A winding method suitable for high-pressure large-volume carbon fiber full-winding gas cylinder

Abstract

This invention provides a winding method suitable for high-pressure, large-volume carbon fiber fully wound gas cylinders, comprising the following steps: S1, establishing a finite element model based on the cylinder's structure and material properties to determine ideal layup parameters; S2, conducting winding simulation tests using an inner liner sample to obtain mandrel size deviation, winding angle deviation, and the actual optimal friction coefficient; S3, determining actual layup parameters based on the ideal layup parameters, mandrel size deviation, winding angle deviation, and the actual optimal friction coefficient; S4, determining the resin used for cylinder winding, preparing the adhesive solution with the resin, and determining the mass ratio of resin, curing agent, accelerator, and polymerization inhibitor in the adhesive solution; S5, setting the parameters of the winding equipment to complete the carbon fiber winding. The winding method for high-pressure, large-volume carbon fiber fully wound gas cylinders described in this invention solves the problem of winding and forming high-pressure, large-volume carbon fiber fully wound gas cylinders, improving winding efficiency and reducing costs.

Description

Technical Field

[0001] This invention relates to the field of pressure vessel manufacturing, and more specifically, to a winding method suitable for high-pressure, large-volume carbon fiber fully wound gas cylinders. Background Technology

[0002] With the continuous development of modern industrial technology, the demand for pressure vessels in high-tech fields such as hydrogen storage, semiconductors, marine engineering, and aerospace is constantly increasing. Carbon fiber fully wound gas cylinders, characterized by their light weight, high gas pressure, large storage capacity, and high safety, are gradually being applied in the chemical energy and aerospace fields, with particularly high demand for high-pressure, large-volume carbon fiber fully wound gas cylinders. These cylinders consist of a highly malleable aluminum alloy inner liner and a pressure-bearing fiber-wound shell.

[0003] The fiber-wound shell of a high-pressure, large-volume carbon fiber fully wound gas cylinder is typically constructed by winding carbon fiber and then curing it into a fiber shell. This fiber shell is the main pressure-bearing body of the composite gas cylinder, and the winding process has high requirements. The quality of the finished product directly affects the pressure-bearing performance of the equipment.

[0004] High-pressure, large-volume carbon fiber fully wound gas cylinders, currently, are still in the research stage in China, with a capacity of 450L or more. Due to the large diameter, thin inner wall, and long length of this type of gas cylinder, conventional winding methods are not applicable to winding this type of gas cylinder.

[0005] Existing technology, patent application number CN202310405741.7, discloses a lightweight carbon fiber fully wound gas cylinder and its manufacturing method, including an inner liner, a carbon fiber composite layer disposed on the outer wall of the inner liner, and a glass fiber protective layer disposed on the outer surface of the carbon fiber composite layer; the inner liner is made by deep drawing steel plate, and the inner liner is formed with a single-sided closed end; the carbon fiber composite layer includes a spiral wound layer with a winding angle of a first preset angle and a circumferential wound layer with a winding angle of a second preset angle. Although this patent can effectively reduce manufacturing and transportation costs and achieve lightweight and low-cost gas cylinders, it cannot be used for high-pressure, large-volume carbon fiber fully wound gas cylinders above 450L. Because this type of gas cylinder has a large size, it requires a large amount of expensive carbon fiber and other auxiliary materials, and improper winding will result in a large waste of cost and time.

[0006] In view of this, the present invention is hereby proposed. Summary of the Invention

[0007] The purpose of this invention is to propose a winding method suitable for high-pressure, large-volume carbon fiber fully wound gas cylinders, in order to solve the problem that conventional winding methods in the prior art cannot be used for high-pressure, large-volume carbon fiber fully wound gas cylinders with a capacity of 450L or more. Since this type of gas cylinder has a large size, it requires a large amount of expensive carbon fiber and other auxiliary materials. If the winding is not done properly, it will cause a lot of cost and time waste.

