WO2014183233A1 - 一种制作塑料托盘的方法和塑料托盘 - Google Patents

一种制作塑料托盘的方法和塑料托盘 Download PDF

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Publication number
WO2014183233A1
WO2014183233A1 PCT/CN2013/000602 CN2013000602W WO2014183233A1 WO 2014183233 A1 WO2014183233 A1 WO 2014183233A1 CN 2013000602 W CN2013000602 W CN 2013000602W WO 2014183233 A1 WO2014183233 A1 WO 2014183233A1
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WO
WIPO (PCT)
Prior art keywords
thermoplastic
plate
plastic
hollow
bonding
Prior art date
Application number
PCT/CN2013/000602
Other languages
English (en)
French (fr)
Inventor
张岩
Original Assignee
Zhang Yan
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Zhang Yan filed Critical Zhang Yan
Publication of WO2014183233A1 publication Critical patent/WO2014183233A1/zh

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Classifications

    • 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
    • B65D19/00—Pallets or like platforms, with or without side walls, for supporting loads to be lifted or lowered
    • B65D19/0004—Rigid pallets without side walls
    • B65D19/0006—Rigid pallets without side walls the load supporting surface being made of a single element
    • B65D19/0008—Rigid pallets without side walls the load supporting surface being made of a single element forming a continuous plane contact surface
    • B65D19/002—Rigid pallets without side walls the load supporting surface being made of a single element forming a continuous plane contact surface the base surface being made of more than one element
    • B65D19/0024—Rigid pallets without side walls the load supporting surface being made of a single element forming a continuous plane contact surface the base surface being made of more than one element forming discontinuous or non-planar contact surfaces
    • B65D19/0026—Rigid pallets without side walls the load supporting surface being made of a single element forming a continuous plane contact surface the base surface being made of more than one element forming discontinuous or non-planar contact surfaces and each contact surface having a stringer-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
    • B65D2519/00009—Materials
    • B65D2519/00014—Materials for the load supporting surface
    • B65D2519/00034—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
    • B65D2519/00009—Materials
    • B65D2519/00049—Materials for the base surface
    • B65D2519/00069—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
    • B65D2519/00323—Overall construction of the base surface 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
    • B65D2519/00313—Overall construction of the base surface
    • B65D2519/00328—Overall construction of the base surface shape of the contact surface of the base
    • B65D2519/00333—Overall construction of the base surface shape of the contact surface of the base contact surface having a stringer-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
    • 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
    • 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
    • B65D2519/00567—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 mechanical connection, e.g. snap-fitted

Definitions

  • the present invention relates to a method of making a plastic tray and a plastic tray. Halo technology
  • pallets are now widely used in production, transportation, warehousing and distribution, and are considered to be one of the two key innovations in the logistics industry in the 20th century.
  • pallets play a huge role in modern logistics with the use of forklifts.
  • the benefits that pallets bring to the modern logistics industry are mainly reflected in: Unitization, standardization and standardization of goods packaging, protection of goods, and convenience of logistics and business flow.
  • plastic pallets are made of thermoplastics such as polyethylene and polypropylene, plus some additives for improving performance, which are processed by injection molding, blow molding and the like.
  • plastic pallets Compared with wooden pallets, plastic pallets have good integrity, are hygienic and clean, easy to be washed and disinfected, and have the characteristics of light weight, no nails, acid and alkali resistance, mildew resistance, etc., and their service life is 5-7 of wooden pallets. Times.
  • plastic pallets meet environmental requirements and waste disc materials can be recycled.
  • Plastic pallets can be classified as follows according to their shape:
  • Double-sided plastic pallets including: flat-sided double-sided plastic pallets (can only be used for four-way mechanical forklifts), grid double-sided plastic pallets (can only be used for four-way mechanical forklifts);
  • plastic pallets have the following four molding methods: The first one: injection molding.
  • the plastic pallet products produced by injection molding are flat, smooth, stiff and compact, and have a wide degree of product design freedom. They are divided into double-sided integral plastic trays and double-sided assembled plastic trays.
  • the double-sided integral tray generally has a weight of more than 15 kg/block, and the shape is relatively complicated.
  • the extrusion-hollow blow molding of the plastic tray is similar to the general hollow product blow molding method. Because of its large size and double-sided type, a larger extruder, a mold clamping machine and a mold are required. At present, domestic hollow molding machine manufacturers have developed a large-scale hollow molding machine that specializes in high-speed production of high-strength blow molding trays. It is produced by HMWHDPE high-strength plastics, with high forming speed, good product quality, high strength, high rigidity and very long
  • the service life of the general blown tray can reach 5 ⁇ 10 years, and it can work stably in the environment of -40 ⁇ 40 °C.
  • the dynamic load of its products can reach more than 3t, and the flexural strength reaches a high level.
  • the third type vacuum forming method.
  • Plastic trays produced by vacuum forming are also available in single-sided and double-sided versions.
  • Single-sided blister trays are mostly used for packaging and transportation of small motors (such as vacuum cleaner motors, power tool motors, etc.) and wire trays. Recently, they have developed rapidly and are mainly used exclusively.
  • the double-sided blister trays are assembled in two forms: the upper half is an extruded fixed length, fixed width plastic sheet, and the lower half is a large vacuum blister; the upper and lower half are large vacuum blister product.
  • the method requires large-scale vacuum blistering equipment for production molding, and the equipment cost is low, and the mold cost is also low, but the product wall thickness is not uniform.
  • the plastic pallets produced by the method are assembled, that is, using an extruder, a machine head and the like, respectively, extruding the slats for the upper and lower plates and the I-shaped connecting plates with the compound wings for the connection support. Then assemble again.
  • wood-plastic composites has driven the development of plastic pallets for extrusion molding. It is based on natural plant fiber (including wood flour husk, straw powder, rice bran, etc.) and waste plastics.
  • the present invention provides a method for manufacturing a plastic tray, which can manufacture a plastic tray with a small self-weight and a large load, and is simple and compact, and can flexibly manufacture plastic trays of various specifications. .
  • the present invention provides the following technical solution - a method for manufacturing a plastic tray, comprising: bonding thermoplastic sheets to form individual beams or legs of a plastic tray, and forming thermoplastic sheets into plastic a flat plate of the tray; bonding the beam to the flat plate to form a plastic tray, or assembling the beam into a keel and then bonding with the flat plate to form a plastic tray, or bonding the foot to the flat plate to form a plastic tray.
  • the step of forming the thermoplastic into the flat plate of the plastic tray comprises: heating the bonding faces of the plurality of thermoplastic sheets until a molten layer is present, and then stacking the plurality of thermoplastic sheets to make the plurality of The molten layers are bonded to each other and then cooled and solidified to be bonded into a flat plate of a plastic tray.
  • the step of bonding the thermoplastic sheets to form the individual beams or the legs of the plastic tray comprises: cutting the thermoplastic sheet according to the specifications of the beam or the foot; The adhesive faces of the plurality of thermoplastic sheets are heated until a molten layer is formed, and then the cut plurality of thermoplastic sheets are stacked, and the plurality of the molten layers are bonded together and then cooled and solidified to be bonded into a plastic tray.
