A tank box heat preservation foaming structure and a foaming method

Abstract

This invention provides a tank container insulation foaming structure and foaming method, including a compression molding module for foaming and a clamping and fixing module for fixing the compression molding module; the compression molding module includes a flat plate connected to the tank container, an arc-shaped plate disposed on the flat plate, and a connecting plate for connecting the flat plate and the arc-shaped plate, forming a foaming space between the arc-shaped plate and the tank container; the clamping and fixing module includes a fixing frame for fixing the flat plate, a clamping rod for fastening the fixing frame, and a connecting piece for connecting the clamping rod to the tank container; after the fixing frame is connected to the compression molding module, the fixing frame is fastened to the tank container by the clamping rod, and the clamping rod is connected to the tank container by the connecting piece; after the connection is completed, foaming material is filled into the foaming space for foaming treatment.

Description

Technical Field

[0001] This invention relates to the field of tank insulation technology, and is particularly applicable to a tank insulation foaming structure and foaming method. Background Technology

[0002] Currently, most container types in the tank container industry require insulation, and there are various types of insulation: rock wool filling, PU board laying, etc. Tank containers typically use rock wool filling for insulation, which is used for media that are not sensitive to ambient temperature. This involves wrapping sheet-like rock wool insulation material around the cylinder and then covering the outer layer with fiberglass sheets, which serves to insulate the container during conventional steam heating. However, it cannot achieve a good insulation effect for containers with higher insulation requirements.

[0003] For tank containers with high insulation requirements, foam insulation is used. However, the foaming process is complicated, and the foaming material can push up the foaming mold under violent reaction, causing damage to the foaming mold and causing the foaming material to flow out of the foaming mold, which cannot effectively insulate the tank container. Summary of the Invention

[0004] The purpose of this invention is to solve the above problems by providing a tank insulation foaming structure and foaming method.

[0005] To achieve the above-mentioned objectives, the present invention provides a tank insulation foaming structure, including a pressing and molding module for foaming and a clamping and fixing module for fixing the pressing and molding module.

[0006] The compression molding module includes a flat plate connected to the tank, an arc-shaped plate disposed on the flat plate, and a connecting plate for connecting the flat plate and the arc-shaped plate, wherein a foaming space is formed between the arc-shaped plate and the tank.

[0007] The clamping and fixing module includes a fixing frame for fixing the plate, a clamping rod for fastening the fixing frame, and a connecting piece for connecting the clamping rod to the tank box.

[0008] After the fixed frame is connected to the compression molding module, the fixed frame is fastened to the tank box by the clamping rod, and the clamping rod is connected to the tank box by the connector; after the connection is completed, foaming material is filled into the foaming space for foaming treatment.

[0009] More specifically, the fixed frame is provided with fastening reinforcing ribs.

[0010] More specifically, the fixing frame includes a plurality of fixing rods disposed on the plate, and the plurality of fixing rods are connected end to end around the perimeter of the plate.

[0011] A method for insulating and foaming a tank container based on the above-mentioned tank container insulation foaming structure includes the following steps:

[0012] S1. Attach aluminum foil to the front and rear end caps of the tank container. Use sealant to attach the end caps to the aluminum foil contact surfaces. Extend the aluminum foil as far as possible into the neck ring and attach it securely.

[0013] S2, place a plastic film on the outer surface of the end cap and connect the tank insulation foam structure to the two end frames;

[0014] S3, develop a slurry injection hole at the top of the collar, offset from the weld seam;

[0015] S4, the injection time of the foaming material is calculated based on the volume of the foamed head, the casting density and the injection flow rate;

[0016] S5, inject foaming material into the insulation foaming structure of the tank container;

[0017] S6, after the set time for static foaming, remove the foaming structure of the tank at both ends of the end cap;

[0018] S7, Check the quality and appearance of the insulation layer surface;

[0019] S8, Install fiberglass end caps on the insulation layer. The surface of the end caps should be free of defects. After marking and cutting, the perimeter should be straight and free of burrs. The gap between the perimeter and the end frames and the outer support should be uniform.

[0020] S9. Drill rivet holes from the center of the straight edge of the outer cladding board toward the edge, ensuring that the outer cladding board is free of wavy wrinkles.

[0021] S10, use sealant to apply adhesive and connect the outer casing to the tank container.

[0022] More specifically, in step S4,

[0023] t=(V 体 ρ) / v 速

[0024] Volume of the foaming space: V 体 ;

[0025] Density of insulation layer: ρ;

[0026] Infusion flow rate: v 速 ;

[0027] Time for injecting foaming material: t;

[0028] More specifically, in step S4,

[0029] Room temperature < 0℃, v 速 =1.9kg / s;

[0030] 0℃≤room temperature≤30℃, v速 =2kg / s;

[0031] 30℃ < room temperature, v 速 =2.1kg / s.

