CN116398803A - Lightweight carbon fiber fully wound gas cylinder and manufacturing method - Google Patents

Abstract

The invention relates to the technical field of gas cylinder structures and processing, and discloses a lightweight carbon fiber fully-wound gas cylinder and a manufacturing method thereof, wherein the lightweight carbon fiber fully-wound gas cylinder comprises a liner, a carbon fiber composite layer arranged on the outer wall of the liner, and a glass fiber protective layer arranged on the outer surface of the carbon fiber composite layer; the inner container is manufactured by adopting a steel plate deep drawing molding process, and is molded by a unilateral closing; the carbon fiber composite layer comprises a spiral winding layer with a winding angle of a first preset angle and a circumferential winding layer with a winding angle of a second preset angle. The gas cylinder provided by the invention has stable performance and lighter weight, is convenient to manufacture, can effectively reduce manufacturing and transportation costs, and realizes the light weight and low cost of the gas cylinder.

Description

Lightweight carbon fiber fully wound gas cylinder and manufacturing method

technical field

The invention relates to the technical field of gas cylinder structure and processing, in particular to a lightweight carbon fiber fully wound gas cylinder and a manufacturing method thereof.

Background technique

Cargo transportation is one of the main modes of modern transportation, and it is also one of the two basic modes of transportation that constitute land cargo transportation. It occupies an important position in the entire transportation field and is playing an increasingly important role. Since cargo transportation is less affected by climate and natural conditions, and has a large transportation capacity and single-vehicle loading capacity, it has an advantage in the regularity of transportation.

Trucks are widely used land freight transport vehicles. With the continuous increase of their number, the freight cost of trucks continues to increase under the condition of limited fuel supply in the market. In order to reduce freight costs, freight trucks with lower transportation costs have become the main demand in the current market, and natural gas (CNG) trucks are in line with this market demand, especially in Xinjiang and other areas where natural gas is abundant (the natural gas used for vehicles is less than 2 yuan/cubic ) areas for long-distance freight transport, its transportation cost can save more than 200,000 yuan per year compared with traditional diesel trucks, and its exhaust emissions are more environmentally friendly and more environmentally friendly.

However, natural gas trucks, as a kind of gas-fueled heavy-duty vehicles fueled by natural gas, need a large amount of natural gas to ensure their transportation endurance during operation; and the continuous supply of natural gas needs to carry several large-capacity gas cylinders ( Compressed natural gas storage tanks), the setting of these gas cylinders adds a lot of additional weight to the natural gas truck, which has a certain impact on the improvement of the vehicle's carrying capacity; the large dead weight of the gas cylinder itself also makes the actual amount of natural gas loaded on the natural gas truck relatively small. The battery life is difficult to improve. In order to further optimize the carrying capacity, battery life and economy of natural gas trucks, the lightweight and low cost of gas cylinders is one of the effective means. However, how to reduce the dead weight and cost of gas cylinders is still an urgent problem to be solved.

In addition, in the transportation of the gas cylinder itself, due to the limited weight of goods that can be loaded on a single truck, in the existing natural gas cylinder transportation, the self-weight of the gas cylinder often occupies a large part of the weight of a single cargo load, which also leads to The self-transportation cost of existing gas cylinders is relatively high.

Contents of the invention

The present invention intends to provide a lightweight carbon fiber fully wound gas cylinder and a manufacturing method thereof. The gas cylinder has stable performance and light weight, is easy to manufacture, can effectively reduce manufacturing and transportation costs, and realizes lightweight and low-cost gas cylinders.

In order to achieve the above object, the basic scheme provided by the present invention is:

Option One

Lightweight carbon fiber fully wound gas cylinders, including an inner tank and a carbon fiber composite layer on the outer wall of the inner tank; The composite layer includes a helically wound layer whose winding angle is a first preset angle and a hoop wound layer whose winding angle is a second preset angle.

Further, the first preset angle is 8°-15°.

Further, the second preset angle is 85°-90°.

Further, the liner includes a bottle mouth, an upper sealing head, a barrel body and a lower sealing portion arranged in sequence; the spiral winding layer is wound on the inner liner; the hoop winding layer is wound on the barrel body.

