Bamboo container floor and method of making same

Abstract

The application provides a bamboo container floor and a manufacturing method thereof. The bamboo container floor comprises a base material and a thermoplastic fiber layer. The thermoplastic fiber layer is attached to the bottom surface of the base material, and a plurality of hot-pressed tenon parts are formed on the surface of the thermoplastic fiber layer by hot pressing, which are used for matching and clamping with the bottom of the container. The bamboo container floor and the manufacturing method thereof are convenient for processing the bamboo container floor, simple in process, and greatly improve the manufacturing efficiency. Moreover, the bamboo container floor manufactured by the manufacturing method has high strength and high structural stability.

Description

Technical Field

[0001] This invention relates to the field of container flooring processing, and in particular to a bamboo container flooring and its manufacturing method. Background Technology

[0002] Currently, in the container bamboo and wood flooring manufacturing industry, a crucial step in the production process is tenoning. In the current industry, this is typically done separately after the flooring is formed, using a tenoning machine to create longitudinal tenons. A tenoning machine is a device used to process tenons into container flooring. The process of tenoning the flooring separately is complex, requiring chamfering and processing of the sawn edges. This process is complex, time-consuming, and labor-intensive. Summary of the Invention

[0003] One objective of this invention is to overcome the shortcomings of the prior art and provide a bamboo container floor with a simple process and high production efficiency, as well as a method for manufacturing the same.

[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0005] A type of bamboo container flooring, comprising: Substrate, including bamboo; A thermoplastic fiber layer is attached to the bottom surface of the substrate. Multiple thermoplastic fiber layers are formed on the surface by hot pressing. The thermoplastic fiber layers are used to engage and fix with the bottom of the container.

[0006] Furthermore, the hot-pressed tenon includes tenons extending along both sides of the bottom of the substrate.

[0007] Furthermore, the thickness of the tenon is between 4mm and 5mm, and the width is between 28mm and 30mm.

[0008] Furthermore, multiple hot-pressed tenons are evenly distributed on the bottom surface of the substrate.

[0009] Furthermore, the bottom of the hot-pressed tenon is arched.

[0010] Furthermore, the substrate has a surface layer on the side opposite to the thermoplastic fiber layer, the surface layer including a wood veneer and a film layer, the film layer covering the surface of the wood veneer.

[0011] A method for manufacturing bamboo container flooring includes: A thermoplastic fiber layer is bonded to the bottom surface of the substrate; The floor is placed on a heat-pressing pad, with the thermoplastic fiber layer in contact with the heat-pressing pad; The thermoplastic fiber layer is hot-pressed to form a hot-pressed tenon groove.

[0012] Furthermore, the step of hot-pressing the thermoplastic fiber layer to form a hot-pressed tenon groove includes: a hot-pressing temperature of 135 degrees Celsius to 140 degrees Celsius; and a hot-pressing pressure of 21 MPa to 23 MPa.

[0013] Furthermore, the step of hot-pressing the thermoplastic fiber layer to form a hot-pressed tenon groove includes: hot-pressing time of 40-45 minutes.

[0014] Furthermore, in the step of hot-pressing the thermoplastic fiber layer to form a hot-pressed tenon groove, the hot-pressed tenon groove is formed in one hot-pressing process.

[0015] As can be seen from the above technical solution, the present invention has at least the following advantages and positive effects: In this application, the bamboo container flooring utilizes a thermoplastic fiber layer to allow the hot-pressed tenon joints to be simultaneously hot-pressed during the substrate's hot-pressing process, simplifying the procedure. Furthermore, the hot-pressing of the bamboo container flooring in this embodiment solves problems such as board cracking and burrs that may occur during the tenoning process. Additionally, the thermoplastic fiber layer ensures that the strength of the hot-pressed tenon joints meets relevant standards.