[0008] To achieve the above objectives, the technical solution of the present invention is implemented as follows:

[0009] A winding method for high-pressure, large-volume carbon fiber fully wound gas cylinders, wherein the gas cylinder includes an inner liner and a fiber-wound shell, and the fiber-wound shell is formed by winding carbon fiber with the inner liner as a core mold and curing it with resin;

[0010] The winding method applicable to high-pressure, large-volume carbon fiber fully wound gas cylinders includes the following steps:

[0011] S1. Based on the cylinder structure and material properties, a finite element model is established to determine the ideal layup parameters;

[0012] S2. Using the inner liner sample, a winding simulation test was conducted to obtain the core mold size deviation value, winding angle deviation value, and actual optimal friction coefficient;

[0013] S3. Determine the actual layup parameters by combining the ideal layup parameters, mandrel size deviation, winding angle deviation, and the actual optimal friction coefficient;

[0014] S4. Determine the resin to be used for cylinder winding, prepare the adhesive solution with the resin, and determine the mass ratio of resin, curing agent, accelerator and polymerization inhibitor in the adhesive solution;

[0015] S5. Set the parameters of the winding equipment to complete the carbon fiber winding.

[0016] The present invention describes a winding method for high-pressure, large-volume carbon fiber fully wound gas cylinders, with steps S1 to S5 being interconnected and inseparable. Step S1 establishes a finite element model based on the cylinder's structure and material properties to determine ideal layup parameters. This improves winding efficiency and increases the success rate of winding. Step S2 conducts a winding simulation test using a small inner sample before formal winding. This further confirms the accuracy of the ideal layup parameters obtained in step S1, increasing the success rate of winding and preventing significant cost and time waste caused by improper winding. Step S3 further optimizes the ideal layup parameters using the mandrel size deviation, winding angle deviation, and actual optimal friction coefficient obtained in step S2, further increasing the success rate of winding. Step S4 ensures both the strength of the fiber-wound shell and prevents the adhesive from drying during prolonged winding, thus further improving winding efficiency. In summary, steps S1 to S5 solved the problem of winding and forming high-pressure, large-volume carbon fiber fully wound gas cylinders, improving the efficiency of winding and forming and reducing costs while ensuring the winding and forming process.

[0017] Furthermore, the working pressure of the gas cylinder is greater than or equal to 50 MPa, and the volume of the gas cylinder is greater than 450 L.

[0018] The winding method of the present invention, applicable to high-pressure, large-volume carbon fiber fully wound gas cylinders, can be used for winding high-pressure, large-volume carbon fiber fully wound gas cylinders with a working pressure greater than or equal to 50MPa and a volume greater than 450L.

[0019] Furthermore, in step S2, the simulation experiment includes a fiber closure test to determine the mandrel size deviation value. The fiber closure test specifically includes the following steps: using inner liner samples of different diameters as mandrels for trial winding, determining the range of variation of the mandrel outer diameter tolerance within which no gaps appear between the fiber abrasive belts, thereby obtaining the mandrel size deviation value.

[0020] The inner liner, as the mandrel, acts as the matrix during the winding process. Therefore, the change in the outer diameter of the inner liner affects the winding of the fibers. Thus, before winding, trial winding is carried out using inner liner samples of different diameters to determine the range of variation of the mandrel outer diameter tolerance and to ensure that no gaps appear between the fiber abrasive belts.

[0021] Furthermore, in step S2, the simulation experiment includes a winding angle test to determine the winding angle deviation value. The winding angle test specifically includes the following steps: through an inner liner sample experiment, the winding effect of different winding angles in multiple winding tests is statistically analyzed to determine how much the angle deviation exceeds before fiber slippage occurs, thereby determining the actual angle deviation value.

[0022] Furthermore, in step S2, the simulation experiment includes a friction coefficient test to determine the actual optimal friction coefficient. The friction coefficient test includes the following steps: testing the deviation of the yarn point from the theoretical point under different friction conditions, and analyzing and determining the actual optimal friction coefficient within the allowable deviation range.

[0023] Furthermore, in step S4, the resin is an epoxy resin.