  • Each beam or each foot is
  • the step of bonding the thermoplastic sheets to form the individual beams or the legs of the plastic tray comprises: heating the bonding faces of the plurality of thermoplastic sheets until a molten layer is present; The plastic sheets are stacked, and the plurality of the molten layers are attached to each other and then cooled and solidified to be bonded; the plurality of thermoplastic sheets bonded together are cut into the beams of the plastic tray according to the width of the beam or each Only feet.
  • thermoplastic sheet is laid on the perforated plate, and the underside of the perforated plate is a negative pressure so that The thermoplastic sheet is adsorbed on the perforated plate.
  • the heating is performed using an infrared lamp, a hot air blower, or a hot plate.
  • the thermoplastic sheet material is a hollow sheet; when the stacking is performed, the reinforcing ribs of the adjacent hollow sheets are not parallel to each other.
  • the strip softening region intersects the reinforcing ribs of the hollow plate.
  • the strip-shaped softening region is heated by an infrared lamp tube parallel to the folding groove, and the infrared lamp tube has heat shielding plates on both sides thereof, wherein the heat insulation plate is used to concentrate the heat of the infrared lamp tube Folding the groove; or heating the strip softening zone with a hot air blower, and adjusting the nozzle for outputting the hot air to concentrate the heat at the folding groove.
  • the thermoplastic sheet material is a polypropylene hollow board or a polyethylene hollow board.
  • the thermoplastic plastic sheet is bonded into the plastic tray, and the equipment of the injection molding machine, the mold and the like is not required, and the cost is low; since the plastic sheet is cut and then bonded, the various specifications can be flexibly manufactured.
  • the hollow plate is a widely used plastic plate, and the hollow plate can be used to produce a plastic tray with a small weight and a large load. Taking polypropylene hollow board as an example, its weight is generally 6-8kg, and the bearing capacity is equal to the weight.
  • a plastic tray for injection molding is about 40% larger.
  • the manufacturing process of the beam and the foot of the plastic tray of the invention is simple and reliable, has high production efficiency, and can well guarantee product quality.
  • FIG. 1A is a schematic view showing the structure of a hollow plate according to the prior art
  • FIG. 1B is a schematic view showing the reinforcing ribs of the hollow plate intersecting each other according to an embodiment of the present invention
  • FIG. 2A is a hollow plate according to an embodiment of the present invention. a schematic diagram of heating the strip-shaped softened region
  • FIG. 2B is a schematic view of pressing a band-shaped softened region into a folded groove on a hollow panel according to an embodiment of the present invention
  • Figure 3A is a schematic illustration of the folding groove arrangement when the hollow sheet is folded into a W shape in accordance with an embodiment of the present invention
  • Figure 3B is a schematic view showing a heating state when a hollow plate is folded into a W shape according to an embodiment of the present invention
  • 3C is a schematic view showing a collapsed state of a hollow plate folded into a W shape according to an embodiment of the present invention
  • FIG. 4A is a schematic view of an assembled keel according to an embodiment of the present invention
  • FIG. 4B is a schematic view of an assembled keel according to an embodiment of the present invention
  • FIG. 5 is a schematic view of a plastic tray produced by a method according to an embodiment of the present invention.
  • the plastic tray is formed by stacking and bonding thermoplastic sheets. Specifically, the thermoplastic sheets are bonded to the individual beams of the plastic tray, or are bonded to each foot; the upper plate and the lower plate of the plastic tray are also made of thermoplastic, and may be laminated with a plurality of thermoplastic sheets.
  • thermoplastic material directly into the upper plate, the lower plate, or in one piece; finally, bond the beams to the plate, or combine the beams into keels. Rebond to the plate, or bond each foot to the plate in a certain distribution. Can be made into a single-sided tray or a double-sided tray. Plastic bonding can use various existing adhesives, but the adhesive often contains some harmful substances, is not environmentally friendly, and adds extra cost, so the preferred way is to use the physical properties of the thermoplastic itself to heat it. After softening, they are bonded to each other and cooled and bonded together. The manner in which the various parts of the plastic tray are manufactured is further described below.
  • thermoplastic sheets When manufacturing a flat plate, if a plurality of thermoplastic sheets are laminated and bonded, the bonding faces of the plurality of thermoplastic sheets may be heated until a molten layer is formed, and then the thermoplastic sheets are stacked to form a plurality of molten layers. Adhere to each other and bond to a flat plate after cooling and solidification.
  • a heating plate may be used for heating, which is a contact heating; non-contact heating may also be employed, for example, an infrared lamp tube, a hot air blower, etc., to avoid smoke from contact heating.
  • thermoplastic sheet In order to increase production efficiency and save energy, it is possible to heat a strip-like or lattice-like molten region on the surface of the thermoplastic sheet instead of heating all of its plane to melt.
  • the edge of the thermoplastic sheet may be pressed, or the thermoplastic sheet may be laid on a vacuum suction plate, or a combination of the two measures.
  • the vacuum adsorption plate has a flat box shape as a whole, and one of the two sides with the largest area has a plurality of holes, and the air is sucked from the inside of the vacuum adsorption plate to realize a negative pressure under the side of the hole, thereby sucking the thermoplastic plate. On the side.
  • the thermoplastic sheet may be a hollow board (or a corrugated board), such as a polypropylene hollow board or a polyethylene hollow board, or may be made of other thermoplastics.
  • Fig. 1A is a schematic view showing the structure of a hollow plate according to the prior art. As shown in Fig. 1A, such a hollow plate has upper and lower outer plates 1 1 and 12 and a plurality of reinforcing ribs 13 in the middle. In order to make the produced flat plate have higher strength, when the hollow plate is attached, the reinforcing ribs of the two plates may not be parallel to each other. For example, when the two hollow plates are attached, the reinforcing ribs are perpendicular to each other or 45°.
  • FIG. 1B is a schematic view of the reinforcing ribs of the hollow plate intersecting each other according to an embodiment of the present invention.
  • the reinforcing rib 151 in the former is substantially perpendicular to the reinforcing rib 161 in the latter in the flat plate 17 (only the schematic is shown in the drawing.
  • the surface is the outer surface of the outer layer, and the reinforcing rib of the actual hollow sheet is inside.
  • the thermoplastic sheet can be cut according to the specifications of the beam or the foot.
  • the thermoplastic sheet is cut into strips of O.lmx lm.
  • the thermoplastic sheet is cut into small pieces of O.lmxO.lm; then the bonded faces of the cut pieces of thermoplastic sheet are heated until a molten layer appears. Then, the cut pieces of the thermoplastic sheet are stacked, the plurality of molten layers are attached, and finally cooled and solidified to obtain the beams or the legs of the plastic tray.
  • the thermoplastic sheet can be cut with a water jet, which avoids environmental pollution caused by the hot knife cutting and thermal deformation of the thermoplastic sheet.
  • the beam or the foot it is also possible to first bond the large-area thermoplastic sheet first, and then use the above-mentioned method of manufacturing the flat plate, and then cut according to the specifications of the beam or the foot, but at this time, in order to ensure the beam or the foot The bonding is firm.
  • the flat surface of the thermoplastic sheet should be heated to melt.
  • the beam or the foot can also be made of a hollow plate. Because it is also a laminated structure, the ribs of the hollow plates of each layer can have an angle between them to increase the strength of the beam or the foot.
