Foamed plastic plate and its forming process

Abstract

The application provides a foamed plastic plate and a forming process thereof. The foamed plastic plate comprises a first plate surface and a second plate surface, the first plate surface and the second plate surface are arranged side by side, a sandwich layer is arranged between the first plate surface and the second plate surface, and the sandwich layer is parallel to the first plate surface and the second plate surface. A gap layer is formed between the sandwich layer and the first plate surface and the second plate surface, and a plurality of wedge-shaped holes are arranged on the sandwich layer. A foam is formed between the first plate surface and the second plate surface. The foam enters between the first plate surface and the sandwich layer through the wedge-shaped hole during the forming process, and the foam enters between the second plate surface and the sandwich layer through the wedge-shaped hole during the forming process. The foam is integrally formed in the wedge-shaped hole, between the first plate surface and the sandwich layer, and between the second plate surface and the sandwich layer. The technical scheme has a reasonable structure design, is convenient for processing and forming, and can improve the strength of the foamed plastic plate as a whole.

Description

Technical Field

[0001] This invention belongs to the technical field of foamed plastic sheets, specifically relating to a foamed plastic sheet and its molding process. Background Technology

[0002] Due to its flexible molding structure and high plasticity, foamed plastic sheets are gradually being adopted by people. However, the existing foamed plastic sheet molding structure design is relatively simple, resulting in insufficient strength and inability to meet people's conventional needs.

[0003] Given the technical problems existing in the aforementioned foamed plastic sheets, there are currently no relevant solutions; therefore, there is an urgent need to find effective solutions to address these issues. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of the above-mentioned technologies by proposing a foamed plastic sheet and its molding process, aiming to solve the problem of insufficient strength of existing foamed plastic sheets.

[0005] This invention provides a foamed plastic sheet, comprising a first surface and a second surface arranged side by side, with a core layer provided between the first and second surfaces, the core layer being parallel to both the first and second surfaces; a gap layer is formed between the core layer and the first and second surfaces, and the core layer has multiple wedge-shaped holes; foam is formed between the first and second surfaces; during the molding process, the foam enters between the first surface and the core layer through the wedge-shaped holes, and also enters between the second surface and the core layer through the wedge-shaped holes; the foam is integrally formed within the wedge-shaped holes, between the first surface and the core layer, and between the second surface and the core layer.

[0006] Furthermore, the sandwich layer includes a first sandwich layer and a second sandwich layer, with a foam layer formed between the first sandwich layer and the second sandwich layer. The first sandwich layer is located between the foam layer and the first panel, and the second sandwich layer is located between the foam layer and the second panel. The foam enters the space between the first panel and the first sandwich layer through wedge-shaped holes on the first sandwich layer. The foam enters the space between the second panel and the second sandwich layer through wedge-shaped holes on the second sandwich layer.

[0007] Furthermore, the wedge-shaped hole is a through hole; a first wedge-shaped surface is formed on one side of the wedge-shaped hole, and a second wedge-shaped surface is formed on the other side of the wedge-shaped hole; the foam passes through the wedge-shaped hole and forms wedge-shaped interlocking surfaces with the first wedge-shaped surface and the second wedge-shaped surface respectively.

[0008] Furthermore, the first wedge surface and the second wedge surface are non-straight walls, thereby forming a non-linear through hole between the first wedge surface and the second wedge surface.

[0009] Furthermore, the first wedge surface is a convex surface and the second wedge surface is a concave surface; or, the first wedge surface and the second wedge surface are both convex surfaces; or, the first wedge surface and the second wedge surface are both concave surfaces.

[0010] Furthermore, pits are formed on the inner surfaces of the first and second plates, and cavities are formed on the inner walls of the pits; the foam is wedged into the pits and engaged with the foam pores in the cavities.

[0011] Furthermore, the inner side of the first board is bonded to one side of the foam through a first adhesive layer; the inner side of the second board is bonded to the other side of the foam through a second adhesive layer; organic adhesives are added to the first adhesive layer and the second adhesive layer respectively.