[0024] Furthermore, in step S4, the mass ratio of resin, curing agent, accelerator and polymerization inhibitor in the adhesive solution is 100:3:2:1.

[0025] The adhesive prepared using this mass ratio of epoxy resin, curing agent, accelerator, and polymerization inhibitor can ensure both the strength of the fiber-wound shell of the high-pressure, large-volume carbon fiber fully wound gas cylinder and prevent the adhesive from drying out during long-term winding. At a temperature of 30℃, by continuously replacing old adhesive with new, the winding time using this adhesive can approach 10 hours.

[0026] Furthermore, step S5 includes the following steps:

[0027] S51. Lead the carbon fiber yarn out from the yarn frame, pass it through the steering wheel, the dip tank and the winding nozzle in sequence, and tie the yarn to the winding nozzle to complete the yarn threading;

[0028] S52. Prepare the adhesive solution according to the mass ratio, pour the prepared adhesive solution into the adhesive tank, and when the room temperature is greater than 15℃, set the temperature of the adhesive tank to 25~35℃.

[0029] S53. Wrap the inner liner at both ends with the fixing fixture and fix it on the wrapping machine;

[0030] S54. Untie the carbon fiber yarn attached to the winding nozzle and manually wind it around the inner liner, ensuring that the carbon fiber yarn does not slip with the inner liner. Rotate the gas cylinder until the resin-impregnated carbon fiber yarn is pulled onto the inner liner to begin and complete the carbon fiber winding.

[0031] Furthermore, in step S54, the tension of a single carbon fiber strand is 40N.

[0032] Applying tension can generate a certain pre-tightening force between the carbon fiber and the aluminum alloy inner liner, thereby further improving the fatigue resistance of the hydrogen storage cylinder.

[0033] Furthermore, in step S54, the winding speed is ≤ 95% of the fastest speed of the winding device.

[0034] An appropriate winding speed ensures that the carbon fiber is wound evenly and consistently onto the aluminum alloy inner liner. The winding speed refers to the rotational speed of the aluminum alloy inner liner.

[0035] Compared with existing technologies, the winding method for high-pressure, large-volume carbon fiber fully wound gas cylinders described in this invention has the following advantages:

[0036] The present invention describes a winding method for high-pressure, large-volume carbon fiber fully wound gas cylinders, with steps S1 to S5 being interconnected and inseparable. Step S1 establishes a finite element model based on the cylinder's structure and material properties to determine ideal layup parameters. This improves winding efficiency and increases the success rate of winding. Step S2 conducts a winding simulation test using a small inner sample before formal winding. This further confirms the accuracy of the ideal layup parameters obtained in step S1, increasing the success rate of winding and preventing significant cost and time waste caused by improper winding. Step S3 further optimizes the ideal layup parameters using the mandrel size deviation, winding angle deviation, and actual optimal friction coefficient obtained in step S2, further increasing the success rate of winding. Step S4 ensures both the strength of the fiber-wound shell and prevents the adhesive from drying during prolonged winding, thus further improving winding efficiency. In summary, the winding method of gas cylinders in steps S1 to S5 solves the problem of winding and forming high-pressure, large-volume carbon fiber fully wound gas cylinders, improving the efficiency of winding and forming and reducing costs while ensuring the winding and forming process. Attached Figure Description

[0037] Figure 1 This is a schematic diagram of the layup parameters of a finite element model simulation of a winding method for a high-pressure, large-volume carbon fiber fully wound gas cylinder, as described in an embodiment of the present invention.

[0038] Figure 2 This is a schematic diagram illustrating the winding state of a high-pressure, large-volume carbon fiber fully wound gas cylinder according to an embodiment of the present invention.

[0039] Explanation of reference numerals in the attached figures:

[0040] 100. Inner liner; 101. Straight section; 102. Bottle head. Detailed Implementation

[0041] It should be noted that, unless otherwise specified, the embodiments and features described in the embodiments of the present invention can be combined with each other. The descriptions of "first," "second," etc., mentioned in the embodiments of the present invention are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by the present invention.