  • the above method for manufacturing the beam or the foot is to bond a plurality of thermoplastic sheets, and it is also possible to fold a single large thermoplastic sheet in a certain manner to obtain a beam or a foot, and to apply the respective bonding surfaces.
  • the molten layers are heated and bonded to each other.
  • a hollow plate is still used in this embodiment, and a folding groove is first formed on the hollow plate of the plate, and then folded along the folding groove.
  • the bonding surface is heated out of the molten layer before the hollow board surfaces on both sides of the folding groove are bonded to each other so as to be bonded after bonding.
  • the method of making the folded groove is to first heat the strip-shaped softened region on the hollow plate (in this case, no heating to melt), and then flatten the softened region to form a folded groove. It is preferable to use an infrared lamp or a hot air heater for heating because their temperature is easy to adjust, and the temperature can be changed in an approximately abrupt manner, and the work efficiency is high.
  • an infrared lamp tube is taken as an example for specific description. 2A is a schematic view of heating a strip-shaped softened region on a hollow panel in accordance with an embodiment of the present invention.
  • FIG. 2B is a schematic view of pressing a strip-shaped softened region into a folded groove on a hollow panel in accordance with an embodiment of the present invention.
  • the hollow plate 20 is laid on the vacuum adsorption plate 21, and pressed on both sides by the pressing wheels 221 and 222, and the infrared lamp tube 23 is placed on the hollow plate 20 to be formed into a folding groove.
  • the plate on both sides of the folding groove is not softened, and the heat insulating plate 24 may be attached to the infrared lamp tube 23.
  • the infrared lamp tube 23 is moved along its axial direction (in the direction of the drawing to the inside of the paper), so that the hollow plate 20 produces a band-shaped softened region, which is then shown by Fig. 2B, by a pressure roller or a pressure block (shown in the figure) It follows that the pressure roller 25) follows the infrared lamp tube 23 and advances therewith, thus pressing the softened area into a folded groove before it is cooled.
  • This approach has many advantages over the prior art practice of grooving with a tool. If the tool is grooved in the cooling state, more plate debris will be generated, and because there are many folding grooves, the machine will generate a lot of noise and vibration or even resonance when the groove is opened, which seriously affects the health of the operator and the machine.
  • the method is non-contact heating, does not generate vibration and debris, and can accurately control the position and width of the folding groove by pressing soft or briquetting, and realize heating concentration by control to ensure two folding grooves.
  • the side plate shape, so the manner of making the folding groove in this embodiment is obviously superior to the prior art method of using the tool to groove.
  • a relatively simple folding method is the so-called accordion mode, that is, the hollow plate is folded into a W shape. It should be noted that the folding groove The production must be carried out according to the folding method.
  • FIG. 3A is a schematic view showing a distribution of a folding groove when a hollow plate is folded into a W shape according to an embodiment of the present invention.
  • the folding grooves 31, 32, 33 are alternately distributed on both sides of the hollow plate 30.
  • more fold grooves can be made to form a continuous plurality of W shapes. According to this folding groove, the hollow plate is folded into the state of Fig. 3B, and Fig.
  • FIG. 3B is a schematic view showing the heating state when the hollow plate is folded into a W shape according to an embodiment of the present invention.
  • the hollow plate 30 has not yet been completely collapsed, forming a plurality of V-shapes (two V-shaped openings are shown upward and V-shaped one opening downwards), at which time each V-shaped The open side of the portion heats the inner surface of the V-shaped portion, for example, by heating the infrared lamp tubes 36, 37, 38 in the drawing to obtain a molten layer.
  • the hollow plate is gathered as shown in Fig. 3C to obtain a beam or a foot.
  • FIG. 3C is a schematic view showing a collapsed state of a hollow plate folded into a W shape according to an embodiment of the present invention.
  • the respective molten layers are bonded to each other, and at this time, the beam or the foot of the plastic tray is obtained by cooling.
  • the folding groove functions as a beam to make the hollow plate less deformable, and as long as the heating speed is fast enough,
  • the softened layer is heated and the hollow sheet is gathered prior to deformation.
  • the softened layer is heated within 3 seconds and the deformation is not caused by the folding.
  • This simultaneous heating and one-time folding manufacturing process has high production efficiency.
  • a sheet material it can be folded into a multi-layer structure in many ways, and the folding method is similar to the method for folding a corrugated board in the prior art in the production of a paper tray (for example, the folding method disclosed in Patent PCT/CN2010001455, except There are many other folding methods besides).
  • the bonding surfaces on both sides of the folding groove are heated to be melted, and then folded along the folding groove to bond the bonding surfaces on both sides. That is, the process is to heat both sides of one folding groove, fold and fit along the folding groove; and heat the other side of the folding groove, fold and fit along the folding groove; until the overall folding is completed. Since this operation method is to fold and fit along the folding groove in succession, the plate is pressed to prevent it from being thermally deformed each time it is heated.
  • the heated band-shaped softened region may be neither perpendicular nor parallel to the reinforcing rib of the hollow plate, so that the reinforcing ribs in the adjacent layers are inevitably not parallel or vertical after folding. Instead, it forms a certain angle, which helps to improve the mechanical strength of the resulting beam or foot.
  • the above is described by taking an infrared lamp for heating.
  • a hot air blower can be used, and by adjusting the size of the hot air outlet, heat can be concentrated in the folding groove. After the beam is made, the beam can be glued directly to the plate, or the beam can be assembled into a keel and bonded to the plate.
  • the upper and lower ends of the cross section of the beam can be wider than the middle.
  • the shape can be directly folded into the shape, or the beam having a rectangular cross section can be made first, and then the groove can be formed on the upper and lower sides.
  • Sheet metal parts Refer specifically to Figures 3D through 3G. 3D-3G are schematic illustrations of cross sections of several beams in accordance with an embodiment of the present invention. Both ends 301, 302 of the beam 300 in Fig. 3D are wider than the middle portion 303, and both ends are trapezoidal. The ends of the beam in Figure 3E are also wider than the middle, with a trapezoid at one end and a rectangular shape at the other end.
  • the beams in Figures 3D and 3E can be folded directly from plastic sheets.
  • the beam 330 in Fig. 3F is composed of a beam 331 having a rectangular cross section and two sheet member members 332, 333 which are formed by folding in the manner described above.
  • the sheet members 332, 333 are placed on the beam 331 of rectangular cross section, it is also necessary to heat each of the bonding surfaces to obtain a softened layer.
  • the gap can be cut in the middle of the beam and then inserted.
  • the fork hole can also be cut into the beam.
  • the molten layer is heated on the joint surface of the beam and the flat plate, and the molten layer is heated by the flat plate, and finally the two are bonded together to be cooled and solidified to be bonded to obtain a molded plastic tray.
  • FIG. 4A is a schematic view of an assembled keel according to an embodiment of the present invention
  • FIG. 4B is a schematic view of an assembled and formed keel according to an embodiment of the present invention. As shown in FIG. 4A, the beams are inserted into each other through the gaps therein.
  • the notches 41, 42, 43 on the beam 40 are respectively inserted into the notches 44, 45, 46 on the other beams, thereby obtaining the structure shown in FIG. 4B.
  • the fork holes 47, 48 are also shown in Figure 4A. 4A and 4B show a keel composed of three beams and three longitudinal beams, and the beam and stringers may be other numbers. For the foot, it is directly heated out of the molten layer, and the molten layer is heated out at the corresponding portion of the flat plate and then bonded, cooled and solidified.
