An integrally formed reinforced composite air cargo pallet and method of processing the same

Abstract

The application provides a reinforced composite integrally-formed air transport container pallet and a processing method thereof. The pallet is integrally formed by using reinforced composite material, and the integrality of the pallet is realized, and a vacuum composite process is avoided. The container pallet comprises a pallet body and a tethering ring installed on the pallet body through a nut plate. The pallet body is a plate-shaped structure integrally formed by using reinforced composite material. After integrally formed, the pallet body is uniformly and spacedly provided with a plurality of serrations on four side edges. A tethering ring installation opening for installing the tethering ring is reserved. The nut plate is installed in the tethering ring installation opening, and the nut plate is used for providing a connecting interface of the tethering ring. After the tethering ring is installed, the tethering ring installation opening is filled with reinforced composite material through secondary local injection.

Description

Technical Field

[0001] This invention relates to a transport container pallet, specifically a reinforced composite material one-piece molded air transport container pallet, belonging to the technical field of mechanical devices and transport equipment. Background Technology

[0002] Air transport container pallets fall into two main categories: military and civilian. The concept was first proposed by the United States in the 1960s. The 463L pallet was first used in the military field to realize air containerized transportation, giving full play to the advantages of large transport aircraft and ultra-long range, and achieving the strategic goal of high-efficiency global air delivery.

[0003] Air transport container pallets are one of the main forms of air container transport. Currently, there are two main standards: the US standard and the Russian standard, which are customized by the United States and Russia (the former Soviet Union) respectively for air transport container specifications and corresponding product interfaces. Since the beginning of the 21st century, China has referenced and designed air transport container equipment interfaces and parameters suitable for the Chinese military. Drawing on the standards and container equipment of both countries, my country began to develop and design air transport container pallets that meet the conditions for military use, and these gradually began to be put into military use after 2010.

[0004] my country mainly draws on the US military's 463L system to develop air transport container pallets, which adopt a composite structure of aluminum alloy and core material. However, some problems have gradually emerged, mainly including high requirements for composite process and relatively complex procedures; the core material cannot meet the corresponding flame retardant standards to achieve complete flame retardancy at the aviation level; and aluminum alloy materials are prone to corrosion in humid and coastal areas, which can easily cause "hollowing" problems.

[0005] In summary, traditional air transport container pallets suffer from problems such as high production difficulty, high cost, and insufficient environmental adaptability and reliability. Summary of the Invention

[0006] In view of this, the present invention provides an integrated air transport container pallet made of reinforced composite material. Based on reinforced composite material, it adopts integrated injection molding to achieve the overall structure of the pallet and avoids the vacuum bonding process.

[0007] The technical solution of the present invention is: a reinforced composite material integrally molded air transport container pallet, comprising: a pallet body and a tethering ring installed on the pallet body by a nut plate;

[0008] The pallet body is a plate-shaped structure integrally injection molded from reinforced composite material;

[0009] The tray body, after being injection molded in one piece, has several serrations evenly distributed on its four sides; and it is equipped with a tethering ring installation port for installing tethering rings.

[0010] A nut plate is installed inside the tether ring mounting port, and the nut plate is used to provide a connection interface for the tether ring.

[0011] After the tethering rings are installed, the mounting openings of each tethering ring are filled with reinforced composite material through secondary local injection molding.

[0012] As a preferred embodiment of the present invention, the reinforcing composite material is a 30% to 40% carbon fiber reinforced polyetheretherketone composite material.

[0013] As a preferred embodiment of the present invention, the outer surface of the tray body has a reinforcing coating.

[0014] As a preferred embodiment of the present invention, the reinforcing coating is a nano-reinforcing coating.

[0015] As a preferred embodiment of the present invention: the retaining ring mounting port is located at the four corners of the tray body and between two adjacent saw teeth;

[0016] Based on this, the nut plate includes a strip nut plate and a right-angle nut plate; wherein the strip nut plate is installed in the tethering ring mounting hole between two adjacent serrations, and the right-angle nut plate is installed in the tethering ring mounting hole at the four corners.

[0017] Furthermore, this invention provides a processing method for integrally molded air transport container pallets made of reinforced composite materials:

[0018] First, the pallet body is formed: a one-piece injection molding process is used, in which a hot-melt reinforced composite material with physical fluidity is injected into the mold cavity; after cooling under a set pressure, the one-piece injection molding of the pallet body is completed; after molding, the pallet body is precision machined.

[0019] After the pallet body is finished, the nut plate and tie rings are installed. After the tie rings are installed, the installation ports of each tie ring are filled with secondary injection molding.