[0032] More specifically, in step S2, before the tank insulation foam structure is connected to the two end frames, a release agent is applied to the foaming space of the tank insulation foam structure.

[0033] More specifically, in step S5, the foaming material is a mixture of polyether and isocyanate.

[0034] More specifically, the ratio of the combined polyether to isocyanate is 1:1.2.

[0035] More specifically, in step S6, if the room temperature is greater than 20°C, the static foaming time is 90 minutes; if the room temperature is less than 20°C, the static foaming time is 120 minutes.

[0036] This invention mainly designs a tank container insulation foaming structure and foaming method. By setting up a pressing and molding module to form a foaming space, the foaming material foams in the foaming space to form an insulation layer. The insulation layer is consistent with the shape of the tank container head, thus better insulating the tank container head. A clamping and fixing module is set up to press the pressing and molding module and connect it to the tank container frame, preventing excessive foaming reaction during the foaming process, deformation of the pressing and molding module, or lifting of the pressing and molding module, which would hinder the foaming reaction. Attached Figure Description

[0037] Exemplary embodiments of this application will now be described in detail with reference to the accompanying drawings. It should be understood that the embodiments described below are for illustrative purposes only and do not limit the scope of this application. In the accompanying drawings:

[0038] Figure 1 This is a three-dimensional structural schematic diagram of the present invention;

[0039] Figure 2 This is a schematic diagram of the main body structure of the present invention;

[0040] Figure 3 This is a schematic diagram of the foaming structure at the tank head of the present invention;

[0041] In the diagram: 1. Flat plate; 2. Curved plate; 3. Connecting plate; 4. Fixed frame; 41. Fixed rod; 5. Fastening reinforcing rib; 6. Pressing rod; 71. First plate; 72. Second plate; 8. Tank frame; 9. Tank; 10. Foaming space. Detailed Implementation

[0042] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of the embodiments of this invention will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The described embodiments are some, but not all, embodiments of this invention. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this invention, and should not be construed as limiting the invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0043] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this invention 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. Therefore, they should not be construed as limiting the scope of protection of this invention. The embodiments of this invention will now be described in detail with reference to the accompanying drawings.

[0044] It should be understood that the accompanying drawings are for illustrative purposes only.

[0045] A type of tank container insulation foam structure, such as Figure 1-3 As shown, it includes a compression molding module for foaming and a clamping and fixing module for fixing the compression molding module. The foaming structure of the tank box is connected to the end cap of the tank box 9 to perform the foaming operation.

[0046] The compression molding module includes a flat plate 1 connected to the tank 9, an arc plate 2 disposed on the flat plate 1, and a connecting plate 3 for connecting the flat plate 1 and the arc plate 2. A foaming space 10 is formed between the arc plate 2 and the tank 9.

[0047] The flat plate 1 is connected to the tank head. The flat plate 1 is designed according to the structure of the tank's end frames and the shape of the outer casing. Connecting holes for the curved plate 2 are provided on the flat plate 1, matching the curved plate 2 for easy installation. When the curved plate 2 is installed on the flat plate 1, there are parts of the curved plate 2 that cannot be fully connected to the flat plate 1, creating a gap between them that prevents foaming. Therefore, a connecting plate 3 is provided to connect the flat plate 1 and the curved plate 2, facilitating foaming. After the flat plate 1, curved plate 2, and connecting plate 3 are connected, a sealed foaming space 10 is formed between the flat plate 1, the curved plate 2, and the tank head. The foaming material reacts within this space to form an insulation layer. Once formed, the insulation layer adheres tightly to the tank head, ensuring effective insulation. The flat plate 1 and curved plate 2 are adaptable to different tank models 9, ensuring that the resulting insulation layer is also adaptable to different tank models 9, guaranteeing effective insulation for the tank head.

[0048] The clamping and fixing module includes a fixing frame 4 for fixing the plate 1, a clamping rod 6 for fastening the fixing frame 4, and a connecting piece for connecting the clamping rod 6 and the tank 9.

[0049] The fixing frame 4 includes several fixing rods arranged around the plate 1. The number of fixing rods is determined according to the shape of the plate 1. Specifically, eight fixing rods are provided, connected end-to-end around the perimeter of the plate 1. All fixing rods are connected to the plate 1, and the connection method can be adhesive, welding, or integral molding. In this design, the fixing rods are welded to the plate 1 to support its perimeter. To prevent localized deformation of the plate 1 due to compression during the foaming process, reinforcing ribs 5 are provided on the plate 1 to enhance its strength.

