Super + type insulation box semi-finished product manufacturing method

Abstract

The invention discloses a method for manufacturing a Super + type insulation box semi-finished product. The method comprises the following steps: 1) manufacturing a single-piece large plate of an insulation box; (2) an anti-dripping rubber plate is laid on the conveying bottom plate, then a plurality of insulation box single-piece large plates are stacked in sequence, and in the process, the anti-dripping rubber plate is laid on each top plywood; (3) after the set stacking layer number is reached, a top pressing plate is laid on the anti-dripping glue plate of the last layer of insulation box single-piece large plate; (4) pressing in a pressing machine, wherein an elastic pressing plate is arranged on the bottom surface of an upper pressing plate of the pressing machine attached to the top pressing plate; (5) after pressing is completed, the top pressing plate, the anti-dripping rubber plates on all the layers and the insulation box single-piece large plates on all the layers are unstacked one by one in sequence; and (6) after aging, the insulation box single-piece large plate is subjected to finish machining, and a plurality of insulation box semi-finished products are formed after slitting. The production efficiency can be improved, the manufacturing cost is reduced, and the finished product quality is stabilized.

Description

Technical Field

[0001] The present invention relates to the technical field of manufacturing a Super+ type insulation box, and more particularly to a method for manufacturing a semi-finished product of a Super+ type insulation box. Background Art

[0002] The NO96 Super+ liquid cargo containment system is a large-scale LNG containment system with a boil-off rate (BOR) as low as 0.085% V / d for a typical capacity of 174,000 cubic meters (compared to 0.10% V / d for the NO96 L03+ and 0.10 to 0.085% V / d for the MARK III). As shipowners increasingly focus on reducing boil-off rates to minimize transportation losses, the NO96 Super+ liquid cargo containment system meets the increasing market demand for larger and ultra-large LNG carriers with greater capacity.

[0003] As core components of the LNG containment system, insulation boxes constructed from reinforced polyurethane sheet materials utilize modular, standard prefabricated components. These can accommodate various cargo tank shapes and capacities, making them easy to assemble and suitable for large-scale production. Insulation boxes are primarily categorized as Super+, L03+, and MARK III. While Super+, L03+, and MARK III insulation boxes all utilize reinforced polyurethane sheet materials as their primary low-temperature insulation, their structural characteristics lead to significant differences in the manufacturing process between Super+ and other polyurethane insulation boxes.

[0004] Currently, the manufacturing of Super+ insulation boxes mostly draws on the methods of polyurethane insulation boxes such as MARK III or L03+. The general manufacturing process includes: gluing, correction, laminating, stacking, pressing, aging and other processes. However, due to the essential differences in the product structure of polyurethane insulation boxes such as MARK III or L03+ and Super+ insulation boxes, these manufacturing methods are difficult to apply to the manufacturing of Super+ insulation boxes, and it is also difficult to ensure the final product quality. For example, patent application number 201910350163.5 discloses a method for assembling and manufacturing bottom components of large-size polyurethane insulation boxes for LNG ships, and patent application number 201910350160.1 discloses a box assembly system and method for polyurethane insulation boxes for LNG ships. Both patents propose corresponding process methods for the manufacturing of polyurethane insulation boxes such as MARKIII or L03+, but have the following problems:

[0005] 1) Laminating each assembled insulation box body to prevent glue from leaking out of each box during lamination from contaminating adjacent boxes. This method can cause displacement of the panels that have already been aligned in the X and Y directions during the lamination process, resulting in issues such as retroperitoneal offset and misalignment of panels, even after alignment in the X and Y directions.

[0006] 2) After gluing and assembly, but before lamination, the various types of boards (plywood or RSB) bonded to the reinforced polyurethane board were corrected in the X and Y directions to reduce misalignment during assembly. However, the control of the board assembly quality in the Z direction was neglected. Because the plywood on the top of the second layer of the Super+ insulation box is thin (9mm), the material itself may be warped due to its own flatness. As a result, it will not be completely aligned with the reinforced polyurethane board before lamination after assembly. As a result, during the transportation process before entering the press for lamination, a large amount of air is introduced between the top layer of plywood and the glue layer due to repeated vibration. As a result, this air cannot be completely eliminated during the lamination process, resulting in large bubbles, which seriously affect the bonding strength.