[0012] Accordingly, in conjunction with the above solutions, the present invention also provides a molding process for a foamed plastic sheet, used to mold the aforementioned foamed plastic sheet; the molding process includes the following steps:

[0013] S1: The first plate and the second plate are arranged side by side to form a gap sandwich layer. A core layer is provided in the gap sandwich layer and the core layer is parallel to the first plate and the second plate, respectively.

[0014] S2: Foaming is used to fill the gap between the core layer and the first plate surface and the core layer through wedge-shaped holes on the core layer, and foaming is used to fill the gap between the second plate surface and the core layer through wedge-shaped holes on the core layer.

[0015] S3: The foaming process is integrally formed within the wedge-shaped holes, between the first plate and the core layer, and between the second plate and the core layer.

[0016] Further, in step S1: the inner surfaces of the first and second plates are pre-formed with recesses, and the inner walls of the recesses are formed with holes; in step S2: one side of the foam is wedged into the recess on the inner surface of the first plate and engages with the foaming holes in the holes; the other side of the foam is wedged into the recess on the inner surface of the second plate and engages with the foaming holes in the holes.

[0017] Furthermore, in step S1: the inner surfaces of the first and second plates are pre-coated with organic adhesives.

[0018] Furthermore, in step S2: during the molding process, the foam adheres to the organic adhesive on the inner side of the first board through one side, thereby forming a first adhesive layer; during the molding process, the foam adheres to the organic adhesive on the inner side of the second board through the other side, thereby forming a second adhesive layer.

[0019] Furthermore, in step S2: the filling foam is irradiated with electromagnetic waves.

[0020] In step S1: The outer surfaces of the first and second plates are pre-coated with calcium carbonate coatings.

[0021] The technical solution provided in this case has a reasonable structural design, is easy to process and mold, and can improve the overall strength of foamed plastic sheets. Attached Figure Description

[0022] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0023] The present invention will be further described below with reference to the accompanying drawings:

[0024] Figure 1 This is a cross-sectional view of a foamed plastic sheet structure according to the present invention;

[0025] Figure 2 This is a partial cross-sectional view of an embodiment of a foamed plastic sheet structure according to the present invention.

[0026] In the figure: 1. First panel; 2. Second panel; 3. Foaming; 4. First core layer; 5. Second core layer; 6. First adhesive layer; 7. Second adhesive layer; 8. Wedge-shaped hole; 81. First wedge-shaped surface; 82. Second wedge-shaped surface. Detailed Implementation

[0027] To make the technical problems to be solved, the technical solutions, and the beneficial effects of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention.

[0028] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0029] 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 indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. "Several" means one or more, unless otherwise explicitly specified.

[0030] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They 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 limitations on this invention.

[0031] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0032] As shown in Figure 1 to Figure 2 As shown, the present invention provides a foamed plastic sheet, the foamed plastic sheet including a first sheet surface 1 and a second sheet surface 2, wherein the first sheet surface 1 and the second sheet surface 2 are arranged side by side, and a core layer is provided between the first sheet surface 1 and the second sheet surface 2, the core layer being parallel to the first sheet surface 1 and the second sheet surface 2 respectively; furthermore, a gap layer is formed between the core layer and the first sheet surface 1 and the second sheet surface 2 respectively, and the core layer is provided with a plurality of wedge-shaped holes 8, thereby forming a foaming space; furthermore, a foam 3 is formed between the first sheet surface 1 and the second sheet surface 2; the foam 3 is formed during the molding process. The foam 3 enters the space between the first plate surface 1 and the core layer through the wedge-shaped hole 8, and also enters the space between the second plate surface 2 and the core layer through the wedge-shaped hole 8 during the molding process, forming a foam filling layer. Specifically, the foam 3 is integrally formed in the wedge-shaped hole 8, between the first plate surface 1 and the core layer, and between the second plate surface 2 and the core layer, respectively, and forms a wedge-shaped interlocking structure with the wedge-shaped holes 8 of the first plate surface 1, the second plate surface 2, and the core layer, thereby improving the strength of the foamed plastic sheet. The foamed plastic sheet provided by the present invention has a more reasonable structural design, is convenient for processing and molding, and can improve the overall strength of the foamed plastic sheet.