[0020] As a preferred embodiment of the present invention: after completing the secondary injection molding filling, the formed pallet is trimmed and the surface of the pallet body is roughened to make it suitable for spraying the reinforcing coating. Then, the reinforcing coating is sprayed and cured on the pallet surface.

[0021] As a preferred embodiment of the present invention, the method for forming a hot-melt reinforced composite material with physical fluidity is as follows:

[0022] The particulate matter of the raw materials used in reinforcing composite materials is heated and pressurized to achieve the thermal melt flow of the raw materials.

[0023] As a preferred embodiment of the present invention: during secondary injection filling, the tethering ring mounting ports at different positions are simultaneously injection filled, and the secondary injection filling involves pressure injection molding of the hot-melt reinforced composite material.

[0024] Beneficial effects:

[0025] (1) The reinforced composite material integrated air transport container pallet of the present invention adopts integrated injection molding and secondary local injection filling to realize the overall structure of the pallet; abandoning the composite bonding and riveting process of traditional air transport container pallets, it can make the overall structure of the pallet body better, reduce the difficulty of the process, and realize repeatable injection production with one-time mold opening.

[0026] (2) In the reinforced composite material integrated air transport container pallet of the present invention, the pallet body is a solid core integrated structure, eliminating the use of wooden core material as a filling force-bearing component, and solving the disadvantages of traditional core material balsa wood being susceptible to moisture and flammability.

[0027] (3) In this invention, the reinforcing composite material used for injection molding is a 30% to 40% carbon fiber reinforced polyether ether ketone composite material. This reinforced composite material combines the excellent properties of polyether ether ketone with the high strength properties of carbon fiber. It has high rigidity, high modulus, and ultra-wear-resistant self-lubricating properties, and can be used for injection molding and extrusion molding. This material has good heat resistance and excellent flame retardant properties.

[0028] (4) In this invention, the outer surface of the pallet body has a two-component reinforced coating, which, together with the reinforced composite material, can achieve better anti-corrosion performance and greatly improve service life in coastal and humid areas.

[0029] (5) The processing method of the present invention adopts the one-piece molding technology, and realizes repeated injection molding through one-time mold development, realizing mass production and reducing costs by 20%; and can realize material recycling, reduce usage costs, and after damage and lifespan, the material can be evaluated and recycled. Attached Figure Description

[0030] Figure 1 This is a schematic diagram (front view) of the overall structure of the integrated injection-molded air transport container pallet of the present invention;

[0031] Figure 2 This is a partial detail view of the air transport container pallet after integral injection molding according to the present invention;

[0032] Figure 3 This is a schematic diagram (bottom) of the overall structure of the air transport container pallet after integral injection molding according to the present invention;

[0033] Figure 4Detailed diagram of the installation of tie rings on an integrated injection-molded aviation container pallet;

[0034] Figure 5 This is a schematic diagram of the structure of a strip-shaped nut plate;

[0035] Figure 6 This is a schematic diagram of the right-angle nut plate.

[0036] Figure 7 This is a partial detail of the container pallet after secondary local injection molding filling of the tether ring mounting port.

[0037] Among them: 1-Pallet body, 2-Sawtooth, 3-Tethering ring, 4-Strip nut plate, 5-Right angle nut plate, 6-Tethering ring mounting port. Detailed Implementation

[0038] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0039] Example 1:

[0040] This embodiment provides an integrally molded air transport container pallet based on composite materials. The container pallet is based on reinforced composite materials and adopts integral molding injection technology to achieve an integral structure, avoiding the vacuum composite process.

[0041] This composite material-based one-piece molded air transport container pallet is a flat pallet in a pallet assembly using plate mesh technology. In addition, the pallet assembly also includes attachments, such as tethering nets, tethering straps, and tethering rings (usually D-type shackles).

[0042] In use, the goods stacked on the pallet are locked together by the tethering net and tethering straps to form a single container. This container can be lifted by a crane, loaded by an air loader, or unloaded by a conveyor roller. The entire container can be transferred in one operation. It is highly efficient, convenient, and adaptable, effectively reducing loading and unloading time, saving a lot of manpower, facilitating mechanized operations, and improving the efficiency of military supply support.

[0043] This embodiment provides an air transport container pallet based on composite reinforced materials and using one-piece molding technology to achieve consistent interfaces.

[0044] This composite material-based one-piece molded air transport container pallet includes a pallet body 1 and tethering rings 3 mounted on the pallet body 1 via nut plates. The pallet body 1 is a plate-like structure (i.e., a solid one-piece structure) integrally injection molded from a reinforced composite material. As an example, the reinforcing composite material is 30%–40% carbon fiber reinforced polyetheretherketone (PEEK) composite material. This reinforced composite material combines the excellent properties of PEEK with the high strength of carbon fiber, exhibiting high rigidity, high modulus, and ultra-wear-resistant self-lubricating properties, making it suitable for injection molding and extrusion molding. The material also has good heat resistance and excellent flame retardant properties.