  • the plastic tray of various specifications can be obtained by the above manufacturing method, and the form of the beam or the keel or the foot can be flexibly determined according to actual needs, for example, two kinds of plastic trays as shown in FIG. 5A and FIG. 5B can be produced.
  • 5A and 5B are schematic views of the outer shape of two plastic trays according to the present embodiment.
  • the plastic tray in Fig. 5A comprises a keel composed of four beams, wherein each layer of plastic sheets is stacked in a horizontal direction, so that higher strength can be obtained.
  • the plastic tray in Figure 5B is a nine-legged flat tray.
  • the thermoplastic plastic sheet is bonded into the plastic tray, and the large injection molding machine, the mold and the like are not required, and the cost is low; since the plastic sheet is cut and then bonded, the flexible manufacturing can be variously performed.
  • the hollow plate is a widely used plastic plate, and the hollow plate can be used to produce a plastic tray with a small weight and a large load. Taking a polypropylene hollow plate as an example, its self-weight is generally 6-8 kg, and the bearing capacity is about 40% larger than that of an injection molded plastic pallet of the same weight.
  • the manufacturing process of the beam and the foot of the plastic tray in the embodiment is simple and reliable, has high production efficiency, and can well ensure product quality.

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Abstract

一种制作塑料托盘的方法和由该方法制作而成的塑料托盘。该方法包括：将热塑性塑料板材进行粘接从而构成塑料托盘的各条梁或各只脚，以及将热塑性塑料板材制作成塑料托盘的平板，将所述梁与所述平板粘接构成塑料托盘，或者将所述梁组装成龙骨然后与所述平板粘接构成塑料托盘，或者将所述脚与所属平板粘接构成塑料托盘。该方法能够制造出自重较小、承载较大的塑料托盘，并且设备较为简单、小型，以及能够灵活的制造出各种规格的塑料托盘。

Description

一种制作塑料托盘的方法和塑料托盘 技术领域 本发明涉及一种制作塑料托盘的方法和塑料托盘。 背暈技术
中国国家标准《物流术语》对托盘（pallet) 的定义是： 用于集装、 堆放、 搬运和运输的放置作为单元负荷的货物和制品的水平平台装置。 作为与集装箱类似的一种集装设备， 托盘现已广泛应用于生产、 运输、 仓储和流通等领域,被认为是 20世纪物流产业中两大关键性创新之一。 托盘作为物流运作过程中重要的装卸、 储存和运输设备， 与叉车配套 使用在现代物流中发挥着巨大的作用。 托盘给现代物流业带来的效益 主要体现在： 可以实现物品包装的单元化、 规范化和标准化， 保护物 品， 方便物流和商流。 中国物流与采购联合会托盘专业委员会于 2002年 9月对北京、天 津、 上海、 广州四大城市的 300余家生产、 运输、 仓储和流通企业进 行了调査， 调査显示： 中国现拥有各种类托盘约 5000万〜 7000万片， 每年产量递增 2000万片左右。 其中木制平托盘约占 90%、 塑料平托盘 占 8%、 钢制托盘、 复合材料托盘以及纸制托盘合计占 2%。 随着对生产条件、 仓储条件、 过程控制、 品质管理的要求不断提 高， 由于木托盘在卫生状况及规范生产上无法克服的局限性， 以及纸 制托盘在防水方面遇到的困难， 塑料托盘的产量递增较快， 并很快占 据了一席之地。 目前已广泛应用于机械、 电子、 食品、 医药、 服装等 行业。 现有的塑料托盘是使用聚乙烯、 聚丙烯等热塑性塑料， 加上一 些改善性能的添加剂， 通过注塑、 吹塑等工艺加工而成的。 与木质托 盘相比， 塑料托盘整体性好， 卫生洁净， 易于冲洗消毒， 在使用中具 有质轻、无钉刺、耐酸碱、不霉变等特点，其使用寿命是木托盘的 5— 7 倍。 此外， 塑料托盘符合环保要求， 废盘材料可以回收利用。 塑料托盘按照外形可以有如下分类：
1、 双面使用型塑料托盘， 其中包括： 平板双面型塑料托盘 （只能用于机械叉车四向使用） ， 网格双面型塑料托盘 （只能用于机械叉车四向使用） ；