Further, it also includes a glass fiber protection layer arranged on the outer surface of the carbon fiber composite layer; the glass fiber protection layer is hoop-wound around the cylinder body.

Further, the wall thickness of the barrel part is 3.7mm-4.3mm.

Further, a tail plug is provided on the bottom surface of the lower sealing head; the tail plug includes an upper connecting portion and a lower connecting portion which are integrally made; a threaded hole is opened in the center of the upper connecting portion; the lower connecting portion The bottom surface is a circular arc surface.

Option II

A method for manufacturing a lightweight carbon fiber fully wound gas cylinder is used to manufacture a lightweight carbon fiber fully wound gas cylinder as described in Scheme 1; comprising the following steps:

Step 1: select the steel plate as the blank; draw the blank into a cup-shaped body by drawing forming process;

Step 2: heat-spin the cup-shaped body to obtain a liner with a bottle mouth at one end;

Step 3: Winding and setting a carbon fiber composite layer on the inner tank; winding and setting a glass fiber protective layer on the carbon fiber composite layer.

Further, in step 2, it also includes: gluing a tail plug on the bottom surface of the lower sealing head of the liner; the bottom surface of the lower connecting portion of the tail plug is bonded to the bottom surface of the lower sealing head.

Working principle and advantage of the present invention are:

First of all, the liner of this scheme is a steel liner made of deep-drawn steel plate and closed by unilateral hot spinning. The overall wall thickness is evenly distributed, and the quality of the gas cylinder is stable; The wall thickness of the liner is improved, especially the wall thickness of the cylinder body is reduced to 3.7mm-4.3mm, and the fluctuation of the wall thickness can be controlled within 0.6mm. The production quality is high and the manufacturing efficiency is high. Compared with the conventional double-ended liner obtained by sealing both ends of the steel pipe, due to the limitation of its process, the wall thickness fluctuates greatly (greater than or equal to 1mm) and the wall thickness of the cylinder body is often greater than 10mm. The setting also makes the wall thicknesses of the upper head and the lower head uneven, and the overall inner tank is heavier. This solution effectively optimizes the quality of the inner tank through process improvement and structural improvement. Under the same capacity conditions, the wall thickness distribution of this solution is more uniform, the structural performance is more stable, and the weight of the inner tank is lighter, which can greatly reduce transportation costs.

Secondly, while reducing and uniforming the wall thickness of the inner tank, this solution can also ensure that the pressure bearing capacity of the inner tank is fully up to the standard. In this proposal, the winding method of the carbon fiber composite layer and the glass fiber protective layer is carefully limited. The carbon fiber composite layer is divided into helical winding layer and hoop winding layer, and the respective winding angles and winding areas are specially defined. Under this winding condition, this scheme can use less winding material than conventional winding to assist The inner liner achieves better pressure bearing performance; while further reducing the weight of the gas cylinder, it also saves the materials used for the carbon fiber composite layer, which can greatly reduce the production cost. In addition, the setting of the tail plug and the one-sided bottle mouth make it easy to connect the two ends of the inner tank with tooling for support, which is convenient for assembly line production and helps to improve the production efficiency of the gas cylinder.

Description of drawings

Fig. 1 is the overall structure schematic diagram of the embodiment of lightweight carbon fiber fully wound gas cylinder and manufacturing method of the present invention;

Fig. 2 is the enlarged schematic view of the structure at I in Fig. 1 of the light weight carbon fiber fully wound gas cylinder and the manufacturing method embodiment of the present invention;

Fig. 3 is a schematic diagram of the structure of the mouth of the lightweight carbon fiber fully wound gas cylinder and the embodiment of the manufacturing method of the present invention;

Fig. 4 is a schematic diagram of the structure of the lower head of the light-weight carbon fiber fully wound gas cylinder and the embodiment of the manufacturing method of the present invention;

Fig. 5 is a schematic diagram of the winding method of the spiral winding layer of the lightweight carbon fiber fully wound gas cylinder and the manufacturing method embodiment of the present invention;

Fig. 6 is a schematic diagram of the winding method of the hoop winding layer of the light-weight carbon fiber fully wound gas cylinder and the manufacturing method embodiment of the present invention.