[0050] Because the foaming material releases heat and expands in volume during the reaction, it exerts an outward impact force on the flat plate 1. If the pressing and molding module undergoes plastic deformation, it may cause leakage of the foaming material, thereby contaminating the paint. To further enhance the strength of the pressing and molding module, clamping rods 6 are installed on the fixed frame 4. Several clamping rods 6 are installed according to the size of the fixed frame 4. The clamping rods 6 are arranged in parallel and are all connected to the fixed frame 4. The connection method can be adhesive, welding, or integral molding. In this solution, the clamping rods 6 are welded to the fixed frame 4. The installation of clamping rods 6 can further enhance the strength of the pressing and molding module and effectively prevent deformation of the pressing and molding module during the foaming process. The length of the clamping rods 6 needs to be set to ensure that they can be fixed to the frame of the tank 9 after being connected to the connector.

[0051] The connector includes a first plate 71 connected to the clamping rod 6 and a second plate 72 connected to the first plate 71. The first plate 71 is welded to the clamping rod 6, and the first plate 71 is welded to the second plate 72. The tank insulation foam structure is connected to the tank 9 through the second plate 72.

[0052] The thermal insulation foam structure of the tank box is hoisted onto the tank box 9 by a crane. The clamping rod 6 contacts the tank box frame 8. A first bolt hole is opened on the clamping rod 6, a second bolt hole is opened on the tank box frame 8, and a third bolt hole is opened on the second plate 72. Bolts pass through the first bolt hole, the second bolt hole, and the third bolt hole in sequence to connect the clamping rod 6, the tank box frame 8, and the second plate 72, thereby setting the thermal insulation foam structure of the tank box onto the tank box 9.

[0053] The specific installation steps for the tank container insulation foam structure are as follows:

[0054] The arc-shaped plate 2 is connected to the flat plate 1, and the connecting plate 3 connects the arc-shaped plate 2 and the flat plate 1, so that a closed foaming space 10 is formed between the flat plate 1, the arc-shaped plate 2, the connecting plate 3, and the tank 9. Several fixing rods are set around the perimeter of the flat plate 1, and the ends of the fixing rods are connected to form a fixing frame 4, which is connected to the flat plate 1 to support the flat plate 1. Fastening reinforcing ribs 5 are set on the flat plate 1 to increase the strength of the flat plate 1. A clamping rod 6 is connected to the fixing frame 4, a first plate 71 is connected to the clamping rod 6, and a second plate 72 is connected to the first plate 71. The tank insulation foaming structure is installed. After the tank insulation foaming structure is installed, a crane is used to hoist the tank insulation foaming structure onto the tank 9, and then the tank insulation foaming structure is connected to the tank frame 8 and tightened with bolts. After the connection is completed, foaming material is filled into the foaming space 10 for foaming treatment.

[0055] A method for insulating and foaming tank containers includes the following steps:

[0056] S1. Clean the end caps at both ends of the tank 9. Then, attach aluminum foil to the end caps at the front and rear ends of the tank 9. Use sealant to attach the end caps to the contact surface with the aluminum foil. Extend the aluminum foil as far as possible to the inside of the neck ring and attach it firmly.

[0057] The aluminum foil is left on after foaming is complete. The aluminum foil can prevent high temperatures and block condensation, thus protecting the foamed material.

[0058] S2, a plastic film is placed on the outer surface of both end caps, and the plastic film is used to cover the end caps of the tank box as much as possible. The tank box insulation foam structure is lifted by a crane. A release agent is applied to the foam space 10 of the tank box insulation foam structure. Then the crane moves the tank box insulation foam structure to the two end frames respectively. The tank box insulation foam structure is connected to the tank box frame 8 by bolts.

[0059] The plastic film and release agent are both used to facilitate the subsequent disassembly of the tank insulation foam structure. Only one of these two can be used. However, if only the plastic film is used, it is prone to damage during the foaming process, and the foaming material may leak out and adhere to the tank insulation foam structure, causing contamination. Therefore, the plastic film needs to be constantly replaced, resulting in waste and high costs. If only the release agent is used, because it is liquid, it will flow from the upper part of the foaming space 10 to the lower part before it is completely dry, leaving the upper part uncovered and hindering proper demolding of the upper part of the tank insulation foam structure. However, if the release agent is allowed to dry completely before installing the tank insulation foam structure, the foaming material will still adhere to the structure, making demolding inconvenient.