2、 单面使用型塑料托盘， 其中包括： 平板九脚型塑料托盘、 网格九脚型塑料托盘 （机械或者手动都可 以四向使用） ； 平板田字型塑料托盘、 网格田字型塑料托盘 （只能用于机械叉车 四向使用） ； 平板川字型塑料托盘、 网格川字型塑料托盘（机械叉车四向使用， 手动叉车双向使用） 。 目前塑料托盘有以下四种成型方式： 第一种： 注塑成型法。 注塑成型法生产的塑料托盘制品平整、 光洁、 挺括、 密实， 产品 设计自由度较大， 分为双面型整体式塑料托盘和双面型组装式塑料托 盘。 双面型整体式托盘一般产品自重在 15 千克 /块以上， 形状比较复 杂， 要求锁模力在 2500吨以上的注塑机生产。 该类托盘造型复杂， 投 资大， 成本也比较高， 但因生产工序少， 生产效率相对较高， 产品质 量较好。 目前一般塑料加工厂采用此法并不多。 双面型组装式托盘， 即将双面型整体式托盘分为上下两片， 分别 注塑成型后再组装而成。 虽然此产品需 2 副模具， 但模具结构大大减 化， 模具总投资仍比整体式便宜， 同时对设备锁模力的要求也降低了， 锁模力≥1500吨即可， 一般塑料加工厂均比较容易做到。 第二种： 挤出一中空吹塑成型法。 塑料托盘的挤出一中空吹塑成型与一般的中空制品吹塑成型方法 相类似， 因其产品较大， 且为双面型， 需要较大的挤出机、 合模机和 模具等。 目前国内中空成型机制造厂家已经研发出专业高速生产高强 度吹塑托盘的超大型中空成型机， 采用 HMWHDPE高强度塑料生产， 成型速度快， 产品质量好， 具有高强度， 高刚度， 非常长的使用寿命， 一般吹塑托盘的使用寿命可以达到 5~10年， 同时可以在 -40~40°C的环 境下稳定工作。 其产品的动载可以达到 3t以上， 抗弯强度均达到较高 的水平。 是一些需要长寿命， 高强度使用环境的首选托盘， 目前其价 格比其他的塑料托盘高， 但同时其使用寿命也相当长。 第三种： 真空吸塑成型法。 真空吸塑成型法生产的塑料托盘也有单面型和双面型两种。 单面 型吸塑托盘多用于小电机 （如吸尘器电机、 电动工具电机等） 以及电 线盘等包装、 运输， 最近发展较快， 且以专用为主。 双面型吸塑托盘 均为组装式， 分 2种形式： 上半片为挤出的定长、 定宽塑料板材， 下 半片为大型真空吸塑制品； 上、 下半片均为大型的真空吸塑制品。 该 法生产成型需要大型的真空吸塑设备， 设备费用较低， 模具费用也较 低， 但产品壁厚不均匀。 第四种： 挤出成型法。 该法生产的塑料托盘均为组装式， 即采用挤出机、 机头等设备， 分别挤出作为上、 下面板用的板条和作为连接支撑用的带有复翼的工 字形连接板， 然后再进行组装。 木塑复合材料的出现， 推动了挤出成 型法塑料托盘的发展。 它是以天然植物纤维 （包括木粉果壳、 秸秆粉、 稻糠等） 和废弃塑料为主要原料， 使塑料托盘既具有木质感， 又具有 耐水、 防虫害的优点， 并且可以刨、 锯、 钉。 现有的塑料托盘存在的主要问题是自重较大； 并且制造设备通常 为大型设备， 投资和占地面积都比较大； 另外塑料托盘的规格受到制 造设备的限制。 发明内容 有鉴于此， 本发明提供一种制作塑料托盘的方法， 能够制造出自 重较小、 承载较大的塑料托盘， 并且设备较为简单、 小型， 以及能够 灵活地制造出各种规格的塑料托盘。 为实现上述目的， 本发明提供如下技术方案- 一种制作塑料托盘的方法， 包括： 将热塑性塑料板材进行粘接从 而构成塑料托盘的各条梁或各只脚， 以及将热塑性塑料板材制作成塑 料托盘的平板； 将所述梁与所述平板粘接构成塑料托盘， 或者将所述 梁组装成龙骨然后与所述平板粘接构成塑料托盘， 或者将所述脚与所 述平板粘接构成塑料托盘。
可选地， 将热塑性塑料制作成塑料托盘的平板的步骤包括： 将多 张热塑性塑料板材的粘合面加热直至出现熔融层， 然后将所述多张热 塑性塑料板材叠置， 使多个所述熔融层相贴合再冷却固化从而粘合成 塑料托盘的平板。 可选地， 将热塑性塑料板材进行粘接从而构成塑料托盘的各条梁 或各只脚的步骤包括： 将热塑性塑料板材按照所述梁或所述脚的规格 进行裁切； 将裁切后的多片热塑性塑料板材的粘合面加热直至出现熔 融层， 然后将所述裁切后的多片热塑性塑料板材叠置， 使多个所述熔 融层相贴合再冷却固化从而粘合成塑料托盘的各条梁或各只脚。
可选地， 将热塑性塑料板材进行粘接从而构成塑料托盘的各条梁 或各只脚的步骤包括： 将多张热塑性塑料板材的粘合面加热， 直至出 现熔融层； 将所述多张热塑性塑料板材叠置， 使多个所述熔融层相贴 合再冷却固化从而粘合； 将粘合在一起的多张热塑性塑料板材按照所 述梁的宽度裁切成塑料托盘的各条梁或各只脚。
可选地， 在所述将多张热塑性塑料板材的粘合面加热的步骤中， 所述热塑性塑料板材平铺在带孔的板上， 所述带孔的板的下方为负压 从而使所述热塑性塑料板材吸附在所述带孔的板上。
可选地， 采用红外线灯管、 热风机、 或者加热板进行所述加热。 可选地， 所述热塑性塑料板材为中空板； 在进行所述叠置时， 使 相邻的中空板的补强肋不互相平行。 可选地， 所述热塑性塑料板材为中空板； 将热塑性塑料板材进行 粘接从而构成塑料托盘的各条梁或各只脚的步骤包括： 根据预选的折 叠方式， 在所述中空板上的折叠槽处加热出平行的多个带状软化区域; 在所述带状软化区域冷却之前， 从加热的一侧对所述带状软化区域进 行压制从而形成折叠槽； 沿所述折叠槽对所述板材按所述折叠方式进 行折叠， 其中在沿各条折叠槽进行折叠之前， 先将该折叠槽与相邻两 条折叠槽之间的贴合面加热至熔融， 然后沿该折叠槽折叠使所述贴合 面贴合。 可选地， 所述热塑性塑料板材为中空板； 将热塑性塑料板材进行 粘接从而构成塑料托盘的各条梁或各只脚的步骤包括： 在所述中空板 上加热出多个将所述中空板等分的带状软化区域， 相邻的带状软化区 域的加热方向处于所述中空板的异侧； 在所述带状软化区域冷却之前， 从加热的一侧对所述带状软化区域进行压制从而形成折叠槽； 沿所述 折叠槽对所述中空板进行折叠使其呈 W形；在所述 W形的中空板中的 每个 V形部分的开口侧对该 V形部分的内表面加热得到熔融层； 将所 述 W形的中空板收拢使各部分 V形部分的内表面贴合然后冷却固化。 可选地， 所述带状软化区域与所述中空板的补强肋交叉。 可选地， 采用平行于所述折叠槽的红外线灯管加热出所述带状软 化区域， 该红外线灯管两侧有隔热板， 所述隔热板用于使红外线灯管 的热量集中在折叠槽处； 或者釆用热风机加热出所述带状软化区域， 并且调节输出热风的管口使热量集中的折叠槽处。 可选地， 所述热塑性塑料板材为聚丙烯中空板或聚乙烯中空板。 根据本发明的技术方案， 用热塑性塑料板材粘接成塑料托盘， 无 需大型的注塑机、 模具等设备， 成本较低； 因为是裁切塑料板材然后 粘接， 所以可灵活地制造各种规格的塑料托盘。 中空板是广泛采用的 塑料板材， 利用中空板可以制作得到自重较小、 承载较大的塑料托盘。 以聚丙烯中空板为例， 其自重一般在 6-8kg， 而承重能力比同等重量的 一次注塑成型的塑料托盘大 40%左右。 另外本发明的塑料托盘的梁和 脚的制造工艺简单可靠， 有较高的生产效率， 并能够很好地保证产品 质量。 附图说明
附图用于更好地理解本发明， 不构成对本发明的不当限定。其中： 图 1A是根据现有的一种中空板的结构的示意图； 图 1B是根据本发明实施例的中空板的补强肋相互交叉的示意图； 图 2A 是根据本发明实施例的在中空板上加热出带状软化区域的 示意图；
图 2B 是根据本发明实施例的将中空板上的将带状软化区域压成 折叠槽的示意图；
图 3A是根据本发明实施例的将中空板折叠成 W形时的折叠槽分 布的示意图；
图 3B是根据本发明实施例的将中空板折叠成 W形时的加热状态 的示意图；
图 3C是根据本发明实施例的将折叠成 W形的中空板的收拢状态 的示意图；