Detailed ways

Further detailed explanation through specific implementation mode below:

The marks in the accompanying drawings include: liner 1, bottle mouth 2, bottle mouth 21, bottle mouth thread 22, upper sealing head 3, cylinder body 4, lower sealing head 5, tail plug 6, upper connecting part 61 , the lower connection part 62 , the spiral winding layer 7 , the hoop winding layer 8 , and the glass fiber protection layer 9 .

The embodiment is basically shown in Figure 1: a lightweight carbon fiber fully wound gas cylinder, including an inner tank 1, a carbon fiber composite layer on the outer wall of the inner tank 1, and a glass fiber protective layer 9 on the outer surface of the carbon fiber composite layer .

The liner 1 is made by steel plate deep drawing process, and the liner 1 is formed by unilateral closing. The liner 1 includes a bottle mouth 2, an upper sealing head 3, a barrel body 4 and a lower sealing head 5 arranged in sequence; wherein, the inner wall of the bottle mouth 21 of the bottle mouth 2 is provided with a bottle thread 22, It is used to connect the positioning tool during the production process of the gas cylinder to facilitate the processing of the gas cylinder, and is also used to connect the cylinder valve when the gas cylinder is in use for easy assembly, as shown in Figure 3. The wall thickness of the upper sealing head 3 is greater than the wall thickness of the barrel body 4, and the wall thickness of the upper sealing head 3 shows a decreasing trend from the place close to the bottle mouth 21 to the place close to the barrel body. Under this structural condition, the upper sealing head The wall thickness of the part 3 changes evenly, and the wall thickness of the barrel part 4 is evenly connected, and the strength of the bottle mouth 21 can be guaranteed to be sufficient. The wall thickness of the barrel part 4 is 3.7mm-4.3mm. The wall thickness of the cylinder body is relatively thin, and the fluctuation of the wall thickness is controlled within 0.6mm. The overall wall thickness of the inner tank 1 is evenly distributed, and the structural quality is more stable; the overall weight of the inner tank 1 is lighter, the weight reduction effect is better, and the transportation cost is lower.

As shown in FIG. 2 , the carbon fiber composite layer includes a helical winding layer 7 whose winding angle is a first preset angle and a hoop winding layer 8 whose winding angle is a second preset angle. Wherein, the material of the carbon fiber composite layer is high-performance carbon fiber impregnated with epoxy resin. The spiral winding layer 7 is wound on the inner tank 1 ; the hoop winding layer 8 is wound on the barrel portion 4 . And the spirally wound layer 7 is in direct contact with the liner 1 ; the hoop wound layer 8 is wound on the spirally wound layer 7 . Specifically, the first preset angle is 8°-15°; the second preset angle is 85°-90°; the width of a single winding of the spirally wound layer 7 and the hoop wound layer 8 is controlled at 28- 36mm range. The glass fiber protective layer 9 is hoop-wound around the barrel part 4 . Wherein, the material of the glass fiber protective layer 9 is glass fiber impregnated with epoxy resin; the winding method is the same as that of the hoop winding layer 8 of the carbon fiber composite layer. Under this structural condition, the axial strength and circumferential strength of the liner 1 are enhanced, which can ensure that the pressure-bearing performance of the gas cylinder meets the standard requirements; the setting of the glass fiber protective layer 9 can better protect the carbon fiber composite layer and ensure that the carbon fiber Composite layers are able to share pressure stably.

As shown in Figure 4, a tail plug 6 is provided on the bottom surface of the lower sealing portion 5; the tail plug 6 includes an upper connecting portion 61 and a lower connecting portion 62 made integrally; the center of the upper connecting portion 61 A threaded hole is opened at the place; the bottom surface of the lower connecting portion 62 is a circular arc surface. Specifically, the bottom surface of the lower connecting portion 62 is attached to the bottom surface of the lower sealing portion 5 of the inner container 1 .

