Lightweight composite material gas cylinder and preparation method thereof

Abstract

The invention discloses a light-weight composite material gas cylinder and a preparation method thereof, and relates to the technical field of automobile parts, the light-weight composite material gas cylinder comprises a non-metal inner container, and is characterized in that a fiber resin reinforcing layer is wound outside the inner container, cylinder mouths are arranged at two ends of the inner container, sealing inserts are arranged in the cylinder mouths, and end sheaths are in threaded connection with the outer parts of the cylinder mouths; the end sheath is in threaded connection with a metal end, and a first sealing ring is arranged between the metal end and the sealing insert; according to the light-weight composite material gas cylinder and the preparation method thereof, the gas cylinder is light in weight, high in fatigue resistance and stable in end connection, the overall strength of the end position is guaranteed while the sealing performance is guaranteed, the gas leakage phenomenon is avoided, compared with a metal inner container gas cylinder, the problem that a pipeline is blocked by welding slag generated by a metal welding process is solved, and the service life of the gas cylinder is prolonged. The sealing structure has the advantages of corrosion resistance, zero welding seam, reliable sealing and the like, reduces the servicing mass of the automobile, improves the power of the automobile and reduces the fuel consumption.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile parts, and in particular to a lightweight composite material gas cylinder and a preparation method thereof. Background Art

[0002] Gas cylinders are gas storage devices in vehicle braking systems. They store compressed gas from an air compressor and are used in systems like braking and whistles. Trucks use gas in numerous applications, from small components like whistles to large components like brakes. Traditional metal gas cylinders are made of aluminum or steel. Steel cylinders are heavier and require a surface anti-corrosion coating, while aluminum cylinders are lighter, but both require welding. Existing Type III wrapped gas cylinders have a metal liner with designated inlet and outlet ports, sensor interfaces, and other features at both ends. The ends are welded to the metal liner and wrapped with a fiber-resin composite material.

[0003] Defects of traditional metal gas cylinders: They are heavy, and the ends and the bottle body need to be welded in many places. Porosity defects are prone to appear at the welds, leading to the risk of product leakage. Defects of existing Type III wrapped gas cylinders: Compared with Type IV gas cylinders, Type III gas cylinders use metal inner liners, which are heavier. At the same time, the metal ends and the inner liners are connected by welding, and porosity is prone to appear at the welds, leading to leakage defects. In addition, welding at the end position will produce welding slag, and the inside of the inner liners cannot be cleaned, so the welding slag remains, which eventually leads to gas line blockage, and then causes a series of problems such as high fuel consumption and reduced power of the vehicle.

[0004] Therefore, it is necessary to design a lightweight composite material gas cylinder and a preparation method thereof to improve the above problems. Summary of the Invention

[0005] In response to the above-mentioned problems in the prior art, the present invention provides a lightweight composite material gas cylinder and a preparation method thereof, which has the advantages of corrosion resistance, zero welds, and reliable sealing.

[0006] To achieve the above object, the technical solution adopted by the present invention is:

[0007] A lightweight composite gas cylinder includes a non-metallic liner with a fiber resin reinforcement layer wrapped around the outside of the liner. The two ends of the liner are provided with a bottle mouth, the inside of the bottle mouth is provided with a sealing insert, the outside of the bottle mouth is threadedly connected to an end sleeve, the end sleeve is threadedly connected to a metal end, and a first sealing ring is provided between the metal end and the sealing insert.

[0008] As a preferred embodiment of the present invention, the sealing insert is embedded in the bottle mouth during the inner liner processing.

[0009] As a preferred embodiment of the present invention, the inner liner is integrally formed from polyethylene material.

[0010] As a preferred embodiment of the present invention, the material of the sealing insert is the same as that of the inner container.

[0011] As a preferred embodiment of the present invention, the end sheath is provided with unequal-pitch threads.

[0012] As a preferred embodiment of the present invention, a brim is formed extending from the end sheath, and a plurality of notches are provided on the brim.

[0013] As a preferred embodiment of the present invention, a second sealing ring is provided on the metal end.

[0014] As a preferred embodiment of the present invention, the metal end is connected to a drain pipe, which is built into the inner tank.