图 4A是根据本发明实施例的组装龙骨的示意图； 图 4B是根据本发明实施例的组装成型的龙骨的示意图； 图 5是根据本发明实施例的方法制作得到的一种塑料托盘的示意 图。 具体实施方式
以下结合附图对本发明的示范性实施例做出说明， 其中包括本发 明实施例的各种细节以助于理解， 应当将它们认为仅仅是示范性的。 因此， 本领域普通技术人员应当认识到， 可以对这里描述的实施例做 出各种改变和修改， 而不会背离本发明的范围和精神。 同样， 为了清 楚和简明， 以下的描述中省略了对公知功能和结构的描述。 在本发明实施例中， 塑料托盘是采用热塑性塑料板材叠置粘接而 成。 具体而言， 采用热塑性塑料板材粘接成塑料托盘的各条梁， 或者 粘接成各只脚； 塑料托盘的上平板、 下平板也采用热塑性塑料制成， 可以是多张热塑性塑料板材层叠粘接， 在允许的情况下， 也可直接裁 切单张热塑性塑料板材作为上平板、 下平板， 或者采用一体成型的方 式制作； 最后将各条梁粘接在平板上， 或者将梁组合成龙骨再粘接到 平板上， 或者将各只脚按照一定的分布方式粘接到平板上。 可以制成 单面型托盘或双面型托盘。 塑料的粘接可以采用现有的各种粘接剂， 但粘接剂往往含有一些有害物质， 不够环保， 并且增加额外成本， 所 以较为优选的方式是利用热塑性塑料本身的物理性质， 将其加热软化 后互相贴合冷却即粘接到一起。 以下对塑料托盘各部分的制造方式作 进一步说明。 在制造平板时， 如果采用多张热塑性塑料板材层叠粘接的方式， 可以先将多张热塑性塑料板材的粘合面加热直至出现熔融层， 然后将 这些热塑性塑料板材叠置， 使多个熔融层相贴合， 冷却固化之后即粘 合成平板。 本实施例中， 加热时可采用加热板， 这是一种接触式加热； 也可 采用非接触式加热， 例如采用红外线灯管、 热风机等， 以避免接触式 加热导致的冒烟现象。 为了提高生产效率以及节省能源， 可以在热塑 性板材表面加热出条状的或者点阵状的熔融区域， 而不是将其平面全 部加热至熔融。 另外在加热时， 为了防止热塑性板材受热弯翘， 可以 对热塑性板材边缘进行压制， 或者将热塑性塑料板材平铺在真空吸附 板上， 或者两种措施结合使用。 真空吸附板整体呈扁盒状， 面积最大 的两个侧面中的一个上有多个孔， 从真空吸附板内向外抽气即实现有 孔的侧面下方为负压， 从而将热塑性塑料板材吸在该侧面上。 本实施例中， 热塑性塑料板材可采用中空板 （或称瓦楞板） ， 例 如聚丙烯中空板或聚乙烯中空板， 也可以是其他热塑性塑料制成的中 空板。图 1A是根据现有的一种中空板的结构的示意图。如图 1A所示， 这种中空板具有上下的外层板 1 1、 12以及中间的多个补强肋 13。 为了 使制作出的平板有较高的强度， 在将中空板贴合时， 可以使二者的补 强肋不互相平行， 例如两张中空板贴合时， 补强肋互相垂直或呈 45°夹 角， 三张中空板贴合时， 相邻中空板的补强肋夹角为 60。。 图 1B是根 据本发明实施例的中空板的补强肋相互交叉的示意图。 图 1B所示， 中 空板 15和中空板 16贴合得到平板 17之后， 前者中的补强肋 151与后 者中的补强肋 161在平板 17中基本垂直 （图中仅为示意， 贴合面是外 层板的外表面， 实际的中空板的补强肋在其内部） 。 在制造梁或者脚时， 可以先将热塑性塑料板材按照梁或脚的规格 进行裁切， 例如梁的宽度是 0.1m, 长度是 lm， 则将热塑性塑料板材裁 切成 O.lmx lm的长条， 又如脚的规格是 O.lmxO.lm, 则将热塑性塑料 板材裁切成 O.lmxO.lm的小块； 再将裁切后的多片热塑性塑料板材的 粘合面加热直至出现熔融层， 然后将裁切后的多片热塑性塑料板材叠 置， 使多个熔融层相贴合， 最后进行冷却固化从而得到塑料托盘的各 条梁或各只脚。 可采用水刀对热塑性塑料板材进行裁切， 这样可以避 免热刀裁切时冒烟造成环境污染以及热塑性塑料板材受热变形。 在制造梁或者脚时， 也可先将大面积的热塑性塑料板材先粘合， 可采用上述的制造平板的方式， 然后再按照梁或脚的规格进行裁切， 但此时为了保证梁或脚粘接牢固， 在将大面积的热塑性塑料板材粘合 时， 应当将热塑性塑料板材的平面全部加热至熔融。 梁或者脚同样可采用中空板制作， 因为同样是层叠的结构， 所以 各层中空板的肋之间可以有夹角， 以增加梁或者脚的强度。 以上的制造梁或者脚的方式是将多片热塑性塑料板材粘合而成， 另外也可以将单张较大的热塑性塑料板材按一定的方式进行折叠从而 得到梁或脚， 并且将各个贴合面加热出熔融层再互相粘合。 如采用这 种方式， 本实施例中仍采用中空板， 首先在板中空板上加工出折叠槽， 然后沿折叠槽进行折叠。 在折叠槽两侧的中空板板面贴合之前将贴合 面加热出熔融层， 从而使贴合之后粘接。 本实施例中， 制作折叠槽的方法是先在中空板上加热出带状的软 化区域 （此时无需加热至熔融） ， 然后将该软化区域压扁从而形成折 叠槽。 最好是采用红外线灯管或者热风机进行加热， 因为它们的温度 易于调节， 并且温度能够以近似突变的方式变化， 有较高的作业效率。 以下结合图 2A至图 2B， 以采用红外线灯管为例具体说明。 图 2A是根 据本发明实施例的在中空板上加热出带状软化区域的示意图； 图 2B是 根据本发明实施例的将中空板上的将带状软化区域压成折叠槽的示意 图。 如图 2A所示， 在制作折叠槽时， 将中空板 20铺在真空吸附板 21 上， 并用压制轮 221、 222在两边压制， 将红外线灯管 23放置在中空 板 20的需要制作折叠槽的一侧， 为了使加热更加集中， 不至于软化折 叠槽两侧的板材， 可以在红外线灯管 23上加装隔热板 24。将红外线灯 管 23沿其轴向运动 （按图中视角是向纸面内） , 使中空板 20产生带 状的软化区域， 然后由图 2B所示， 由压轮或压块（图中示出的是压轮 25 ) 跟随在红外线灯管 23后面并随之前进， 这样在该软化区域冷却之 前就将其压制成折叠槽。 这种方式比现有技术中用刀具开槽的做法来 说具有很多好处。 如果在冷却状态下用刀具开槽， 会产生较多的板材 碎屑， 并且因为折叠槽很多， 同时开槽时机器设备会产生很大的噪声 和振动甚至是共振， 严重影响操作人员健康以及机器寿命； 折叠槽具 有较高的精度要求， 精度不达标时容易导致折叠失败， 但冷却状态下 用刀具开槽的方式由于产生很大的振动， 因此影响开槽的精度， 导致 工序的合格率降低。 如果采用热刀开槽， 则一是存在冒烟现象， 污染 环境； 二是使槽两侧板材受热变形， 影响折叠成型； 三是热刀上容易 粘附熔化的塑料， 使再次的开槽操作精度降低， 同样影响折叠成型。 而本实施例中的这种方式是非接触式加热， 不产生振动和碎屑， 并且 能够通过压软或压块精确地控制折叠槽的位置和宽度， 以及通过控制 实现加热集中以保证折叠槽两侧板材形状， 所以本实施例中的这种制 作折叠槽的方式明显优于现有技术中的采用刀具开槽的做法。 在制作出折叠槽之后， 即可进行折叠。 