This embodiment also provides a method for manufacturing a lightweight carbon fiber fully wound gas cylinder, which is used to manufacture the above-mentioned lightweight carbon fiber fully wound gas cylinder; including the following steps:

Step 1: select a steel plate as a blank; draw the blank into a cup-shaped body using a drawing forming process.

Specifically, in this embodiment, a large-tonnage press is used to perform three cold drawing formings, and between the first deep drawing and the second deep drawing process and between the second deep drawing and the third deep drawing process During the period, the annealing process and surface treatment process are used to treat the drawn blank. And the drawing speed is controlled at 95-120mm/min.

And during annealing, the billet heating temperature is set at 805±10°C, and the temperature is lowered with the furnace for 28-32 minutes. In the surface treatment process, the surface treatment is carried out in three steps of pickling, phosphating and saponification; in the pickling step, the sulfuric acid solution with a mass percentage of 26% is used, the mass concentration of the corrosion inhibitor is 0.45g/L, and the solution temperature 50-60°C, pickling time 20-18min; in the phosphating step, zinc-based phosphating solution is used, the total acidity is 25-30 drops, the free acidity is 3-7 drops, the phosphating temperature is 65-80°C, the phosphating The time is 28-32 minutes; in the saponification step, a fatty acid saponification solution is used, the mass concentration is 86g/L, the free base is <0.3%, the temperature is 35-45° C., and the time is 10-12 minutes.

Step 2: heat-spin the cup-shaped body to obtain an inner container 1 with a bottle mouth 21 at one end. And when the hot spinning is closed, the heating temperature is set at 1157-1160°C.

Under the above-mentioned process conditions, the wall thickness of the lower sealing portion 5 of the obtained inner tank 1 is relatively thin and the thickness distribution is uniform. The wall thickness of the upper sealing head 3 of the liner 1 is greater than the wall thickness of the barrel body 4, and the wall thickness of the upper sealing head 3 from the place close to the bottle mouth 21 to the place close to the barrel body shows a decreasing trend, and the barrel body 4 The thickness distribution of the wall thickness is uniform and the thickness is controlled to be 3.7mm-4.3mm. The overall inner tank 1 has a uniform wall thickness, stable structural quality and light weight.

Specifically, heat treatment is also carried out on the inner tank 1. In this embodiment, the heat treatment operations adopted include metal quenching treatment and tempering heat treatment, which can make the material tensile strength of the steel inner tank 1 reach 950MPa, which can fully meet the requirements of the gas cylinder. Pressure standard requirements.

It also includes bonding the tail plug 6 to the bottom surface of the lower sealing portion 5 of the inner tank 1; Specifically, the lower connecting portion 62 of the tail plug 6 and the bottom surface of the lower sealing portion 5 are bonded with high-temperature-resistant high-strength glue.

Step 3: Winding and setting a carbon fiber composite layer on the inner tank 1; winding and setting a glass fiber protective layer 9 on the carbon fiber composite layer.

Concretely, before winding, through the bottle mouth 21 of the bottle mouth part 2 and the tail plug 6 bonded to the lower sealing head 5, the inner tank 1 can be screwed together by using tooling to cooperate with the threads of the bottle mouth 21 and the tail plug 6. The end is held up to facilitate the winding operation of the inner tank 1. As shown in Figure 5, when the carbon fiber composite layer is wound, the spirally wound layer 7 is first provided, and this layer starts to spirally wind from the R angle where the bottle mouth 2 and the upper sealing head 3 connect to the tail plug 6, And wrapping the lower connection part 62 of the tail plug 6, the upper sealing part 3, the barrel part 4 and the lower sealing part 5 can greatly enhance the axial strength of the inner tank 1. Moreover, the width of a single winding of the spiral winding layer 7 is controlled within the range of 28-36mm. Under this special size setting, it can be ensured that the R angle, the turning point of the bottle shoulder of the upper sealing head 3, the lower sealing The transition of each spiral winding layer material at the bottom turning point of the head 5 is smooth and tightly wrapped; compared with directly wrapping with a large width material, although the winding steps of the large width material are reduced, the seams of each winding material are less, It seems to have better pressure-bearing performance and efficiency, but in fact, the fit between the large-width material and the inner liner 1 with the curvature is not good, and the wrapping in the curvature area tends to bulge at the edge of the winding material, which needs to be overlapped Winding, the actual consumables are more, and the pressure-bearing performance is not good; while this scheme carries out winding at a specific width, the possible material overlapping area can be controlled smaller, the material fit is higher, and the utility of the carbon fiber composite layer material can be maximized , to ensure the full performance of the pressure bearing and reduce the amount of materials used. In addition, using the tail plug 6 and the bottle mouth 21 to support both ends of the liner 1 for winding can ensure that the winding efficiency of this solution is sufficient.