[0016] The aforementioned method for manufacturing bamboo container flooring allows for simultaneous hot-pressing and gluing of the thermoplastic fiber layer, bamboo, and wood veneer. Therefore, in a single hot-pressing process, the substrate can be hot-pressed and formed, and the bottom of the substrate can be formed with hot-pressed tongue and groove for installation. Since the tongue and groove are formed in a single hot-pressing operation, the bamboo container flooring can be manufactured in one step. Thus, this method avoids the need for tongue and groove cutting and subsequent additional processes, simplifying the process and significantly improving manufacturing efficiency. Attached Figure Description

[0017] Figure 1 This is a structural schematic diagram of a bamboo container floor according to an embodiment of the present invention.

[0018] Figure 2 This is a structural schematic diagram of a bamboo container floor according to another embodiment of the present invention.

[0019] Figure 3 This is a simplified structural diagram of a bamboo container floor according to an embodiment of the present invention.

[0020] Figure 4 This is a simplified structural diagram of a bamboo container floor according to another embodiment of the present invention.

[0021] Figure 5 This is a flowchart of a method for manufacturing bamboo container flooring according to an embodiment of the present invention.

[0022] The following are explanations of the reference numerals in the attached drawings: 10, bamboo container flooring; 11, substrate; 110, bamboo strip; 111, bamboo; 112, wood veneer; 12, thermoplastic fiber layer; 13, hot-pressed tenon; 131, tenon; 132, hot-pressed tongue and groove; 14, surface layer. Detailed Implementation

[0023] Typical embodiments embodying the features and advantages of the present invention will be described in detail in the following description. It should be understood that the present invention can have various variations in different embodiments without departing from the scope of the present invention, and the descriptions and illustrations herein are for illustrative purposes only and not intended to limit the present invention.

[0024] In the description of this application, it should be understood that, in the embodiments shown in the accompanying drawings, the indications of direction or positional relationships (such as up, down, left, right, front, and back, etc.) are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. These descriptions are appropriate when these elements are in the positions shown in the accompanying drawings. If the description of the positions of these elements changes, these directional indications also change accordingly.

[0025] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this application, "a plurality of" means two or more, unless otherwise explicitly specified.

[0026] Bamboo container flooring is used for installation on the bottom of containers, and can also be used for other bottom surfaces. It has good waterproof and wear-resistant properties. The specific application areas of bamboo container flooring are not limited here.

[0027] Please see Figure 1 The bamboo container floor 10 of this embodiment includes a substrate 11 and a thermoplastic fiber layer 12. The thermoplastic fiber layer 12 is adhered to the bottom surface of the substrate.

[0028] Specifically, in this embodiment, the substrate 11 can be bamboo bundle plywood. Bamboo bundle plywood is a single, complete layer of bamboo. It can be made by directly stacking and neatly arranging bamboo strips 110 after they have been impregnated with resin, and then hot-pressing them into shape. Compared to bamboo curtain plywood, bamboo bundle plywood allows for seamless or smaller gaps between the bamboo strips 110, resulting in higher strength and better preservation of the bamboo's inherent properties. Furthermore, the bamboo strips 110 in the substrate 11 are tightly bonded together, leading to higher bamboo utilization and thus higher strength for the bamboo container floor 10.

[0029] Please see Figure 2 In one embodiment, the substrate 11 includes multiple layers of bamboo 111 and wood veneer 112. The bamboo 111 can also be bamboo plywood. Glue is applied to one side of the wood veneer 112, and the flattened bamboo 111 is then layered together. The multiple layers of bamboo 111 are bonded together with adhesive. After the multiple layers of bamboo 111 are bonded together, they are hot-pressed to ensure they are tightly packed together and tightly composited with the wood veneer 112. The bamboo 111 and wood veneer 112 can each be multiple layers, and they can be arranged in different sequences. Therefore, the structure of the substrate 11 is not limited to a single arrangement sequence, as long as it allows for a tight composite between the bamboo 111 and wood veneer 112.