[0033] Preferably, in combination with the above scheme, as shown in Figures 1 to 12, the following methods are used: Figure 2As shown, the sandwich layer includes a first sandwich layer 4 and a second sandwich layer 5, wherein a foam layer is formed between the first sandwich layer 4 and the second sandwich layer 5, and the first sandwich layer 4 is located between the foam layer and the first panel 1, and the second sandwich layer 5 is located between the foam layer and the second panel 2; specifically, during the molding process, the foam 3 enters between the first panel 1 and the first sandwich layer 4 through the wedge-shaped holes 8 on the first sandwich layer 4, thereby forming a first foam filling layer; furthermore, during the molding process, the foam 3 enters between the second panel 2 and the second sandwich layer 5 through the wedge-shaped holes 8 on the second sandwich layer 5, thereby forming a second foam filling layer, which can enhance the strength of the foamed plastic sheet.

[0034] Preferably, in combination with the above scheme, as shown in Figures 1 to 12, the following methods are used: Figure 2 As shown, in this embodiment, the wedge-shaped hole 8 is designed as a through hole; specifically, a first wedge-shaped surface 81 is formed on one side of the wedge-shaped hole 8, and a second wedge-shaped surface 82 is formed on the other side of the wedge-shaped hole 8; further, the foam 3 passes through the wedge-shaped hole 8 and forms wedge-shaped interlocking surfaces with the first wedge-shaped surface 81 and the second wedge-shaped surface 82 respectively; by adopting the above scheme, by forming wedge-shaped surfaces on both sides of the wedge-shaped hole 8, the foam can form wedge-shaped interlocking surfaces during the molding process, thereby improving the overall strength.

[0035] Preferably, in combination with the above scheme, as shown in Figures 1 to 12, the following methods are used: Figure 2 As shown, the first wedge surface 81 and the second wedge surface 82 are non-straight walls (i.e., the longitudinal section of the wedge hole 8 is an irregular shape), which makes a non-linear through hole formed between the first wedge surface 81 and the second wedge surface 82. By designing this non-straight wall, the wedge-shaped interlocking surface formed between the first wedge surface 81 and the second wedge surface 82 is more reliable.

[0036] Preferably, in combination with the above scheme, as shown in Figures 1 to 12, the following methods are used: Figure 2 As shown in this embodiment, as a preferred implementation scheme one: the first wedge surface 81 is designed as a convex surface, and the second wedge surface 82 is designed as a concave surface. Through the concave and convex surfaces and the foamed wedge shape, the interlocking force can be effectively improved and the strength of the foamed plastic board can be increased.

[0037] Preferably, in combination with the above scheme, as shown in Figures 1 to 12, the following methods are used: Figure 2 As shown in this embodiment, as a preferred implementation scheme two: the first wedge surface 81 and the second wedge surface 82 are convex surfaces. Through the convex surface and the foamed wedge shape, the interlocking force can be effectively improved and the strength of the foamed plastic sheet can be increased.

[0038] Preferably, in combination with the above scheme, as shown in Figures 1 to 12, the following methods are used: Figure 2 As shown in this embodiment, as a preferred implementation scheme three: the first wedge surface 81 and the second wedge surface 82 are concave surfaces. Through the concave surface and the foamed wedge shape, the interlocking force can be effectively improved and the strength of the foamed plastic board can be increased.

[0039] Preferably, in combination with the above scheme, as shown in Figures 1 to 12, the following methods are used: Figure 2 As shown, a pit is formed on the surface of the inner side of the first plate 1, and a cavity is formed on the inner sidewall of the pit; specifically, the foam 3 is wedged into the pit and engages with the foam pores in the cavity, thereby improving the engagement force between the first plate 1 and the foam 3; furthermore, a pit is formed on the surface of the inner side of the second plate 2, and a cavity is formed on the inner sidewall of the pit; specifically, the foam 3 is wedged into the pit and engages with the foam pores in the cavity, thereby improving the engagement force between the second plate 2 and the foam 3.

[0040] Preferably, in combination with the above scheme, as shown in Figures 1 to 12, the following methods are used: Figure 2 As shown, the inner side of the first panel 1 is bonded to one side of the foam 3 by the first adhesive layer 6; further, the inner side of the second panel 2 is bonded to the other side of the foam 3 by the second adhesive layer 7; specifically, the first adhesive layer 6 and the second adhesive layer 7 are respectively added with organic adhesive to improve the bonding strength.