[0015] A method for preparing a gas cylinder as described in any one of the above items, comprising the steps of:

[0016] S1. One-piece molded liner with sealing insert;

[0017] S2. Apply structural adhesive to the connection between the inner bottle mouth and the end cap, then screw the end cap in place.

[0018] S3. Place the first sealing ring into the end sheath, screw the metal end into the end sheath and tighten;

[0019] S4. Wrap a fiber resin reinforcement layer around the outside of the liner, fully covering the liner and the contact area between the end sheath and the liner during the wrapping process;

[0020] S5. Install accessories after curing.

[0021] Due to the adoption of the above technical solution, compared with the prior art, the beneficial effects of the present invention are:

[0022] 1. The lightweight composite material gas cylinder and its preparation method of the present invention are lightweight, have high fatigue resistance, stable end connections, ensure tightness while maintaining overall strength at the end, and are leak-free. Compared with metal liner gas cylinders, they avoid the problem of welding slag clogging pipelines caused by metal welding processes, and have the advantages of corrosion resistance, zero welds, and reliable sealing.

[0023] 2. The lightweight composite material gas cylinder and its preparation method of the present invention reduce the curb weight of the vehicle, improve the vehicle power, and reduce fuel consumption. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] By referring to the following description in conjunction with the accompanying drawings, and with a more complete understanding of the present invention, other objects and results of the present invention will become more clear and easy to understand. In the accompanying drawings:

[0025] Figure 1 It is a perspective view of an example of the present invention;

[0026] Figure 2 It is a schematic diagram of the structural relationship of an embodiment of the present invention;

[0027] Figure 3 It is an exploded view of an example of the present invention;

[0028] The reference numerals include: inner liner 1, bottle mouth 11, fiber resin reinforcement layer 2, sealing insert 3, end sheath 4, cap brim 41, notch 42, metal end 5, first sealing ring 6, drain pipe 7. DETAILED DESCRIPTION

[0029] The following will provide a clear and complete description of the technical solutions of various embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the embodiments described are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of the present invention.

[0030] In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0031] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "connected," and "connected" should be understood broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to internal connections between two components. It should be noted that all figures are illustrative only. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0032] The present invention will be further described in detail below through specific implementation examples in conjunction with the accompanying drawings.

[0033] Reference Figures 1 to 3 , Figure 1 is a perspective view of an example of the present invention, Figure 2 It is a schematic diagram of the structural relationship of an embodiment of the present invention, Figure 3It is an exploded view of an example of the present invention. The present invention provides a lightweight composite material gas cylinder, including an inner liner 1, a fiber resin reinforcement layer 2, a sealing insert 3, an end sleeve 4, a metal end 5, a first sealing ring 6, and a drain pipe 7. The inner liner 1 is a non-metallic inner liner. In one embodiment, the inner liner 1 is integrally formed by polyethylene material. The outer surface of the inner liner 1 is wrapped with a fiber resin reinforcement layer 2. The thickness of the reinforcement layer 2 is preferably set to 1.5mm to 3mm. The reinforcement layer 2 is wrapped around the end sleeve 4 during the winding process, which protects the inner liner 1 and improves the position strength of the end sleeve 4. Bottle mouths 11 are provided at both ends of the inner liner 1. The inside of the bottle mouth 11 A sealing insert 3 is provided. The sealing insert 3 is embedded in the bottle mouth 11 during the processing of the inner liner 1. It mainly plays a role in strengthening the seal. The material of the sealing insert 3 is the same as that of the inner liner 1. The outer surface of the bottle mouth 11 is threadedly connected to the end cap sleeve 4. The end cap sleeve 4 is threadedly connected to the metal end 5. A first sealing ring 6 is provided between the metal end 5 and the sealing insert 3. The metal end 5 is pressed against the bottle mouth 11 of the inner liner 1. The first sealing ring 6 presses the sealing insert 3 to achieve a sealing effect between the metal end 5 and the inner liner 1. The metal end 5 is connected to a drain pipe 7. The drain pipe 7 is built into the inner liner 1 to facilitate the discharge of liquid from the inner liner 1. The end cap sleeve 4 is in the shape of a cap. The end cap sleeve 4 extends to form a brim 41. The brim 41 is set between the inner liner 1 and the reinforcement layer 2. The brim 41 is provided with multiple notches 42. The notches 42 are used to prevent slipping and increase friction to prevent the reinforcement layer 2 from rotating, thereby ensuring the sealing effect.