[0042] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0043] This invention proposes a winding method suitable for high-pressure, large-volume carbon fiber fully wound gas cylinders. The gas cylinder includes an inner liner 100 and a fiber wound shell. The fiber wound shell is formed by winding carbon fiber with the inner liner 100 as a core mold and curing it with resin.

[0044] The winding method applicable to high-pressure, large-volume carbon fiber fully wound gas cylinders includes the following steps:

[0045] S1. Based on the cylinder structure and material properties, a finite element model is established to determine the ideal layup parameters;

[0046] S2. Using a 100mm inner liner sample, a winding simulation test was conducted to obtain the core mold size deviation, winding angle deviation, and the actual optimal friction coefficient.

[0047] S3. Determine the actual layup parameters by combining the ideal layup parameters, mandrel size deviation, winding angle deviation, and the actual optimal friction coefficient;

[0048] S4. Determine the resin to be used for cylinder winding, prepare the adhesive solution with the resin, and determine the mass ratio of resin, curing agent, accelerator and polymerization inhibitor in the adhesive solution;

[0049] S5. Set the parameters of the winding equipment to complete the carbon fiber winding.

[0050] The present invention describes a winding method for high-pressure, large-volume carbon fiber fully wound gas cylinders, with steps S1 to S5 being interconnected and inseparable. Step S1 establishes a finite element model based on the cylinder's structure and material properties to determine ideal layup parameters. This improves winding efficiency and increases the success rate of winding. Step S2 conducts a winding simulation test using a 100mm inner liner sample before formal winding. This further confirms the accuracy of the ideal layup parameters obtained in step S1, increasing the success rate of winding and preventing significant cost and time waste due to improper winding. Step S3 further optimizes the ideal layup parameters using the mandrel size deviation, winding angle deviation, and actual optimal friction coefficient obtained in step S2, further improving the success rate of winding. Step S4 ensures both the strength of the fiber-wound shell and prevents the adhesive from drying during prolonged winding, thus further improving winding efficiency. In summary, the winding method of gas cylinders in steps S1 to S5 solves the problem of winding and forming high-pressure, large-volume carbon fiber fully wound gas cylinders, improving the efficiency of winding and forming and reducing costs while ensuring the winding and forming process.

[0051] Specifically, the working pressure of the gas cylinder is greater than or equal to 50 MPa, and the volume of the gas cylinder is greater than 450 L.

[0052] The winding method of the present invention, applicable to high-pressure, large-volume carbon fiber fully wound gas cylinders, can be used for winding high-pressure, large-volume carbon fiber fully wound gas cylinders with a working pressure greater than or equal to 50MPa and a volume greater than 450L.

[0053] Specifically, step S1 includes the following steps:

[0054] S11. Establish a finite element model based on the cylinder structure and material properties, and set the initial shell layup parameters using ANSYS finite element analysis software.

[0055] S12. Simulate the actual working conditions under different working conditions, perform failure analysis on the stress under the corresponding working conditions, and compare and determine the ideal shell ply parameters.

[0056] Specifically, in step S11, the cylinder structure of the gas cylinder includes the length of the inner liner 100, the nominal outer diameter of the straight section 101 of the inner liner 100, and the wall thickness of the straight section 101 of the inner liner 100.

[0057] In step S11, the material properties of the gas cylinder include the material of the inner liner 100 and the material of the carbon fiber used for winding.

[0058] More specifically, the material of the inner liner 100 is aluminum alloy, and the material of the inner liner 100 may also be titanium alloy, but is not limited thereto.

[0059] More specifically, the material of the carbon fiber is not specifically limited. The material of the carbon fiber can be T700 carbon fiber, T800 carbon fiber, or T1000 carbon fiber, and is not limited to these.

[0060] In step S11, the shell layup parameters include winding method, winding angle, number of winding layers and single layer thickness.

[0061] Specifically, in step S12, the operating conditions include working test conditions and water pressure test conditions.