[0060] S3, A foaming material injection hole is opened at the top of the neck ring, offset from the weld. The size of the foaming material injection hole is the same as the injection port of the foaming machine. The foaming machine moves to the foaming material injection hole and injects foaming material into the foaming space.

[0061] S4, the injection time of the foaming material is calculated based on the volume of the foaming space, the density of the insulation layer formed by foaming, and the injection flow rate;

[0062] Volume of the foaming space: V 体 ;

[0063] Density of insulation layer: ρ;

[0064] Infusion flow rate: v 速 ;

[0065] Time for injecting foaming material: t;

[0066] Weight of foaming material: m;

[0067] Because m=V 体 ρ, t=m / v, from which we can derive: t=(V 体 ρ) / v 速 ;

[0068] The infusion flow rate is determined based on room temperature, and the specific infusion flow rate is as follows:

[0069] Room temperature < 0℃, v 速 =1.9kg / s;

[0070] 0℃≤room temperature≤30℃, v 速 =2kg / s;

[0071] 30℃ < room temperature, v 速 =2.1kg / s;

[0072] For example, using 3D software, after the insulation foam structure of the tank box is compressed, the volume V of the foam space 10 can be calculated. 体 0.8m 3 To obtain an insulation layer density ρ of 42 kg / m³ 3 The total weight m of the required foaming material is 33.6 kg, and the injection flow rate v is... 速 The speed is 2 kg / s, and the calculated time t is 16.8 s.

[0073] The higher the density of the insulation layer, the better the insulation effect and the faster the flow rate into the foaming space 10. The lower the density of the insulation layer, the worse the insulation effect and the slower the flow rate into the foaming space 10.

[0074] When the injection flow rate is too fast, the foaming material at the bottom has not yet reacted before new foaming material is injected. While the foaming material at the bottom is reacting, it will expand outward, continuously accumulate upward, leak out, and contaminate the tank body, affecting the flowability of the injection material. Moreover, when the injection flow rate is too fast, the density is difficult to control. When the injection flow rate is too slow, the foaming material at the bottom has already reacted before new foaming material is injected, resulting in poor foaming effect.

[0075] The infusion flow rate at higher room temperature is slower than that at lower temperature.

[0076] The volume and pouring density of the foaming space are determined. The faster the pouring flow rate, the shorter the time required to inject the foaming material.

[0077] S5, Inject foaming material into the insulation foaming structure of the tank box. The foaming material is a mixture of polyether and isocyanate, and the ratio of polyether to isocyanate is 1:1.2. Calculate the required amounts of polyether and isocyanate according to the amount of foaming material to be filled.

[0078] S6, when the room temperature is above 20℃, allow it to stand for 90 minutes to foam; when the room temperature is below 20℃, allow it to stand for 120 minutes to foam; after foaming is completed, remove the insulation foam structure of the tank box.

[0079] S7. Inspect the surface quality and appearance of the insulation layer to ensure that the insulation layer is undamaged or defective and to ensure the insulation effect on the tank container.

[0080] S8, Install fiberglass end caps on the insulation layer. The surface of the end caps should be free of defects. After marking and cutting, the perimeter should be straight and free of burrs. The gap between the perimeter and the end frames and the outer support should be uniform.

[0081] S9. Drill rivet holes from the center of the straight edge of the outer cladding plate toward the edge. The outer cladding plate should be free of wavy wrinkles. Drilling rivet holes will fix the outer cladding plate and the insulation layer to the tank box to prevent the outer cladding plate from falling off during transportation, which would damage the insulation layer and affect the insulation effect on the tank box head.

[0082] S10. Use sealant to connect the outer plate to the tank head. When only rivets are used, the outer plate cannot completely cover the insulation layer, and the insulation layer will still be exposed, which can easily cause damage to the insulation layer. Therefore, sealant is used to make the outer plate completely cover the insulation layer to prevent damage to the insulation layer.

[0083] This invention mainly designs a tank container insulation foaming structure and foaming method. By setting a pressing and molding module, a foaming space 10 is formed. The foaming material foams within the foaming space 10 to form an insulation layer. The insulation layer is consistent with the shape of the tank container head, thus better insulating the tank container head. A clamping and fixing module is set to press the pressing and molding module tightly and connect it to the tank container frame 8, preventing excessive foaming reaction during the foaming process, deformation of the pressing and molding module, or lifting of the pressing and molding module, which would hinder the foaming reaction. The foaming of the tank container head according to the tank container insulation foaming structure is simpler than existing technologies and achieves better results, with the formed insulation layer meeting the requirements.

