嵌板的周边，收边是一种纤维强化酚醛材料，具有大于顶层厚度和底层厚度的一定厚度。
2.如权利要求1所述的嵌板，其特征在于，芯层是一个预固化的酚醛强化芯层。
3.如权利要求2所述的嵌板，其特征在于，预固化的酚醛强化芯层包括至少一个酚醛肋条和多个泡沫条，酚醛肋条位于两个泡沫条之间。
4.如权利要求1所述的嵌板，其特征在于，收边加工为包括至少一个配合面。
5.如权利要求4所述的嵌板，其特征在于，配合面是一个搭接面。
6.如权利要求4所述的嵌板，其特征在于，嵌板确定了一个平面，收边加工为包括至少一个贯穿其中的孔，该孔垂直于上述平面。
7.如权利要求1所述的嵌板，其特征在于，芯层还包括至少一个开孔块，开孔块包括一个纤维强化材料块以及一个包封在该块内的金属板，开孔块可以钻孔和攻丝从而为嵌板提供一个具有加强支撑的安装区域。
8.如权利要求1所述的嵌板，其特征在于，芯层还包括至少一个安装件，安装件包括一个纤维强化材料块并且可以钻孔从而为嵌板提供一个具有加强支撑的安装区域。
9.如权利要求1所述的嵌板，其特征在于，顶层、底层、以及收边是酚醛合成物。
10.一种地板组件，包括：
多个嵌板，所述嵌板相互连接并且所述多个嵌板中的每一个嵌板包括
一个顶层；
一个底层；
一个位于顶层和底层之间的芯层；以及
在顶层和底层之间的收边，其特征在于，收边围绕芯层并确定嵌板的周边，收边是一种纤维强化酚醛材料，具有大于顶层厚度和底层厚度的一定厚度。
11.如权利要求10所述的地板组件，其特征在于，芯层是一个预固化的酚醛强化芯层。
12.如权利要求11所述的地板组件，其特征在于，预固化的酚醛强化芯层包括至少一个酚醛肋条和多个泡沫条，酚醛肋条位于两个泡沫条之间。
13.如权利要求10所述的地板组件，其特征在于，收边加工为包括至少一个配合面。
14.如权利要求13所述的地板组件，其特征在于，配合面是一个搭接面。
15.如权利要求13所述的地板组件，其特征在于，嵌板确定了一个平面，收边加工为包括至少一个贯穿其中的孔，该孔垂直于上述平面。
16.如权利要求10所述的地板组件，其特征在于，芯层还包括至少一个开孔块，开孔块包括一个纤维强化材料块以及一个包封在该块内的金属板，开孔块可以钻孔和攻丝从而为嵌板提供一个具有加强支撑的安装区域。
17.如权利要求10所述的地板组件，其特征在于，芯层还包括至少一个安装件，安装件包括一个纤维强化材料块并且可以钻孔从而为嵌板提供一个具有加强支撑的安装区域。
18.如权利要求10所述的地板组件，其特征在于，顶层、底层、以及收边是酚醛合成物。
19.一种用于公交车辆的地板组件，其中公交车辆包括一个车厢组件，车厢组件包括隔开的侧壁、隔开的端壁、以及一个地板支撑组件，所述合成地板组件包括：
多个嵌板，所述嵌板相互连接并且所述多个嵌板中的每一个嵌板包括
一个顶层；
一个底层；
一个位于顶层和底层之间的芯层；以及
在顶层和底层之间的收边，其特征在于，收边围绕芯层并确定嵌板的周边，收边是一种纤维强化酚醛材料，具有大于顶层厚度和底层厚度的一定厚度。
20.如权利要求19所述的地板组件，其特征在于，芯层是一个预固化的酚醛强化芯层。
21.如权利要求20所述的地板组件，其特征在于，预固化的酚醛强化芯层包括至少一个酚醛肋条和多个泡沫条，酚醛肋条位于两个泡沫条之间。
22.如权利要求19所述的地板组件，其特征在于，收边加工为包括至少一个配合面。
23.如权利要求22所述的地板组件，其特征在于，配合面是一个搭接面。
24.如权利要求22所述的地板组件，其特征在于，嵌板确定了一个平面，收边加工为包括至少一个贯穿其中的孔，该孔垂直于上述平面。
25.如权利要求19所述的地板组件，其特征在于，芯层还包括至少一个开孔块，开孔块包括一个纤维强化材料块以及一个包封在该块内的金属板，开孔块可以钻孔和攻丝从而为嵌板提供一个具有加强支撑的安装区域。
26.如权利要求19所述的地板组件，其特征在于，芯层还包括至少一个安装件，安装件包括一个纤维强化材料块并且可以钻孔从而为嵌板提供一个具有加强支撑的安装区域。
27.一种加工预固化的强化芯层的方法，所述方法包括以下步骤：
提供一个泡沫芯层用做基体；
将至少一层织物放置在泡沫芯层基体上面；
用酚醛树脂充分浸渍织物的每一层；
在浸渍的织物上面放置一个泡沫芯层的顶层以形成一个泡沫胶块；
在必需的温度和压力下固化泡沫胶块；以及
冷却泡沫胶块以在泡沫胶块各个泡沫层之间形成完工的压层，使得压层不允许在各个泡沫层之间任何另外的树脂渗透。
28.如权利要求27所述的加工方法，还包括以下步骤：
在浸渍的织物上面放置至少一个泡沫芯层的中间层；
将至少一层织物放置在泡沫芯层的中间层上面；以及
用酚醛树脂浸渍织物的每一层。
29.如权利要求27所述的加工方法，还包括以下步骤：
沿垂直于芯层平面的一个平面切割泡沫胶块，以提供一个预固化的强化芯层的嵌板。
30.如权利要求27所述的加工方法，其特征在于，泡沫芯层是一个刚性的闭孔泡沫。
31.如权利要求27所述的加工方法，其特征在于，织物是玻璃纤维织物。
32.如权利要求31所述的加工方法，其特征在于，玻璃纤维织物是双轴向的。
33.如权利要求27所述的加工方法，其特征在于，温度是恒定的。
34.如权利要求33所述的加工方法，其特征在于，恒定的温度在华氏160和180度之间。
35.如权利要求27所述的加工方法，其特征在于，压力是恒定的。
36.如权利要求35所述的加工方法，其特征在于，压力在每平方英寸25和40磅之间。
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