一种比较简单的折叠方式 是所谓的手风琴方式， 即中空板折叠成 W形。 需要说明的是， 折叠槽 的制作须根据折叠方式进行， 如要折叠成 W形， 则在制作折叠槽时， 相邻的带状软化区域的加热方向应处于中空板异侧， 这样加工得到的 折叠槽如图 3A所示。 图 3A是根据本发明实施例的将中空板折叠成 W 形时的折叠槽分布的示意图。 如图 3A所示， 折叠槽 31、 32、 33交错 地分布在中空板 30的两侧。 如需制作更厚的梁或脚， 可以制作更多的 折叠槽从而形成连续的多个 W形。 按照这种折叠槽， 将中空板折成图 3B的状态， 图 3B是根据本发明实施例的将中空板折叠成 W形时的加 热状态的示意图。 从图 3B可以看出， 中空板 30尚未完全收拢， 形成 多个 V形（图中示出的是两个开口向上的 V形和一个开口向下的 V形）， 此时在每个 V形部分的开口侧对该 V形部分的内表面进行加热， 例如 采用图中的红外线灯管 36、 37、 38进行加热得到熔融层。最后按图 3C 所示将中空板收拢得到梁或者脚。图 3C是根据本发明实施例的将折叠 成 W形的中空板的收拢状态的示意图。 如图 3C所示， 各个熔融层互 相贴合， 此时进行冷却即得到塑料托盘的梁或者脚。 在以上的工序中， 虽然对中空板的贴合面进行了加热， 但折成图 3B所示状态时， 折叠槽 起到了梁的作用使中空板不易变形， 只要加热的速度足够快， 就能够 在变形之前加热出软化层并将中空板收拢。 经实验， 对于聚丙烯中空 板来说， 在 3 秒以内加热出软化层并且收拢就不至于产生变形。 这种 同时加热、 一次收拢的制造工艺具有很高的生产效率。 对于板材来说可以由很多方式将其折叠成多层的结构， 折叠方法 与现有技术中制作纸制托盘时折叠瓦楞板的方法相类似 （例如专利 PCT/CN2010001455中公开的折叠方法，除此之外还有很多其他折叠方 法） 。 对于一般情况下的折叠方式， 由于粘合面分布不像 W形那样有 规律， 所以在根据折叠方式加热出平行的带状软化区域并压制得到折 叠槽之后， 在沿各条折叠槽进行折叠之前先将该折叠槽两侧的贴合面 加热至熔融， 再沿该折叠槽折叠使其两侧的贴合面贴合。 即工序是加 热一个折叠槽两侧， 沿该折叠槽折叠、 贴合； 再加热另一个折叠槽两 侧， 沿该折叠槽折叠、 贴合； 直至整体折叠完成。 因为这种操作方式 是先后沿折叠槽折叠、 贴合， 所以在每次加热时， 要对板材进行压制 以免其受热变形。 为了提高强度， 在制作折叠槽时， 加热出的带状软化区域可以与 中空板的补强肋既不垂直也不平行， 这样折叠之后相邻的层内的补强 肋必然不平行也不垂直， 而是形成一定的夹角， 从而有助于提高制作 得到的梁或脚的机械强度。 以上是以采用红外线灯管进行加热为例进 行了说明， 另外还可以采用热风机， 通过调节其热风出口的大小， 可 使热量集中在折叠槽处。 在制作得到梁之后， 可以将梁直接粘到平板上， 也可以将梁组装 成龙骨再与平板粘接。 为了粘接尽量牢固， 梁的截面的上下两端可以 比中部更宽， 为此， 可以直接折叠成这种形状， 也可以先制作截面为 长方形的梁， 再在上下两侧套上槽形的板材构件。 具体参考图 3D至图 3G。 图 3D至图 3G是根据本发明实施例的几种梁的截面的示意图。 图 3D中的梁 300的两端 301、 302要宽于中部 303， 并且两端都呈梯形。 图 3E中的梁的两端也宽于中部， 一端呈梯形， 另一端呈矩形。 图 3D 和图 3E中的梁都可以采用塑料板材直接折叠而成。 图 3F中的梁 330 是采用矩形截面的梁 331和两个槽形的板材构件 332、 333组成， 板材 构件 332、 333可以采用前文所述的方式折叠制成。在将板材构件 332、 333套到矩形截面的梁 331上时，同样需对各个贴合面进行加热得到软 化层。 也可以只在矩形截面的梁的一端套上槽形板材构件， 如图 3G所 示。 梁的截面的一端或两端加宽也有助于提高梁的强度从而增加整个 塑料托盘的承载能力。 在对多个梁进行组装时， 可以在梁的中间切出缺口然后插接。 梁 上还可以切割得到进叉孔。 然后再在梁与平板的接合面上加热出熔融 层， 并对平板加热出熔融层， 最后将二者贴合冷却固化从而粘接得到 成型的塑料托盘。 图 4A 是根据本实用新型实施例的组装龙骨的示意 图， 图 4B是根据本实用新型实施例的组装成型的龙骨的示意图。 如图 4A所示， 各梁通过其上的缺口互相插接， 例如梁 40上的缺口 41、 42、 43分别与其他梁上的缺口 44、 45、 46插接， 从而得到图 4B中所示的 龙骨。 图 4A中同时示出了进叉孔 47、 48。 图 4A和图 4B示出的是由 三根横梁和三根纵梁构成的龙骨， 横梁与纵梁也可以是其他数目。 对于脚来说， 直接将其加热出熔融层， 并在平板的相应部位加热 出熔融层然后贴合、 冷却固化即可。 采用以上制作方法可以得到各种规格的塑料托盘， 并且梁或者龙 骨或者脚的形式可以根据实际需要灵活确定，例如可以制出图 5A和图 5B所示的两种塑料托盘。图 5A和图 5B是根据本实施例的两种塑料托 盘的外形的示意图。 其中图 5A中的塑料托盘包含四根梁组成的龙骨， 其中的各层塑料板材是沿水平方向层叠， 这样可以获得更高的强度。 图 5B中的塑料托盘是九脚型平板托盘。 根据本发明实施例的技术方案， 用热塑性塑料板材粘接成塑料托 盘， 无需大型的注塑机、 模具等设备， 成本较低； 因为是裁切塑料板 材然后粘接， 所以可灵活地制造各种规格的塑料托盘。 中空板是广泛 采用的塑料板材， 利用中空板可以制作得到自重较小、 承载较大的塑 料托盘。 以聚丙烯中空板为例， 其自重一般在 6-8kg， 而承重能力比同 等重量的一次注塑成型的塑料托盘大 40%左右。 另外本实施例中的塑 料托盘的梁和脚的制造工艺简单可靠， 有较高的生产效率， 并能够很 好地保证产品质量。 上述具体实施方式， 并不构成对本发明保护范围的限制。 本领域 技术人员应该明白的是， 取决于设计要求和其他因素， 可以发生各种 各样的修改、 组合、 子组合和替代。 任何在本发明的精神和原则之内 所作的修改、 等同替换和改进等， 均应包含在本发明保护范围之内。

Claims

权 利 要 求 书 一种制作塑料托盘的方法， 其特征在于， 包括：
将热塑性塑料板材进行粘接从而构成塑料托盘的各条梁或各只 脚， 以及将热塑性塑料制作成塑料托盘的平板；
将所述梁与所述平板粘接构成塑料托盘， 或者将所述梁组装成龙 骨然后与所述平板粘接构成塑料托盘， 或者将所述脚与所述平板粘接 构成塑料托盘。 根据权利要求 1 所述的方法， 其特征在于， 将热塑性塑料制作成塑料 托盘的平板的步骤包括：
将多张热塑性塑料板材的粘合面加热直至出现熔融层， 然后将所 述多张热塑性塑料板材叠置， 使多个所述熔融层相贴合再冷却固化从 而粘合成塑料托盘的平板。 根据权利要求 1 所述的方法， 其特征在于， 将热塑性塑料板材进行粘 接从而构成塑料托盘的各条梁或各只脚的步骤包括：