[0084] The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the specific details of the above embodiments. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solution of the present invention, and these simple modifications all fall within the protection scope of the present invention.

[0085] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present invention will not describe the various possible combinations separately.

[0086] Furthermore, various different embodiments of the present invention can be combined in any way, as long as they do not violate the spirit of the present invention, they should also be regarded as the content disclosed by the present invention.

Claims

1. A tank container insulation foam structure, characterized in that: It includes a compression molding module for foaming and a clamping and fixing module for fixing the compression molding module; The compression molding module includes a flat plate (1) connected to the tank box (9), an arc plate (2) set on the flat plate (1), and a connecting plate (3) for connecting the flat plate (1) and the arc plate (2); the flat plate (1) is connected to the tank box head, and the flat plate (1) is set according to the structure of the frame at both ends of the tank box and the shape of the outer cover plate. After the flat plate (1), the arc plate (2) and the connecting plate (3) are connected, a sealed foaming space (10) is formed between the flat plate (1), the arc plate (2) and the tank box head; The clamping and fixing module includes a fixing frame (4) with a fixing plate (1), a clamping rod (6) for fastening the fixing frame (4), and a connecting piece connecting the clamping rod (6) and the tank box (9). The clamping rod (6) is in contact with the tank box frame (8). The fixed frame (4) includes several fixed rods arranged on the plate (1), and the fixed rods are connected end to end around the perimeter of the plate (1); after the fixed frame (4) is connected to the pressing and molding module, the fixed frame (4) is fastened to the tank (9) by the clamping rod (6), and the clamping rod (6) is connected to the tank (9) by the connector; after the connection is completed, foaming material is filled into the foaming space (10) for foaming treatment; The connector includes a first plate (71) connected to the clamping rod (6) and a second plate (72) connected to the first plate (71). The clamping rod (6), the tank frame (8) and the second plate (72) are connected by bolts, thereby setting the tank insulation foam structure on the tank (9).

2. The tank insulation foam structure according to claim 1, characterized in that: A fastening reinforcing rib (5) is provided on the plate (1).

3. A method for insulating a tank container with a foamed insulation structure based on any one of claims 1-2, characterized in that, Includes the following steps: S1, attach tin foil to the front and rear end caps of the tank (9), and use sealant to attach the tin foil to the contact surface between the end caps and the tin foil. Extend the tin foil as far as possible to the inside of the neck ring and attach it firmly. S2, place a plastic film on the outer surface of the end cap and connect the tank insulation foam structure to the two end frames; S3, develop a slurry injection hole at the top of the collar, offset from the weld seam; S4, the injection time of the foaming material is calculated based on the volume of the foaming space, the density of the insulation layer formed by foaming, and the injection flow rate; S5, inject foaming material into the insulation foaming structure of the tank container; S6, after the set time for static foaming, remove the tank insulation foaming structure at both ends of the end cap; S7, Check the quality and appearance of the insulation layer surface; S8, Install fiberglass end caps on the insulation layer. The surface of the end caps should be free of defects. After marking and cutting, the perimeter should be straight and free of burrs. The gap between the perimeter and the end frames and the outer support should be uniform. S9. Drill rivet holes from the center of the straight edge of the outer cladding board toward the edge, ensuring that the outer cladding board is free of wavy wrinkles. S10, use sealant to apply glue and connect the outer plate to the tank box (9).

4. The tank insulation foaming method according to claim 3, characterized in that: In step S4, t=(V 体 ρ) / v 速 ; Volume of the foaming space: V 体 ; Density of insulation layer: ρ; Perfusion flow rate: v 速 ; Time for injecting foaming material: t.

5. The method for heat insulation foaming of tank containers according to claim 4, characterized in that: In step S4, Room temperature < 0°C, v 速 = 1.9 kg / s; 0℃≤room temperature≤30℃, v 速 =2kg / s; 30℃ < room temperature, v 速 =2.1kg / s.

6. The method for heat insulation foaming of tank containers according to claim 3, characterized in that: In step S2, before the tank insulation foam structure is connected to the two end frames, a release agent is applied to the foaming space of the tank insulation foam structure.

7. The method for heat insulation foaming of tank containers according to claim 3, characterized in that: In step S5, the foaming material is a mixture of polyether and isocyanate.

8. The method for heat insulation foaming of tank containers according to claim 7, characterized in that: The ratio of the combined polyether to isocyanate is 1:1.

2.

9. The method for heat insulation foaming of tank containers according to claim 3, characterized in that: In step S6, if the room temperature is greater than 20°C, the static foaming time is 90 minutes; if the room temperature is less than or equal to 20°C, the static foaming time is 120 minutes.

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