[0030] Please see Figure 1 A surface layer 14 is provided on the side of the substrate 11 facing away from the thermoplastic fiber layer 12. The surface layer 14 may include a wood veneer and a film layer. The film layer covers the surface of the wood veneer. The side of the bamboo container floor 10 with the surface layer 14 is its upper surface. The surface layer 14 has a certain degree of water resistance and wear resistance to ensure that the bamboo container floor 10 is waterproof and wear-resistant.

[0031] The thermoplastic fiber layer 12 is a composite structure in which thermoplastic composite fibers are added to the adhesive layer. These thermoplastic composite fibers are interwoven and fused together in the adhesive, forming a network. The thermoplastic fiber layer 12 is strong and not easily detached, and it has high compressive strength. When the thermoplastic fiber layer 12 is subjected to hot pressure, it will undergo some deformation, but this deformation will not affect the structural stability of the thermoplastic fiber layer 12. The thermoplastic fiber layer 12 can be fiber-reinforced polymer (FRP) thermoplastic fibers.

[0032] A thermoplastic fiber layer 12 is bonded to the bottom surface of the substrate 11. Multiple hot-pressed tenons 13 are formed on the surface of the thermoplastic fiber layer 12. The hot-pressed tenons 13 are used to engage and secure with the bottom of the container. The bottom of the container has protruding structures such as bottom crossbeams; the protruding parts of the bottom crossbeams form a mortise and tenon structure with the hot-pressed tenons 13, facilitating the installation and fixation of the bamboo container floor 10 to the container.

[0033] The shape of the hot-pressed tenon 13 is adapted to the shape of the raised structure on the bottom of the container, and the hot-pressed tenon 13 can be a groove. When the above-mentioned bamboo container floor 10 is installed on the bottom of other equipment, the hot-pressed tenon can also be other irregular structures, as long as they can be adapted to the raised structure installed on the bottom.

[0034] The bamboo container floor 10 of this embodiment utilizes a thermoplastic fiber layer 12 to allow the hot-pressed tenon joint 13 to be simultaneously hot-pressed during the hot-pressing process of the substrate, simplifying the process. Furthermore, the hot-pressing process of the bamboo container floor 10 in this embodiment also solves problems such as board cracking and burrs that may occur during the tenoning process. In addition, the thermoplastic fiber layer 12 ensures that the strength of the hot-pressed tenon joint 13 meets relevant standard requirements.

[0035] Furthermore, the extension direction of the hot-pressed tenon 13 is consistent with the extension direction of the bamboo strips. Therefore, during the hot-pressing process of the hot-pressed tenon 13, the bamboo strips of the bamboo bundle plywood are approximately parallel to each other, and the strength of the bamboo strips themselves does not hinder the forming of the hot-pressed tenon 13, facilitating its hot-pressing. Moreover, the substrate 11 in this embodiment is made of bamboo bundle plywood, which not only has sufficient strength to ensure that its strength is not affected during the hot-pressing process of the hot-pressed tenon 13, but also, since the bamboo strips of the bamboo curtain plywood are bound together by straps, and multiple layers of wood veneer are provided between the multiple layers of bamboo curtain, both the straps and the wood veneer will hinder the hot-pressing process of the hot-pressed tenon 13.

[0036] Please see Figure 3 Specifically, in this embodiment, the bamboo container floor 10 can be a rectangular structure. The bamboo board of the substrate 11 also extends along the long side of the container floor 10. The hot-pressed tenon 13 includes tenons 131 extending along both sides of the bottom of the substrate 11. The tenon 131 is shaped as a groove extending along the long side of the bamboo container floor 10.

[0037] The thickness of the tenon 131 is between 4mm and 5mm, and the width is between 28mm and 30mm. The thickness and width of the tenon 131 meet the tenon specifications of the container floor, so that the bamboo container floor 10 can be easily installed on the bottom of the container.