Then a hoop winding layer 8 is set; and this layer begins to wrap around from the junction of the upper head portion 3 and the body portion 4 to the junction of the body portion 4 and the lower head portion 5, and wraps the whole body portion 4 Covering and wrapping can greatly enhance the circumferential strength of the liner 1, as shown in Fig. 6 .

Further, the glass fiber protective layer 9 is wound on the carbon fiber composite layer; and this layer is also wound from the joint of the upper sealing head 3 and the cylindrical body 4 to the cylindrical body 4 and the lower sealing head 5 The joints can effectively protect the carbon fiber composite layer and ensure the stable pressure of the carbon fiber composite layer.

In practical application, the bottle mouth 21 of the inner tank 1 can be connected with the bottle valve, and compressed natural gas is pressurized from the bottle valve into the inner tank 1 until the pressure reaches the working pressure of the gas cylinder of 20MPa. During this process, the liner 1 expands under pressure and undergoes elastic deformation, which transmits the pressure to the carbon fiber composite layer on the outer surface of the liner 1. The materials of the liner 1 and the carbon fiber composite layer together withstand an internal pressure of 20MPa, which serves to store high-pressure natural gas. effect. At the same time, the glass fiber protective layer 9 continuously protects the carbon fiber composite layer to ensure the overall pressure stability of the gas cylinder.

The gas cylinder provided by this solution has a capacity of 260L, and the weight of a single gas cylinder provided by this solution is as low as 126Kg, which is 10% lower than that of ordinary gas cylinders with the same capacity. Correspondingly, when trucks are used to transport this type of gas cylinder group, the weight of the vehicle will increase less, and a single vehicle can carry more gas cylinders and transport a larger amount of compressed natural gas, which will help greatly reduce transportation costs. Moreover, for CNG trucks (natural gas trucks), the gas cylinders provided by this solution have less weight attached to the vehicle, and the CNG trucks can easily carry more gas cylinders and have a longer cruising range; the production cost of gas cylinders Correspondingly, the configuration cost of CNG trucks can be further reduced, and the economy of CNG trucks can be further improved. The application of the gas cylinder can effectively promote the development of CNG trucks and promote energy saving and emission reduction.

This embodiment provides a lightweight carbon fiber fully wound gas cylinder and its manufacturing method. The liner 1 is a steel liner 1 formed by deep drawing of a steel plate and closed by unilateral hot spinning, and is closed on one side. The overall wall thickness is evenly distributed, and the quality of the gas cylinder is stable; the wall thickness of the liner 1 is small, especially the wall thickness of the barrel part 4 is reduced to 3.7mm-4.3mm, and the wall thickness fluctuation can be controlled within 0.6mm ( The wall thickness fluctuation in conventional gas cylinder production is at least more than 1mm), the production quality is higher, and the manufacturing efficiency is higher (in this embodiment, the best manufacturing efficiency can reach 3min/only). Moreover, while reducing and uniforming the wall thickness of the inner tank 1, it can also ensure that the pressure bearing capacity of the inner tank 1 fully meets the standard.