[0007] 3) During the lamination process, the press plate is a rigid structure that is difficult to adapt to the accumulated flatness errors of each sheet. As a result, the press plate fails to fully and reliably fit the top sheet, resulting in poor pressure uniformity over a large area and poor adhesive layer thickness and bonding consistency after lamination.

[0008] 4) The current overall process flow is to process the plywood and reinforced polyurethane board to the size of the final product separately, then coat the plywood and reinforced polyurethane board with glue, assemble accessories such as wooden wedges, and finally uniformly press and age the entire product to become the final product. This method has high requirements on the dimensional processing accuracy of parts and components and the matching dimensions of each component. In addition, all parts before pressing must be fastened (such as tensioners and other replica tooling). Not only is the process complicated, but the manufacturing cost of auxiliary tooling and the logistics turnover cost of the production process are also high.

[0009] Therefore, providing a reliable and efficient method for manufacturing a semi-finished product of a Super+ type insulation box is an urgent problem to be solved by those skilled in the art. Summary of the Invention

[0010] In view of this, the present invention provides a method for manufacturing a semi-finished product of a Super+ type insulation box, so as to improve production efficiency, reduce manufacturing costs, and stabilize the quality of the finished product.

[0011] In order to achieve the above object, the present invention adopts the following technical solutions:

[0012] A method for manufacturing a semi-finished product of a Super+ type insulation box comprises the following steps:

[0013] 1) Glue the bottom plywood and reinforced polyurethane board. After gluing, the board is transferred to the assembly station. An automatic assembly machine assembles the glued reinforced polyurethane board to the glued bottom plywood. Then, an automatic assembly machine assembles the un-glued top plywood to the reinforced polyurethane board to form a single large panel for the insulation box.

[0014] 2) Pave the anti-drip rubber sheet on the conveyor bottom plate, and then stack multiple insulation box single-piece large panels in sequence. During this process, pave the anti-drip rubber sheet on each top plywood;

[0015] 3) After reaching the set number of stacking layers, a top pressing plate is laid on the anti-drip glue board of the last layer of the insulation box single piece large board, so that the top plywood and / or bottom plywood are bonded to the reinforced polyurethane board;

[0016] 4) Entering the press for pressing, wherein the bottom surface of the upper pressing plate of the press is provided with an elastic pressing plate in contact with the top pressing plate;

[0017] 5) After the lamination is completed, the top pressing plate, the anti-drip glue plates of each layer and the single large plates of each layer of insulation box are unstackered one by one. The top pressing plate and anti-drip glue plates are transported to the gluing and assembly area for subsequent use, and the single large plates of insulation box are transported to the aging area;

[0018] 6) After aging, the single large plate of the insulation box is finely processed and cut into multiple semi-finished insulation boxes.

[0019] Furthermore, the size of the anti-drip rubber plate is larger than the single large plate of the insulation box, the material of the anti-drip rubber plate is PP material or PVC material, and the thickness of the anti-drip rubber plate is 2-4 mm.

[0020] Furthermore, the anti-drip rubber sheet is paved on the top plywood by vacuum adsorption method.

[0021] Furthermore, the size of the top pressing plate is not less than the size of the anti-drip rubber plate.

[0022] It can be seen from this that the present invention provides a method for manufacturing a semi-finished product of a Super+ type insulation box. Compared with the prior art, the present invention has the following beneficial effects:

[0023] 1) Anti-drip rubber sheets: Anti-drip rubber sheets are used between each large panel of the insulation box to avoid hidden dangers such as deviation and misalignment caused by lamination. This makes it easy to achieve full automation of installation and removal (increased efficiency and reduced labor intensity), and is reusable (environmentally friendly and reduces the cost of production consumables).

[0024] 2) Use a top pressure plate: This solves the problem of sheet warping and the inability of the sheets to effectively fit together in the Z direction before being pressed together after assembly, thus reducing its impact on the bonding quality;

[0025] 3) Use elastic pressing plates: This solves the problem of inconsistent stress states at various positions of the rigid pressing plates during the pressing process, due to the flatness tolerances of the plywood and reinforced polyurethane sheets, thereby improving the stability of the key quality indicators of the insulation box.