[0062] Under working test conditions, the pressure is 50 MPa. Under water pressure test conditions, the pressure is 50 MPa * 1.5 = 75 MPa.

[0063] Specifically, in step S2, the simulation experiment includes a fiber closure test to determine the mandrel size deviation value. The fiber closure test specifically includes the following steps: using 100 samples of inner liner with different diameters as mandrels for trial winding, determining the range of variation of the mandrel outer diameter tolerance within which no gaps appear between the fiber sand belts, thereby obtaining the mandrel size deviation value.

[0064] More specifically, the inner liner 100, as the mandrel, plays a matrix role in the winding process. Therefore, the change in the outer diameter of the inner liner 100 affects the winding of the fibers. Thus, before winding, trial winding is carried out using inner liner 100 samples of different diameters to determine the range of variation of the mandrel outer diameter tolerance that prevents gaps from appearing between the fiber abrasive belts, thereby obtaining the mandrel dimensional deviation value.

[0065] Specifically, in step S2, the simulation experiment includes a winding angle test to determine the winding angle deviation value. The winding angle test specifically includes the following steps: through a 100-sample inner liner experiment, the winding effect of different winding angles in multiple winding tests is statistically analyzed to determine how much the angle deviation exceeds before fiber slippage occurs, thereby determining the actual angle deviation value.

[0066] Specifically, in step S2, the simulation experiment includes a friction coefficient test to determine the actual optimal friction coefficient. The friction coefficient test includes the following steps: testing the deviation of the yarn point from the theoretical point under different frictions, and analyzing and determining the actual optimal friction coefficient under the allowable deviation of the yarn.

[0067] Specifically, the resin is not specifically limited.

[0068] Preferably, in step S4, the resin is an epoxy resin, but it is not limited thereto.

[0069] Specifically, in step S4, the mass ratio of epoxy resin, curing agent, accelerator and polymerization inhibitor in the adhesive solution is 100:3:2:1.

[0070] The adhesive prepared using this mass ratio of epoxy resin, curing agent, accelerator, and polymerization inhibitor can ensure both the strength of the fiber-wound shell of the high-pressure, large-volume carbon fiber fully wound gas cylinder and prevent the adhesive from drying out during long-term winding. At a temperature of 30℃, by continuously replacing old adhesive with new, the winding time using this adhesive can approach 10 hours.

[0071] More specifically, the curing agent, accelerator, and polymerization inhibitor are not specifically limited.

[0072] Specifically, step S5 includes the following steps:

[0073] S51. Lead the carbon fiber yarn out from the yarn frame, pass it through the steering wheel, the dip tank and the winding nozzle in sequence, and tie the yarn to the winding nozzle to complete the yarn threading;

[0074] S52. Prepare the adhesive solution according to the mass ratio, pour the prepared adhesive solution into the adhesive tank, and when the room temperature is greater than 15℃, set the temperature of the adhesive tank to 25~35℃.

[0075] In step S52, when the room temperature is greater than 15°C, setting the temperature of the glue tank to 25-35°C can ensure that the glue will not dry during the long-term winding process.

[0076] Preferably, when the room temperature is above 15°C, the temperature of the adhesive tank is set to 30°C. When the temperature is 30°C, by continuously replacing old adhesive with new, the adhesive can be used for continuous winding for nearly 10 hours.

[0077] S53. Install the inner liner 100 with the two ends of the winding and fixing fixture and fix it on the winding machine;

[0078] S54. Untie the carbon fiber yarn attached to the winding nozzle and manually wind it around the inner liner 100, ensuring that the carbon fiber yarn does not slip on the inner liner 100. Rotate the gas cylinder until the resin-impregnated carbon fiber yarn is pulled onto the inner liner 100 to begin and complete the carbon fiber winding.

[0079] Specifically, in step S54, the tension of a single carbon fiber strand is 40N.

[0080] Applying tension can generate a certain pre-tightening force between the carbon fiber and the aluminum alloy inner liner 100, thereby further improving the fatigue resistance of the hydrogen storage cylinder.