[0045] The pallet body 1, made of reinforced composite material through one-piece injection molding, is Figure 1 and Figure 3 The rectangular plate-like structure shown has a number of evenly spaced serrations 2 distributed on its four sides; as shown... Figure 2 As shown, the pallet body 1, after being integrally injection molded, has a reserved tether ring mounting port 6 for installing tether rings 3; the tether ring mounting port 6 is located at the four corners of the pallet body 1 and between two adjacent serrations 2; thus ensuring that the pallet interface is consistent with existing air transport container pallets.

[0046] By adopting one-piece molding technology, the traditional composite bonding and riveting process of air transport container pallets is abandoned, which can make the overall structure of the pallet body 1 better, reduce the difficulty of the process, and enable repeated injection molding production with one-time mold opening.

[0047] After the pallet body 1 is integrally molded, a nut plate is installed inside the tether ring mounting port 6 of the pallet body 1. The nut plate is made of stainless steel, has threaded holes, and is connected to the tether ring 3 by screws, serving as an inner reinforcement to ensure the installation strength of the tether ring 3. The nut plate includes, for example, Figure 5 The strip nut plate 4 shown and as follows Figure 6 The right-angle nut plate 5 shown; the nut plate is used to provide the connection interface for the tethering ring 3 (i.e., the nut plate is provided with threaded holes for threaded connection with the tethering ring 3). A strip-shaped nut plate 4 is installed in the tethering ring mounting port 6 between two adjacent sawtooth 2s, and a right-angle nut plate 5 is installed in the tethering ring mounting ports 6 at the four corners. Figure 4 As shown, a strip nut plate 4 is installed in the tethering ring mounting port 6 between two adjacent saw teeth 2. The tethering ring 3 engages with the threaded hole on the strip nut plate 4 to achieve its installation on the pallet body 1.

[0048] Since the tether ring mounting port 6 remains open after the nut plate is installed inside, to maintain the integrity of the pallet structure, each tether ring mounting port 6 is filled with a secondary local injection molding using reinforced composite material. After the secondary local injection molding, as shown... Figure 7 As shown, the main body of the pallet 1 is structurally complete.

[0049] After the above processes are completed, a reinforcing coating is sprayed onto the outer surface of the pallet body 1 to enhance surface hardness and scratch resistance. As an example, a nano-reinforcing material is sprayed onto the outer surface of the pallet body 1 to form a nano-reinforcing coating. This not only enhances surface hardness and scratch resistance but also achieves complete flame retardancy at an aerospace level. Thus, the application of the two-component nano-reinforcing coating further improves the pallet's corrosion resistance, flame retardancy, and hardness.

[0050] Tests show that the rated load of the air transport container pallet of this invention is not less than 4500 kg. Using 30%–40% carbon fiber reinforced polyetheretherketone composite material, its tensile strength can reach 250 MPa–260 MPa. Its overall performance is superior to aluminum alloy and wood-based composite structures, exhibiting better deformation resistance and structural rigidity. Furthermore, its density is 140 kg / m³. 3 The final total weight of the pallet is less than 80kg, which is less than that of existing aviation container pallets, and its load-bearing capacity is more suitable for integrated airdrop and air transport pallets.

[0051] This invention is based on the replacement of traditional aluminum alloy and wood core materials and processes with reinforced composite materials. It uses an integrally molded complete structure to replace the adhesive composite process structure, so that it has the same mechanical properties, while having better lightweight and flame-retardant properties, reducing production costs, and enabling recycling.

[0052] Example 2:

[0053] This embodiment provides a processing method for the aforementioned one-piece molded air transport container pallet based on composite materials.

[0054] The reinforced composite material used for the integral molding of the pallet body 1 is made by hot-melting and heating mixed material particles. Through special heating and pressurization equipment, the raw materials are hot-melted and flowed, and have the physical state of injection molding and extrusion.

[0055] The manufacturing process of this one-piece molded air transport container pallet is generally divided into three steps:

[0056] The first step is the molding process of the pallet body 1: A one-piece injection molding process is used, employing a dedicated mold (i.e., a mold based on the structure of the pallet body 1 to be molded). The mold consists of an upper mold and a lower mold, allowing for tight clamping. Between the two is a cavity for one-piece injection molding. Through the injection port of the upper mold, a hot-melt composite material with physical fluidity is injected into the cavity. After maintaining the set pressure and cooling, the one-piece injection molding of the pallet body 1 is completed. After molding, the pallet body 1 undergoes precision machining. Key areas, such as the tie-ring mounting port 6, the edges of the pallet body 1, and the outer surface, are processed and trimmed to achieve dimensions and an outer surface that meet the set technical specifications.