将热塑性塑料板材按照所述梁或所述脚的规格进行裁切； 将裁切后的多片热塑性塑料板材的粘合面加热直至出现熔融层， 然后将所述裁切后的多片热塑性塑料板材叠置， 使多个所述熔融层相 贴合再冷却固化从而粘合成塑料托盘的各条梁或各只脚。 根据权利要求 1 所述的方法， 其特征在于， 将热塑性塑料板材进行粘 接从而构成塑料托盘的各条梁或各只脚的步骤包括：
将多张热塑性塑料板材的粘合面加热， 直至出现熔融层； 将所述多张热塑性塑料板材叠置， 使多个所述熔融层相贴合再冷 却固化从而粘合；
将粘合在一起的多张热塑性塑料板材按照所述梁的宽度裁切成塑 料托盘的各条梁或各只脚。
5. 根据权利要求 4所述的方法， 其特征在于， 在所述将多张热塑性塑料 板材的粘合面加热的步骤中， 所述热塑性塑料板材平铺在带孔的板上, 所述带孔的板的下方为负压从而使所述热塑性塑料板材吸附在所述带 孔的板上。
6. 根据权利要求 1至 5中任一项所述的方法， 其特征在于， 采用红外线 灯管、 热风机、 或者加热板进行所述加热。
7. 根据权利要求 2至 5中任一项所述的方法， 其特征在于，
所述热塑性塑料板材为中空板；
在进行所述叠置时， 使相邻的中空板的补强肋不互相平行。
8. 根据权利要求 1 所述的方法， 其特征在于， 所述热塑性塑料板材为中 空板；
将热塑性塑料板材进行粘接从而构成塑料托盘的各条梁或各只脚 的步骤包括：
根据预选的折叠方式， 在所述中空板上的折叠槽处加热出平行的 多个带状软化区域；
在所述带状软化区域冷却之前， 从加热的一侧对所述带状软化区 域进行压制从而形成折叠槽；
沿所述折叠槽对所述板材按所述折叠方式进行折叠， 其中在沿各 条折叠槽进行折叠之前， 先将该折叠槽与相邻两条折叠槽之间的贴合 面加热至熔融， 然后沿该折叠槽折叠使所述贴合面贴合。
9. 根据权利要求 1 所述的方法， 其特征在于， 所述热塑性塑料板材为中 空板；
将热塑性塑料板材进行粘接从而构成塑料托盘的各条梁或各只脚 的步骤包括：
在所述中空板上加热出多个将所述中空板等分的带状软化区域， 相邻的带状软化区域的加热方向处于所述中空板的异侧； 在所述带状软化区域冷却之前， 从加热的一侧对所述带状软化区 域进行压制从而形成折叠槽；
沿所述折叠槽对所述中空板进行折叠使其呈 W形；
在所述 W形的中空板中的每个 V形部分的开口侧对该 V形部分 的内表面加热得到熔融层；
将所述 W形的中空板收拢使各部分 V形部分的内表面贴合然后冷 却固化。 根据权利要求 8或 9所述的方法， 其特征在于， 所述带状软化区域与 所述中空板的补强肋交叉。 根据权利要求 8或 9所述的方法， 其特征在于，
采用平行于所述折叠槽的红外线灯管加热出所述带状软化区域， 该红外线灯管两侧有隔热板， 所述隔热板用于使红外线灯管的热量集 中在折叠槽处；
或者采用热风机加热出所述带状软化区域， 并且调节输出热风的 管口使热量集中的折叠槽处。 根据权利要求 2、 3、 4、 5、 8或 9所述的方法， 其特征在于， 所述热 塑性塑料板材为聚丙烯中空板或聚乙烯中空板。 一种塑料托盘， 具有上平板和 /或下平板， 并具有梁或者多个脚， 其特 征在于，
所述上平板和所述下平板由热塑性塑料制成；
所述梁由热塑性塑料板材层叠粘接而成；
所述脚由热塑性塑料板材层叠粘接而成；
所述脚或者梁与所述上平板粘接， 或者所述脚或者梁与所述上平 板以及所述下平板粘接。 根据权利要求 13所述的塑料托盘， 其特征在于， 所述上平板和所述下 平板由热塑性板材层叠粘接而成。
15. 根据权利要求 13所述的塑料托盘， 其特征在于， 所述梁由多片单独的 热塑性塑料板材层叠粘接而成。
16. 根据权利要求 13所述的塑料托盘， 其特征在于， 所述梁由单片热塑性 塑料板材折叠构成并且相邻的两层间互相粘接。
17. 根据权利要求 13至 16中任一项所述的塑料托盘， 其特征在于， 所述 粘接是所述热塑性塑料板材受热熔融然后互相贴合再冷却固化得到。
18. 根据权利要求 13至 16中任一项所述的塑料托盘， 其特征在于， 所述 梁构成龙骨。
19. 根据权利要求 13至 16中任一项所述的塑料托盘， 其特征在于， 所述 热塑性塑料板材为中空板。
20. 根据权利要求 19所述的塑料托盘， 其特征在于， 所述塑料托盘中， 相 邻的中空板的补强肋不互相平行。
PCT/CN2013/000602 2013-05-17 2013-05-23 一种制作塑料托盘的方法和塑料托盘 WO2014183233A1 (zh)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0326239A1 (en) * 1988-01-29 1989-08-02 Manx Project Development Services Limited Method of producing a pallet
CN1126658A (zh) * 1994-08-12 1996-07-17 智索公司 具有卓越刚性的可加工片材及其制造方法
CN1208387A (zh) * 1996-01-11 1999-02-17 博里利斯股份公司 塑料板台
CN1403254A (zh) * 1999-01-13 2003-03-19 宋维宁 一种复合材料产品
US20110174197A1 (en) * 2010-01-20 2011-07-21 Tooling Technology, Llc Reinforced hollow panel and method of making
CN203372520U (zh) * 2013-05-17 2014-01-01 张岩 一种塑料托盘

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0326239A1 (en) * 1988-01-29 1989-08-02 Manx Project Development Services Limited Method of producing a pallet
CN1126658A (zh) * 1994-08-12 1996-07-17 智索公司 具有卓越刚性的可加工片材及其制造方法
CN1208387A (zh) * 1996-01-11 1999-02-17 博里利斯股份公司 塑料板台
CN1403254A (zh) * 1999-01-13 2003-03-19 宋维宁 一种复合材料产品
US20110174197A1 (en) * 2010-01-20 2011-07-21 Tooling Technology, Llc Reinforced hollow panel and method of making
CN203372520U (zh) * 2013-05-17 2014-01-01 张岩 一种塑料托盘

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