[0081] Specifically, in step S54, the winding speed is ≤ 95% of the fastest speed of the winding device.

[0082] This winding speed ensures that the carbon fiber is wound evenly and consistently onto the aluminum alloy inner liner 100. The winding speed refers to the rotational speed of the aluminum alloy inner liner 100.

[0083] The wound gas cylinders manufactured using this method passed self-tightening, hydrostatic, airtightness, burst, and fatigue tests, verifying the effectiveness of the method.

[0084] Example 1

[0085] like Figure 1 and Figure 2 As shown in the figure, this embodiment proposes a winding method suitable for high-pressure, large-volume carbon fiber fully wound gas cylinders. The gas cylinder is composed of an inner liner 100 and a fiber wound shell. In this embodiment, the working pressure of the gas cylinder is 50 MPa and the volume of the gas cylinder is 500 L.

[0086] The winding method applicable to high-pressure, large-volume carbon fiber fully wound gas cylinders includes the following steps:

[0087] S1. Based on the cylinder structure and material properties, a finite element model is established to determine the ideal layup parameters;

[0088] S2. Using a 100mm inner liner sample, a winding simulation test was conducted to obtain the core mold size deviation, winding angle deviation, and the actual optimal friction coefficient.

[0089] S3. Determine the actual layup parameters by combining the ideal layup parameters, mandrel size deviation, winding angle deviation, and the actual optimal friction coefficient;

[0090] S4. Determine the resin to be used for cylinder winding, prepare the adhesive solution with the resin, and determine the mass ratio of resin, curing agent, accelerator and polymerization inhibitor in the adhesive solution;

[0091] S5. Set the parameters of the winding equipment to complete the carbon fiber winding.

[0092] Specifically, step S1 includes the following steps:

[0093] S11. Establish a finite element model based on the cylinder structure and material properties, and set the initial shell layup parameters using ANSYS finite element analysis software.

[0094] S12. Simulate the actual working conditions under different working conditions, perform failure analysis on the stress under the corresponding working conditions, and compare and determine the ideal shell ply parameters.

[0095] More specifically, in step S11, the cylinder structure of the gas cylinder includes: the length of the inner liner 100 of the gas cylinder is 3200mm, the nominal outer diameter of the straight section 101 of the inner liner 100 is Ф480mm, and the wall thickness of the straight section 101 of the inner liner 100 is 12mm.

[0096] In step S11, the material properties of the gas cylinder include: the inner liner 100 of the gas cylinder is an aluminum alloy inner liner 100, and the carbon fiber used for winding is T700 carbon fiber.

[0097] In step S11, the initial shell layup parameters include the winding method, winding angle, number of winding layers, and thickness of a single winding layer.

[0098] In step S11, the initial shell layup parameters are set:

[0099] Winding method: The straight section 101 of the inner liner 100 is wound using a combination of circumferential winding and spiral winding, while the bottle head 102 of the inner liner 100 is wound using a spiral winding method.

[0100] Winding angle: The winding angle for circular winding is 90°, which is the angle between the winding direction and the cylinder's own axis; the winding angle for spiral winding is 7 to 13°, with a reference winding angle of 10° for spiral winding.

[0101] Number of winding layers: 76 layers.

[0102] Thickness of a single layer of winding: 0.3mm.

[0103] Specifically, in step S12, the operating conditions include working test conditions and water pressure test conditions.

[0104] Under the working test condition, the actual working state under the working test was simulated, and the pressure was set to 50 MPa for safety factor analysis. Under the hydrostatic test condition, the actual working state under the hydrostatic test was simulated, and the pressure was set to 50 MPa * 1.5 = 75 MPa for safety factor analysis. The safety factor under both the working test condition and the hydrostatic test condition is >1, proving that the layup design is reasonable.