[0026] 4) Manufacturing method of large-plate slitting: The large-plate components of the insulation box are glued and pressed together to form semi-finished Super+ single-piece large plates, which are then slitting to form various types of insulation boxes and semi-finished Super+ insulation boxes. The process is simple, reducing manufacturing costs and logistics turnover costs during the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are merely embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying any creative work.

[0028] Figure 1 The accompanying drawing is an exploded view of a single large plate of an insulation box provided by the present invention;

[0029] Figure 2 The accompanying drawing is a structural diagram of the positional relationship between a single large panel and an anti-drip rubber plate of an insulation box after palletizing provided by the present invention;

[0030] Figure 3 The accompanying drawing is a structural diagram of the positional relationship between a single large plate and a top pressing plate of an insulation box after palletizing provided by the present invention;

[0031] Figure 4 The accompanying drawing is a structural schematic diagram of the positional relationship between the elastic pressing plate and the top pressing plate provided by the present invention;

[0032] Figure 5 The accompanying drawing is a schematic structural diagram of a single large plate of an insulation box provided by the present invention being cut into a plurality of semi-finished insulation boxes. DETAILED DESCRIPTION

[0033] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0034] like Figure 1-5 As shown, the embodiment of the present invention discloses a method for manufacturing a semi-finished product of a Super+ type insulation box, comprising the following steps:

[0035] 1) Glue the bottom plywood 11 and the reinforced polyurethane board 12. After gluing, the board is transferred to the assembly station, where an automatic assembly machine assembles the glued reinforced polyurethane board 12 onto the glued bottom plywood 11. Then, an automatic assembly machine assembles the un-glued top plywood 13 onto the reinforced polyurethane board 12 to form a single large panel 1 for the insulation box.

[0036] 2) Pave the anti-drip rubber sheet 3 on the conveying bottom plate 2, and then stack multiple insulation box single-piece large plates 1 in sequence. During this process, pave the anti-drip rubber sheet 3 on each top plywood 13; wherein the size of the anti-drip rubber sheet is larger than the insulation box single-piece large plate 1, and the material of the anti-drip rubber sheet 3 is PP material or PVC material, and the thickness of the anti-drip rubber sheet 3 is 2-4mm, which is convenient for paving and cleaning the residual cured glue in the subsequent process; the anti-drip rubber sheet 3 can not only prevent the glue overflowing during the pressing process of the insulation box single-piece large plate 1 entering the press to contaminate the insulation box single-piece large plate 1 or other auxiliary tooling, but also solve the problem of the previous process using The laminating method solves the problems of offset, misalignment of the panels, and manual removal of the laminating film after lamination and curing caused by the overall correction of the plywood or reinforced polyurethane board 12 (due to the adhesion of the laminating film to the glue after curing, the deformation of the laminating film is large and irregular, making it difficult to automatically remove the laminating film). Finally, after lamination, the single large board 1 of the insulation box can be easily removed and reused, avoiding the problem of one-time use and non-reusability of the laminating process, saving the material cost of the laminating film and reducing the environmental risks caused by the recycling of the disposable laminating film. It can also realize fully automatic paving and removal, improving production efficiency and reducing labor costs and labor intensity.

[0037] Of course, the material of the drip-proof rubber plate 3 can be any material that does not adhere to the special glue for the insulation box, and is not limited to PP material or PVC material;

[0038] 3) After reaching the set number of stacking layers, a top pressing plate 4 is laid on the anti-drip glue plate 3 of the last layer of single-piece insulation box panels 1, so that the top plywood 13 and / or the bottom plywood 11 that may be warped fit together with the reinforced polyurethane sheet 12. This solves the problem of warping of the plywood of the insulation box itself, which may result in incomplete fit with the reinforced polyurethane sheet 12 after gluing and assembly but before pressing. It also prevents the problem of a large amount of air being introduced between the top plywood and the glue layer due to repeated vibration during transportation before entering the press for pressing.