[0038] Please see Figure 4 Specifically, in this embodiment, the bottom surface of the bamboo container floor 10 may also be provided with multiple hot-pressed tenons 132, the bottom of which is arched. The arched hot-pressed tenons 132 can enhance the strength of the floor. The arched hot-pressed tenons 132 correspond to the protruding structure at the bottom of the container, and the protruding structure is correspondingly housed within the hot-pressed tenons 132. Through the mutual cooperation between the hot-pressed tenons 132 and the protruding structure, the floor and the container can be stably fixed.

[0039] Multiple hot-pressed tenons 132 are evenly distributed on the bottom surface of the substrate. These multiple hot-pressed tenons 132 correspond to multiple raised structures on the bottom of the container. The arrangement of the multiple hot-pressed tenons 132 corresponds to the arrangement of the raised structures on the bottom of the container.

[0040] The arch height of the hot-pressed tongue and groove 132 can be designed to be 4mm to 12mm, and the span and arch spacing can be adjusted according to actual conditions. The arch span of the hot-pressed tongue and groove 132 is 4 to 5 times the arch height, and the spacing between two adjacent hot-pressed tongue and groove 132 is 10mm to 30mm. The arch of the hot-pressed tongue and groove 132 can better distribute the connection stress between the floor 10 and the container, and can enhance the strength of the floor 10.

[0041] This application also provides a method for manufacturing bamboo container flooring.

[0042] Please see Figure 5 The method for manufacturing bamboo container flooring in this embodiment includes: Step S11: A thermoplastic fiber layer is bonded to the bottom layer of the substrate to form a floor.

[0043] The substrate 11 is made of bamboo 111 (made from loosened bamboo) and wood veneer 112. A thermoplastic fiber layer 12 is provided on the side of the bamboo 111 facing away from the wood veneer 112. A surface layer 14 is provided on the surface of the substrate 11 facing away from the thermoplastic fiber layer 12. Therefore, the bamboo container floor is arranged in the following order from bottom to top: thermoplastic fiber layer 12, bamboo 111, wood veneer 112, and surface layer 14. The installation order is not limited.

[0044] Using a thermoplastic fiber layer 12 on the bottom surface of the floor can enhance the strength of the floor.

[0045] Step S12: Place the flooring on the hot press pad, with the thermoplastic fiber layer in contact with the hot press pad.

[0046] The hot press pad has protrusions that correspond to the shape of the hot press tenon 13, which hold the thermoplastic fiber layer 12 of the floor against the protrusions of the hot press pad.

[0047] Step S13: Hot-press the thermoplastic fiber layer 12 to form a hot-pressed tenon groove.

[0048] The hot press can simultaneously hot press and bond the thermoplastic fiber layer 12, bamboo and wood veneer 112. Therefore, in one hot pressing process, the hot pressing of the substrate can be achieved, and the bottom of the substrate can also form a hot pressing tenon 13 for installation. The hot pressing tenon 13 is formed in one hot pressing, so the bamboo container floor can be formed in one step.

[0049] The hot-pressed tenon 13, after being hot-pressed, can be directly formed into a chamfered or arched structure according to the shape of the hot-pressing pad, avoiding the tenoning step of the tenoning machine on the floor. Moreover, the tenoning step often has an adverse effect on the strength of the floor. Therefore, the bamboo container floor made using the bamboo container floor manufacturing method of this embodiment has higher strength and more stable quality.

[0050] Therefore, the above-described method for manufacturing bamboo container flooring avoids the need for tongue and groove cutting and various subsequent processes, such as sanding, chamfering, and edge trimming. This embodiment simplifies the overall manufacturing process and significantly improves efficiency. Furthermore, the method eliminates the need for material cutting, preventing waste and saving processing time.

[0051] Specifically, in step S13, the thermoplastic fiber layer 12 is hot-pressed to form a hot-pressed tenon groove. Specifically, the hot-pressing temperature is 135 degrees Celsius to 140 degrees Celsius; the hot-pressing pressure is 21 MPa to 23 MPa; and the hot-pressing time is 40 minutes to 45 minutes.