[0041] Preferably, in conjunction with the above scheme, as shown in Figure 1, a calcium carbonate coating is pre-applied to the outer surfaces of the first plate surface 1 and the second plate surface 2, thereby improving the overall performance of the foamed plastic sheet.

[0042] Accordingly, in conjunction with the above solution, as shown in Figure 1, the present invention also provides a molding process for a foamed plastic sheet, used to mold the aforementioned foamed plastic sheet; specifically, the molding process includes the following steps:

[0043] S1: The first plate surface 1 and the second plate surface 2 are arranged side by side to form a gap sandwich layer. A core layer is provided in the gap sandwich layer and the core layer is parallel to the first plate surface 1 and the second plate surface 2 respectively.

[0044] S2: Fill the gap with foam 3. The foam 3 enters the space between the first plate surface 1 and the core layer through the wedge-shaped holes 8 on the core layer, and the foam 3 enters the space between the second plate surface 2 and the core layer through the wedge-shaped holes 8 on the core layer.

[0045] S3: The foam 3 is integrally formed during the molding process within the wedge-shaped hole 8, between the first plate surface 1 and the core layer, and between the second plate surface 2 and the core layer.

[0046] Preferably, in combination with the above scheme, in step S1: the inner sides of the first plate surface 1 and the second plate surface 2 are respectively pre-formed with pits, and the inner sidewalls of the pits are formed with holes; in step S2: one side of the foam 3 is wedged into the pit on the inner side of the first plate surface 1 and engages with the foaming hole in the hole; the other side of the foam 3 is wedged into the pit on the inner side of the second plate surface 2 and engages with the foaming hole in the hole.

[0047] Preferably, in combination with the above scheme, in step S1: the inner surfaces of the first plate surface 1 and the second plate surface 2 are respectively pre-coated with organic adhesive;

[0048] In step S2: During the molding process, foam 3 is bonded to the organic adhesive on the inner side of the first board 1 through one side, thereby forming the first adhesive layer 6; During the molding process, foam 3 is bonded to the organic adhesive on the inner side of the second board 2 through the other side, thereby forming the second adhesive layer 7.

[0049] Preferably, in combination with the above scheme, in step S2: the foam is irradiated with electromagnetic waves in the filling foam 3, thereby increasing the strength of the foam.

[0050] Preferably, in combination with the above scheme, in step S1: the outer surfaces of the first plate 1 and the second plate 2 are respectively pre-coated with calcium carbonate coating, thereby improving the overall performance of the foamed plastic sheet.

[0051] The technical solution provided in this case has a reasonable structural design, is easy to process and mold, and can improve the overall strength of foamed plastic sheets.

[0052] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the present invention. Any person skilled in the art can make many possible variations and modifications to the technical solution of the present invention, or modify it into equivalent embodiments, without departing from the scope of the present invention. Therefore, any modifications, equivalent changes, and alterations made to the above embodiments based on the technology of the present invention without departing from the scope of the present invention are within the protection scope of the present invention.

Claims

1. A foamed plastic sheet, characterized in that, The foamed plastic sheet includes a first surface (1) and a second surface (2), which are arranged side by side, and a core layer is provided between the first surface (1) and the second surface (2). The core layer is parallel to the first surface (1) and the second surface (2), respectively. A gap layer is formed between the core layer and the first surface (1) and the second surface (2), respectively, and the core layer is provided with a plurality of wedge-shaped holes (8). A foam (3) is formed between the first plate (1) and the second plate (2); the foam (3) enters between the first plate (1) and the core layer through the wedge-shaped hole (8) during the molding process, and the foam (3) enters between the second plate (2) and the core layer through the wedge-shaped hole (8) during the molding process; the foam (3) is integrally formed in the wedge-shaped hole (8), between the first plate (1) and the core layer, and between the second plate (2) and the core layer.