In particular, through the meticulous definition of the winding method of the carbon fiber composite layer and the glass fiber protective layer 9, the auxiliary inner tank 1 can achieve better pressure-bearing performance with less winding material than conventional winding; 1 When the wall thickness is reduced, the weight of the gas cylinder can be further reduced, and at the same time, the pressure-bearing performance of the overall gas cylinder is guaranteed to meet the absolute standard, and the carbon fiber composite layer material is saved. In addition, the reason why this solution can save winding materials is that the wall thickness of the inner tank 1 is controlled very uniformly through specific process settings, and the inner wall strength distribution of each area of the inner tank 1 itself is uniform and the strength fluctuation is smaller than that of conventional gas cylinders. Small, for the carbon fiber composite layer, its winding uniformity can also be improved correspondingly, which helps to reduce the amount of carbon fiber composite layer; moreover, the material of the carbon fiber composite layer is high-performance carbon fiber impregnated epoxy resin, and its material performance is relatively It is better than conventional carbon fiber materials, and can effectively exert the pressure bearing effect of carbon fiber composite layers. Moreover, because the amount of carbon fiber composite layer and the amount of material used in the liner 1 are reduced, even if better carbon fiber materials are used, the production cost of this solution remains low. 20% lower.

What is described above is only an embodiment of the present invention, and the common knowledge such as the specific structure and characteristics known in the scheme is not described too much here, and those of ordinary skill in the art know all the common knowledge in the technical field to which the invention belongs before the filing date or the priority date Technical knowledge, being able to know all the existing technologies in this field, and having the ability to apply conventional experimental methods before this date, those of ordinary skill in the art can improve and implement this plan based on their own abilities under the inspiration given by this application, Some typical known structures or known methods should not be obstacles for those of ordinary skill in the art to implement the present application. It should be pointed out that for those skilled in the art, under the premise of not departing from the structure of the present invention, some modifications and improvements can also be made, which should also be regarded as the protection scope of the present invention, and these will not affect the implementation of the present invention. Effects and utility of patents.

Claims (9)

1. Lightweight carbon fiber fully wound gas cylinder, characterized in that it includes an inner tank and a carbon fiber composite layer arranged on the outer wall of the inner tank; the inner tank is made by steel plate deep drawing process, and the inner tank is unilateral Closing forming; the carbon fiber composite layer includes a helical winding layer whose winding angle is a first preset angle and a hoop winding layer whose winding angle is a second preset angle. 2. The lightweight carbon fiber fully wound gas cylinder according to claim 1, wherein the first preset angle is 8°-15°. 3. The lightweight carbon fiber fully wound gas cylinder according to claim 1, wherein the second preset angle is 85°-90°. 4. The lightweight carbon fiber fully wound gas cylinder according to claim 1, wherein the liner includes a bottle mouth, an upper sealing head, a cylinder body and a lower sealing head arranged in sequence; the spiral The winding layer is wound and arranged on the inner tank; the hoop winding layer is wound and arranged on the cylinder body. 5. The lightweight carbon fiber fully-wound gas cylinder according to claim 4, further comprising a glass fiber protective layer arranged on the outer surface of the carbon fiber composite layer; the glass fiber protective layer is circumferentially wound around the cylinder body . 6 . The lightweight carbon fiber fully wound gas cylinder according to claim 4 , wherein the wall thickness of the cylinder body is 3.7mm-4.3mm. 7. The lightweight carbon fiber fully wound gas cylinder according to claim 4, wherein a tail plug is provided on the bottom surface of the lower sealing head; the tail plug includes an upper connecting portion and a lower connecting portion made integrally part; the center of the upper connection part is provided with a threaded hole; the bottom surface of the lower connection part is a circular arc surface. 8. The method for making a lightweight carbon fiber fully wound gas cylinder is characterized in that it is used to make the lightweight carbon fiber fully wound gas cylinder as claimed in any one of claims 1-7; comprising the following steps: Step 1: select the steel plate as the blank; draw the blank into a cup-shaped body by drawing forming process; Step 2: heat-spin the cup-shaped body to obtain a liner with a bottle mouth at one end; Step 3: Winding and setting a carbon fiber composite layer on the inner tank; winding and setting a glass fiber protective layer on the carbon fiber composite layer. 9. The manufacturing method of lightweight carbon fiber fully wound gas cylinder according to claim 8, characterized in that, in step 2, also comprising, bonding a tail plug on the bottom surface of the lower head of the inner tank; The bottom surface of the lower connection part of the tail plug is bonded to the bottom surface of the lower sealing head.

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