[0057] After the pallet body 1 is finished, the nut plate and tie ring 3 are installed. After the tie ring 3 is installed, the tie ring mounting ports 6 are filled with secondary injection molding. During the secondary injection molding, the tie ring mounting ports 6 at different positions can be filled simultaneously. The secondary injection molding adopts a method of pressure injection molding of hot-melt composite material.

[0058] After the secondary injection molding and filling, the resulting pallet is trimmed, removing burrs and residual cured foreign matter. The surface of the pallet body 1 is roughened to reduce surface flatness, making it suitable for the spraying of the outer two-component reinforcing coating and ensuring stronger coating adhesion. Finally, the reinforcing coating is sprayed and cured.

[0059] Although the present invention has been described in detail above with general descriptions and specific embodiments, modifications or improvements can be made to it, which will be obvious to those skilled in the art. Therefore, all such modifications or improvements made without departing from the spirit of the present invention fall within the scope of protection claimed by the present invention.

Claims

1. A reinforced composite material integrally molded air transport container pallet, characterized in that, include: Pallet body (1) and tethering ring (3) mounted on the pallet body (1) by means of a nut plate; The tray body (1) is a plate-shaped structure integrally injection molded using reinforced composite material, i.e., a solid integral structure; the reinforced composite material is 30% to 40% carbon fiber reinforced polyether ether ketone composite material; The tray body (1) after one-piece injection molding has several serrations (2) evenly distributed on its four sides; and a tethering ring mounting port (6) is reserved for installing tethering rings (3). A nut plate is installed inside the tether ring mounting port (6), and the nut plate is used to provide a connection interface for the tether ring (3); After the tethering ring (3) is installed, the mounting ports (6) of each tethering ring are filled with reinforced composite material by secondary local injection molding. The secondary injection molding is pressure injection molding. At the same time, the mounting ports of the tethering rings at different positions are filled with injection molding to make the tray structure complete.

2. The reinforced composite material integrally molded air transport container pallet as described in claim 1, characterized in that, The outer surface of the tray body (1) has a reinforcing coating.

3. The reinforced composite material integrally molded air transport container pallet as described in claim 2, characterized in that, The reinforcing coating is a nano-reinforced coating.

4. The reinforced composite material integrally molded air transport container pallet as described in any one of claims 1-3, characterized in that, The retaining ring mounting port (6) is located at the four corners of the tray body (1) and between two adjacent serrations (2); Based on this, the nut plate includes a strip nut plate (4) and a right-angle nut plate; wherein the strip nut plate (4) is installed in the tethering ring mounting port (6) between two adjacent saw teeth (2), and the right-angle nut plate (5) is installed in the tethering ring mounting port (6) at the four corners.

5. A processing method for integrally molded air transport container pallets made of reinforced composite materials, characterized in that, The container pallet is the reinforced composite material integrally molded air transport container pallet as described in any one of claims 1-4 above; First, the forming of the pallet body (1) is carried out: a hot melt reinforced composite material with physical fluidity is injected into the mold cavity of the mold using an integral injection molding process; after cooling under a set pressure, the integral injection molding of the pallet body (1) is completed; after forming, the pallet body (1) is precision machined. After the finishing of the pallet body (1), the nut plate and the tie ring (3) are installed. After the tie ring (3) is installed, the installation ports (6) of each tie ring are filled with secondary injection molding.

6. The processing method of the one-piece molded reinforced composite material air transport container pallet as described in claim 5, characterized in that, After the secondary injection filling is completed, the formed pallet is trimmed and the surface of the pallet body (1) is roughened to make it suitable for spraying the reinforcing coating. Then, the reinforcing coating is sprayed and cured on the pallet surface.

7. The processing method of the reinforced composite material integrally molded air transport container pallet as described in claim 5 or 6, characterized in that, The method for forming hot-melt reinforced composite materials with physical fluidity is as follows: The particulate matter of the raw materials used in reinforcing composite materials is heated and pressurized to achieve the thermal melt flow of the raw materials.

8. The processing method of the reinforced composite material integrally molded air transport container pallet as described in claim 5 or 6, characterized in that, During the secondary injection filling, the tethering ring installation ports (6) at different positions are simultaneously filled by injection molding. The secondary injection filling involves pressure injection molding of the hot-melted reinforced composite material.

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