[0052] In the above steps of hot pressing the thermoplastic fiber layer 12 to form a hot-pressed tenon groove, the hot pressing pressure is high, the temperature is low, and the hot pressing time is short to ensure the hot pressing effect of the thermoplastic fiber layer 12.

[0053] The above embodiments are merely illustrative examples of structures. The structures in each embodiment are not fixed combinations. In the absence of structural conflicts, the structures in multiple embodiments can be arbitrarily combined and used.

[0054] Although the invention has been described with reference to several typical embodiments, it should be understood that the terminology used is illustrative and exemplary, and not restrictive. Since the invention can be embodied in many forms without departing from the spirit or essence of the invention, it should be understood that the above embodiments are not limited to any of the foregoing details, but should be interpreted broadly within the spirit and scope defined by the appended claims. Therefore, all variations and modifications falling within the scope of the claims or their equivalents should be covered by the appended claims.

Claims

1. A type of bamboo container flooring, characterized in that, include Substrate, including bamboo; A thermoplastic fiber layer is bonded to the bottom surface of the substrate. The thermoplastic fiber layer is a composite structure in which thermoplastic composite fibers are added to the adhesive layer. Multiple thermoplastic fiber tenons are formed on the surface of the thermoplastic fiber layer by hot pressing. The extension direction of the hot-pressed tenon is consistent with the extension direction of the bamboo strips of the substrate; the thickness of the hot-pressed tenon is 4mm-5mm; The hot pressing of the substrate, the hot pressing bonding of the substrate and the thermoplastic fiber layer, and the hot pressing of the hot pressing tenon are all performed simultaneously in one hot pressing process. The hot pressing tenon is used to engage and fix with the bottom of the container. The hot-pressed tenon includes tenons extending along both sides of the bottom of the substrate, and the thickness of the tenons is between 4mm and 5mm.

2. The bamboo container floor according to claim 1, characterized in that, The width of the tenon is 28mm-30mm.

3. The bamboo container floor according to claim 1, characterized in that, Multiple hot-pressed tenons are evenly distributed on the bottom surface of the substrate.

4. The bamboo container floor according to claim 1, characterized in that, The bottom of the hot-pressed tenon is arched.

5. The bamboo container flooring according to claim 1, characterized in that, The substrate has a surface layer on the side opposite to the thermoplastic fiber layer. The surface layer includes a wood veneer and a film layer, and the film layer covers the surface of the wood veneer.

6. A method for manufacturing bamboo container flooring, characterized in that, include: A thermoplastic fiber layer is bonded to the bottom surface of the substrate, wherein the thermoplastic fiber layer is a composite structure in which thermoplastic composite fibers are added to the adhesive layer; The floor is placed on a heat-pressing pad, with the thermoplastic fiber layer in contact with the heat-pressing pad; The hot pressing of the substrate, the hot pressing bonding of the substrate and the thermoplastic fiber layer, and the hot pressing of the tenon are all performed simultaneously in one hot pressing process, so that the thermoplastic fiber layer is hot-pressed to form the tenon. The extension direction of the tenon is consistent with the extension direction of the bamboo strip of the substrate. The thickness of the tenon is 4mm-5mm. The tenon includes tenons extending along both sides of the bottom of the substrate, and the thickness of the tenons is between 4mm-5mm.

7. The method for manufacturing bamboo container flooring according to claim 6, characterized in that, The step of hot-pressing the thermoplastic fiber layer to form a hot-pressed tenon includes: a hot-pressing temperature of 135 degrees Celsius to 140 degrees Celsius; and a hot-pressing pressure of 21 MPa to 23 MPa.

8. The method for manufacturing bamboo container flooring according to claim 6, characterized in that, The step of hot-pressing the thermoplastic fiber layer to form a hot-pressed tenon includes: hot-pressing time of 40-45 minutes.

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