[0105] Therefore, the ply parameters can be determined. For example... Figure 1 As shown, for example: [90°3 / ±7° / 90°3 / ±9° / 90°3 / ±7° / 90°3 / ±10° / 90°3 / ±7° / 90°2 / ±10° / 90°2 / ±7° / 90°2 / ±12° / 90°2 / ±12° / 90°2 / ±7° / 90°2 / ±13° / 90°2 / ±7° / 90°3 / ±13° / 90°3 / ±7° / 90°3 / ±13° / 90°3 / ±7° / 90°3].

[0106] Specifically, in step S2, the simulation experiment includes a fiber closure test, through which the core mold size deviation is determined to be less than or equal to 5 mm.

[0107] Specifically, in step S2, the simulation experiment includes a winding angle test, which determines that the winding angle deviation is less than or equal to 2°. Therefore, the winding angle of the spiral winding is modified to 8–12°.

[0108] Therefore, the ply parameters can be modified to: [90°3 / ±8° / 90°3 / ±9° / 90°3 / ±8° / 90°3 / ±10° / 90°3 / ±8° / 90°2 / ±10° / 90°2 / ±8° / 90°2 / ±12° / 90°2 / ±12° / 90°2 / ±8° / 90°2 / ±11° / 90°2 / ±8° / 90°3 / ±11° / 90°3 / ±8° / 90°3 / ±11° / 90°3 / ±8° / 90°3 / ±11° / 90°3 / ±8° / 90°3]).

[0109] Specifically, in step S2, the simulation experiment includes a friction coefficient test, which determines that the actual optimal friction coefficient is less than or equal to 0.10.

[0110] Specifically, in step S4, the resin is epoxy resin and the carbon fiber is T700 carbon fiber.

[0111] Specifically, in step S4, the mass ratio of resin, curing agent, accelerator and polymerization inhibitor in the adhesive solution is 100:3:2:1.

[0112] Specifically, step S5 includes the following steps:

[0113] S51. Lead the carbon fiber yarn out from the yarn frame, pass it through the steering wheel, the dip tank and the winding nozzle in sequence, and tie the yarn to the winding nozzle to complete the yarn threading;

[0114] S52. Prepare the adhesive solution according to the mass ratio of epoxy resin: curing agent: accelerator: polymerization inhibitor = 100:3:2:1. Pour the prepared adhesive solution into the glue tank. The adhesive content is 33%. When the room temperature is greater than 15℃, set the temperature of the glue tank to 30℃.

[0115] S53. Install the inner liner 100 with the two ends of the winding and fixing fixture and fix it on the winding machine;

[0116] S54. Untie the carbon fiber yarn attached to the winding nozzle and manually wind it around the inner liner 100, ensuring that the carbon fiber yarn does not slip on the inner liner 100. Rotate the gas cylinder until the resin-impregnated carbon fiber yarn is pulled onto the inner liner 100 to begin and complete the carbon fiber winding.

[0117] Specifically, in step S54, the tension of a single carbon fiber strand is 40N.

[0118] Applying tension can generate a certain pre-tightening force between the carbon fiber and the aluminum alloy inner liner 100, thereby further improving the fatigue resistance of the hydrogen storage cylinder.

[0119] Specifically, in step S54, the winding speed is ≤ 95% of the fastest speed of the winding device.

[0120] This winding speed ensures that the carbon fiber is wound evenly and consistently onto the aluminum alloy inner liner 100. The winding speed refers to the rotational speed of the aluminum alloy inner liner 100.

[0121] The wound gas cylinders manufactured using this method passed self-tightening, water pressure, airtightness, burst, and fatigue tests, with a minimum burst pressure of 151 MPa. The overall fatigue life of the gas cylinders reached more than 12,000 cycles, and the effectiveness of the method was verified through the above tests.

[0122] While the present invention has been disclosed above, it is not limited thereto. Any person skilled in the art can make various modifications and alterations without departing from the spirit and scope of the invention; therefore, the scope of protection of the present invention should be determined by the scope defined in the claims.