2. The foamed plastic sheet according to claim 1, characterized in that, The sandwich layer includes a first sandwich layer (4) and a second sandwich layer (5). A foam layer is formed between the first sandwich layer (4) and the second sandwich layer (5). The first sandwich layer (4) is located between the foam layer and the first board surface (1), and the second sandwich layer (5) is located between the foam layer and the second board surface (2). The foam (3) enters the space between the first board surface (1) and the first sandwich layer (4) through the wedge-shaped hole (8) on the first sandwich layer (4). The foam (3) enters the space between the second board surface (2) and the second sandwich layer (5) through the wedge-shaped hole (8) on the second sandwich layer (5).

3. The foamed plastic sheet according to claim 1, characterized in that, The wedge-shaped hole (8) is a through hole; a first wedge-shaped surface (81) is formed on one side of the wedge-shaped hole (8), and a second wedge-shaped surface (82) is formed on the other side of the wedge-shaped hole (8); the foam (3) passes through the wedge-shaped hole (8) and forms wedge-shaped engagement surfaces with the first wedge-shaped surface (81) and the second wedge-shaped surface (82) respectively.

4. The foamed plastic sheet according to claim 3, characterized in that, The first wedge surface (81) and the second wedge surface (82) are non-straight walls, thereby forming a non-linear through hole between the first wedge surface (81) and the second wedge surface (82).

5. The foamed plastic sheet according to claim 3, characterized in that, The first wedge surface (81) is a convex surface, and the second wedge surface (82) is a concave surface; or, the first wedge surface (81) and the second wedge surface (82) are both convex surfaces; or, the first wedge surface (81) and the second wedge surface (82) are both concave surfaces.

6. The foamed plastic sheet according to claim 1, characterized in that, The inner surfaces of the first plate (1) and the second plate (2) are formed with pits, and the inner walls of the pits are formed with cavities; the foam (3) is wedged into the pits and engages with the foaming pores in the cavities; and / or, The outer surfaces of the first plate (1) and the second plate (2) are respectively coated with calcium carbonate coating.

7. The foamed plastic sheet according to claim 2, characterized in that, The inner side of the first panel (1) is bonded to one side of the foam (3) by a first adhesive layer (6); the inner side of the second panel (2) is bonded to the other side of the foam (3) by a second adhesive layer (7); organic adhesives are added to the first adhesive layer (6) and the second adhesive layer (7).

8. A molding process for a foamed plastic sheet, used to mold the foamed plastic sheet according to any one of claims 1 to 5; characterized in that, The molding process includes the following steps: S1: The first plate surface (1) and the second plate surface (2) are arranged side by side and a gap sandwich is formed. A core layer is provided in the gap sandwich and the core layer is parallel to the first plate surface (1) and the second plate surface (2) respectively. S2: Fill the gap with foam (3), the foam (3) enters the space between the first plate surface (1) and the core layer through the wedge-shaped hole (8) on the core layer, and the foam (3) enters the space between the second plate surface (2) and the core layer through the wedge-shaped hole (8) on the core layer; S3: The foaming (3) is integrally formed during the forming process within the wedge-shaped hole (8), between the first plate surface (1) and the core layer, and between the second plate surface (2) and the core layer.

9. The molding process of the foamed plastic sheet according to claim 8, characterized in that, In step S1: the inner sides of the first plate (1) and the second plate (2) are respectively pre-formed with recesses, and the inner sidewalls of the recesses are formed with holes; in step S2: one side of the foam (3) is wedged into the recess on the inner side of the first plate (1) and engages with the foaming hole in the hole; the other side of the foam (3) is wedged into the recess on the inner side of the second plate (2) and engages with the foaming hole in the hole.

10. The molding process of the foamed plastic sheet according to claim 8, characterized in that, In step S1: the inner surfaces of the first plate surface (1) and the second plate surface (2) are respectively pre-coated with organic adhesive; In step S2: during the molding process, the foam (3) is bonded to the organic adhesive on the inner side of the first board (1) through one side to form a first adhesive layer (6); during the molding process, the foam (3) is bonded to the organic adhesive on the inner side of the second board (2) through the other side to form a second adhesive layer (7). In step S2: the foam is irradiated with electromagnetic waves in the filling foam (3); In step S1: the outer surfaces of the first plate (1) and the second plate (2) are respectively pre-coated with calcium carbonate coating.

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