[0034] In one embodiment, the end cap sleeve 4 is provided with unequally spaced threads for connecting to the bottle mouth 11 of the inner liner 1 and the metal end cap 5. In one embodiment, the metal end cap 5 is provided with a second sealing ring (not shown) to enhance the seal. The metal end cap 5 itself may also be provided with a structure that enhances the seal.

[0035] The present invention also provides a method for preparing the gas cylinder as described in any one of the above items, comprising the steps of:

[0036] S1. One-piece molded liner 1 containing a sealing insert 3;

[0037] S2. Apply structural adhesive to the connection position of the bottle mouth 11 of the liner 1 and the end sheath 4 and screw the end sheath 4;

[0038] S3. Place the first sealing ring 6 inside the end sheath 4, screw the metal end 5 into the end sheath 4 and tighten;

[0039] S4. The outer side of the liner 1 is wrapped with a fiber resin reinforcement layer 2. During the winding process, the liner 1 and the end sheath 4 are fully covered in contact with the liner 1;

[0040] S5. After curing, install accessories such as air pipes, etc.

[0041] The present invention discloses a lightweight composite material gas cylinder and its preparation method. The cylinder is lightweight, and the non-metallic inner liner surface requires no special anti-corrosion treatment, is resistant to aging and corrosion, and significantly reduces the overall weight of the cylinder. The cylinder has high fatigue strength. The innovative connection structure between the non-metallic inner liner and the metal end cap overcomes the welding defects and weight issues of traditional gas cylinders. Furthermore, the end connection is stable and leak-free. Compared to metal-lined gas cylinders, the inner liner is integrally formed, eliminating the need for welding, thus avoiding the problem of slag clogging pipelines caused by metal welding processes. The cylinder has the advantages of corrosion resistance, zero welds, and reliable sealing. The cylinder is cured by high-temperature heating to ensure strength. Various verification tests have shown that it has a higher hardness than metal materials, 3-5 times that of steel or aluminum, and one-fifth the weight. It also has high fatigue strength, with a static fatigue strength 40% higher than that of metal materials, and high corrosion resistance and chemical stability. While ensuring strength and safety, the present invention reduces vehicle curb weight, improves vehicle power, reduces fuel consumption, and reduces exhaust pollution.

[0042] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. A lightweight composite gas cylinder, comprising a non-metallic liner, characterized in that: A fiber resin reinforcement layer is wrapped around the outside of the inner liner, a bottle mouth is provided at both ends of the inner liner, a sealing insert is provided inside the bottle mouth, the outer thread of the bottle mouth is connected to the end sleeve, the end sleeve is threadedly connected to the metal end, and a first sealing ring is provided between the metal end and the sealing insert.

2. A lightweight composite material gas cylinder according to claim 1, characterized in that: The sealing insert is embedded in the bottle mouth during the liner processing.

3. The lightweight composite material gas cylinder according to claim 1, characterized in that: The inner liner is made of polyethylene material.

4. The lightweight composite material gas cylinder according to claim 1, characterized in that: The sealing insert is made of the same material as the liner.

5. The lightweight composite material gas cylinder according to claim 1, characterized in that: The end sheath is provided with unequal-distance threads.

6. The lightweight composite gas cylinder according to claim 1, characterized in that: A brim is extended from the end sheath and a plurality of notches are arranged on the brim.

7. The lightweight composite material gas cylinder according to claim 1, characterized in that: A second sealing ring is provided on the metal end head.

8. The lightweight composite gas cylinder according to claim 1, characterized in that: The metal end is connected to a drain pipe which is built into the inner tank.

9. A method for preparing a gas cylinder according to any one of claims 1 to 8, characterized in that Including steps: S1. One-piece molded liner with sealing insert; S2. Apply structural adhesive to the connection between the inner bottle mouth and the end cap, then screw the end cap in place. S3. Place the first sealing ring into the end sheath, screw the metal end into the end sheath and tighten; S4. Wrap a fiber resin reinforcement layer around the outside of the liner, fully covering the liner and the contact area between the end sheath and the liner during the wrapping process; S5. Install accessories after curing.

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