Claims

1. A winding method suitable for a high-pressure large-volume carbon fiber full-winding gas cylinder, characterized by, The gas cylinder includes an inner liner (100) and a fiber-wound shell, wherein the fiber-wound shell is formed by winding carbon fiber around the inner liner (100) as a core mold and curing it with resin; The winding method applicable to high-pressure, large-volume carbon fiber fully wound gas cylinders includes the following steps: S1. Based on the cylinder structure and material properties, a finite element model is established to determine the ideal layup parameters; S2. Using the inner liner (100) sample, a winding simulation test was conducted to obtain the core mold size deviation value, winding angle deviation value, and actual optimal friction coefficient; S3. Determine the actual layup parameters by combining the ideal layup parameters, mandrel size deviation, winding angle deviation, and the actual optimal friction coefficient. S4. Determine the resin to be used for cylinder winding, prepare the adhesive solution with the resin, and determine the mass ratio of resin, curing agent, accelerator and polymerization inhibitor in the adhesive solution; S5. Set the parameters of the winding equipment to complete the carbon fiber winding; In step S2, the simulation test includes a fiber closure test, through which the core mold size deviation value is determined; the fiber closure test specifically includes the following steps: using inner liner (100) samples of different diameters as core molds for trial winding, determining the range of variation of the core mold outer diameter tolerance within which no gaps appear between the fiber yarns, thereby obtaining the core mold size deviation value; In step S2, the simulation test includes a winding angle test, and the winding angle deviation value is determined by the winding angle test. The winding angle test specifically includes the following steps: through the inner liner (100) small sample test, the winding effect of different winding angles in multiple winding tests is statistically analyzed, and the angle deviation is tested to determine how much the fiber slippage phenomenon will occur, thereby determining the actual angle deviation value.

2. The winding method for high-pressure, large-volume carbon fiber fully wound gas cylinders according to claim 1, characterized in that, The working pressure of the gas cylinder is greater than or equal to 50 MPa, and the volume of the gas cylinder is greater than 450 L.

3. The winding method for high-pressure, large-volume carbon fiber fully wound gas cylinders according to claim 1, characterized in that, In step S2, the simulation test includes a friction coefficient test to determine the actual optimal friction coefficient. The friction coefficient test includes the following steps: testing the deviation of the yarn point from the theoretical point under different friction coefficients, and analyzing and determining the actual optimal friction coefficient under the allowable yarn deviation.

4. The winding method for high-pressure, large-volume carbon fiber fully wound gas cylinders according to claim 1, characterized in that, In step S4, the resin is epoxy resin.

5. A winding method for high-pressure, large-volume carbon fiber fully wound gas cylinders according to claim 4, characterized in that, In step S4, the mass ratio of resin, curing agent, accelerator and polymerization inhibitor in the adhesive solution is 100:3:2:

1.

6. The winding method for high-pressure, large-volume carbon fiber fully wound gas cylinders according to claim 1, characterized in that, Step S5 includes the following steps: S51. Lead the carbon fiber yarn out from the yarn frame, pass it through the steering wheel, the dip tank and the winding nozzle in sequence, and tie the yarn to the winding nozzle to complete the yarn threading; S52. Prepare the adhesive solution according to the mass ratio, pour the prepared adhesive solution into the adhesive tank, and when the room temperature is greater than 15℃, set the temperature of the adhesive tank to 25~35℃. S53. Install the winding and fixing fixtures on both ends of the inner liner (100) and fix them on the winding machine; S54. Untie the carbon fiber yarn tied to the winding nozzle and manually wind it around the inner liner (100), ensuring that the carbon fiber yarn does not slip with the inner liner (100). Rotate the gas cylinder until the resin-impregnated carbon fiber yarn is pulled onto the inner liner (100) to start and complete the carbon fiber winding.

7. A winding method for high-pressure, large-volume carbon fiber fully wound gas cylinders according to claim 6, characterized in that, In step S54, the tension of a single carbon fiber strand is 40N.

8. A winding method for high-pressure, large-volume carbon fiber fully wound gas cylinders according to claim 6, characterized in that, In step S54, the winding speed is ≤ 95% of the fastest speed of the winding device.

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