[0039] 4) Entering the press for pressing, wherein an elastic pressing plate 6 is provided on the bottom surface of the upper pressing plate 5 of the press that is in contact with the top pressing plate 4. In this embodiment, the elastic pressing plate 6 is made of a material with high compressive strength and a certain degree of elasticity, such as an elastic polyurethane material. During the pressing process, the elastic pressing plate 6 can reliably fit with the stacked top pressing plate 4, eliminating the influence of the flatness tolerance of each plywood, reinforced polyurethane board 12 and other boards. During the entire pressing process, the pressure on the pressing surface between the various boards can be balanced, ensuring that the key pressing indicators such as the uniformity of the glue surface, the thickness of the glue layer, and the bonding strength after pressing meet the process requirements;

[0040] 5) After the pressing is completed, the top pressing plate 4, the anti-drip glue plates 3 of each layer, and the single large plates 1 of each layer of the insulation box are destackered one by one. During the destacking process, an automatic destacking device (such as a robot, multi-axis transfer equipment, etc., using a vacuum adsorption method) is used to transport the top pressing plate 4 and the anti-drip glue plates 3 to the gluing and assembly area for subsequent use, and the single large plates 1 of the insulation box are transported to the aging area;

[0041] 6) After aging, the single insulation box plate 1 is finely processed and cut into multiple insulation box semi-finished products 7.

[0042] Specifically, the paving of the anti-drip rubber sheet 3 can be manual paving or automatic paving (such as a robot, a multi-axis transfer device, etc.), and the anti-drip rubber sheet 3 is stably paved on the top plywood 13 by a vacuum adsorption method.

[0043] Specifically, the size of the top pressing plate 4 is not less than that of the anti-drip rubber plate 3 , and its weight can offset the bending deformation of the plywood and enable the plywood to be reliably attached to the reinforced polyurethane plate 12 .

[0044] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. Reference can be made to the common and similar parts between the various embodiments. For the devices disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple, and the relevant parts can be referred to the method description.

[0045] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for manufacturing a semi-finished product of a Super+ type insulation box, characterized in that: The following steps are involved: 1) Glue the bottom plywood and reinforced polyurethane board. After gluing, the board is transferred to the assembly station. An automatic assembly machine assembles the glued reinforced polyurethane board to the glued bottom plywood. Then, an automatic assembly machine assembles the un-glued top plywood to the reinforced polyurethane board to form a single large panel for the insulation box. 2) Pave the anti-drip rubber sheet on the conveyor bottom plate, and then stack multiple insulation box single-piece large panels in sequence. During this process, pave the anti-drip rubber sheet on each top plywood; 3) After reaching the set number of stacking layers, a top pressing plate is laid on the anti-drip glue board of the last layer of the insulation box single piece large board, so that the top plywood and / or bottom plywood fits with the reinforced polyurethane board; 4) Entering the press for pressing, wherein the bottom surface of the upper pressing plate of the press is provided with an elastic pressing plate in contact with the top pressing plate; 5) After the lamination is completed, the top pressing plate, the anti-drip glue plates of each layer and the single large plates of each layer of insulation box are unstackered one by one. The top pressing plate and anti-drip glue plates are transported to the gluing and assembly area for subsequent use, and the single large plates of insulation box are transported to the aging area; 6) After aging, the single large plate of the insulation box is finely processed and cut into multiple semi-finished insulation boxes.

2. The method for manufacturing a semi-finished product of a Super+ type insulation box according to claim 1, characterized in that: The size of the anti-drip rubber plate is larger than the single large plate of the insulation box. The material of the anti-drip rubber plate is PP material or PVC material, and the thickness of the anti-drip rubber plate is 2-4mm.

3. A method for manufacturing a semi-finished product of a Super+ type insulation box according to claim 1 or 2, characterized in that: The anti-drip rubber sheet is installed on the top plywood by vacuum adsorption.

4. The method for manufacturing a semi-finished product of a Super+ type insulation box according to claim 1, characterized in that: The size of the top pressure plate shall not be less than that of the anti-drip rubber plate.

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