Commercial vehicle air cylinder based on fiber reinforced nylon composite material and manufacturing method thereof

Abstract

The invention discloses a commercial vehicle air cylinder based on a fiber reinforced nylon composite material and a manufacturing method of the commercial vehicle air cylinder. The air cylinder aims at solving the problems that an existing iron air cylinder is large in weight and prone to corrosion, and an aluminum alloy air cylinder is low in welding efficiency and prone to damage. An air cylinder main body is formed by bonding a left section cylinder body, a right section cylinder body and a middle fixing ring which are formed by injection through a double-component elastic structural adhesive, reinforcing ribs are uniformly distributed on the inner wall of the cylinder body, a semicircular head part is locally thickened, and a metal insert is pre-embedded at a connector. The manufacturing method comprises the steps of material preparation, injection molding, insert pre-embedding, gluing and bonding, drain valve installation and the like. According to the invention, the remarkable light weight of the air cylinder is realized, for example, the light weight is reduced by 50% compared with an iron air cylinder and is reduced by 33% compared with an aluminum alloy air cylinder, the air cylinder has excellent corrosion resistance, high strength, high toughness and impact resistance, meanwhile, the manufacturing process is simplified, the production efficiency is improved, the service life of a product is prolonged, the manufacturing cost is reduced, and the maintenance is convenient.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle parts, and in particular to a commercial vehicle air reservoir based on fiber-reinforced nylon composite materials and a manufacturing method thereof. Background Art

[0002] Air reservoirs for commercial vehicles are essential components of the vehicle's braking and auxiliary systems, storing compressed air and providing a source of air for the vehicle. Traditional commercial vehicle air reservoirs are primarily made of iron or aluminum alloy.

[0003] Iron air cylinders: They have disadvantages such as being heavy, prone to corrosion, and requiring surface coating for corrosion protection. In addition, the interior is easily corroded by water accumulated in the compressed air, which can contaminate and clog pipes and valves, easily causing safety accidents.

[0004] Aluminum alloy gas cylinder: Although the weight is lighter than that of iron gas cylinder, the welding efficiency is low and the welding quality is difficult to guarantee. In addition, the cost of aluminum alloy materials is relatively high. At the same time, the surface may be dented after being hit by stones, and serious microcracks may occur, posing a safety hazard.

[0005] With the increasing requirements for lightweight and environmental protection of automobiles, the development of a lightweight, high-strength, corrosion-resistant, safe and reliable commercial vehicle air cylinder has become an urgent need for the development of the industry.

[0006] To this end, the present application provides a method to solve the technical problems existing in the prior art. Summary of the Invention

[0007] Purpose of the invention: To provide a commercial vehicle air reservoir based on fiber-reinforced nylon composite material and a manufacturing method thereof, so as to achieve lightweight, high strength, corrosion resistance, safety and reliability of the air reservoir.

[0008] To achieve the above object, the present invention provides the following technical solutions:

[0009] A commercial vehicle air reservoir based on fiber-reinforced nylon composite material, comprising:

[0010] Left section of the cylinder: It is made of fiber-reinforced nylon composite material injection molding and has a hemispherical head. The head is equipped with at least two air inlet / outlet interfaces, a sensor interface and a drainage interface. The interfaces are connected to external pipelines with pre-buried metal inserts.

[0011] Right section cylinder: It is made of fiber-reinforced nylon composite material injection molding and has a hemispherical head. The head is provided with at least two air inlet / outlet interfaces, a sensor interface and a drainage interface. The interfaces are connected to external pipelines with pre-buried metal inserts.

[0012] Middle fixing ring: Made of fiber-reinforced nylon composite material injection molding, it is in the shape of a ring and is used to connect the left and right sections of the cylinder.

[0013] Structural adhesive: used to bond the left and right sections of the cylinder and the middle fixing ring into a closed container. The structural adhesive is a two-component elastic structural adhesive.

[0014] Furthermore, the inner walls of the left section cylinder and the right section cylinder are provided with evenly distributed reinforcing ribs, the height of the reinforcing ribs is 2-3 times the thickness of the cylinder wall, and the semicircular head portion is locally thickened.

[0015] Furthermore, additives such as anti-light aging agents and toughening agents are added to the fiber-reinforced nylon composite material.

[0016] Furthermore, a manual drain valve is installed at the drainage interface.

[0017] A method for manufacturing a commercial vehicle air reservoir based on a fiber-reinforced nylon composite material comprises the following steps:

[0018] S1: Material preparation: Mix nylon resin with fiber material, anti-light aging agent and other additives to prepare fiber-reinforced nylon composite material;

[0019] S2: Injection molding: injecting the fiber-reinforced nylon composite material into the molds of the left section cylinder, the right section cylinder and the middle fixing ring respectively, and performing injection molding to obtain the left section cylinder, the right section cylinder and the middle fixing ring;

[0020] S3: Pre-embedded insert: During the injection molding process, a threaded metal insert is pre-embedded at the end-sealing interface between the left and right sections of the cylinder;

[0021] S4: Gluing and bonding: Apply two-component elastic structural adhesive to the joints of the left and right sections of the cylinder and the middle fixing ring, insert the left and right sections of the cylinder into the middle fixing ring, and allow the structural adhesive to cure to form a closed container;

[0022] S5: Install the drain valve: Install a manual drain valve at the drain interface of the cylinder.

[0023] S6: Air tightness test: Place the air cylinder in the testing machine and fill it with water to test whether it is leaking.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] This application significantly reduces the weight of the air reservoir by replacing traditional iron or aluminum alloy materials with fiber-reinforced nylon composites and using an injection molding process. As shown in the example, the air reservoir weighs 4 kg, which is 50% and 33% lighter than traditional iron and aluminum alloy air reservoirs (8 kg and 6 kg, respectively). This effectively meets the trend of lightweighting vehicles, helps reduce fuel consumption, and improves vehicle economy.

[0026] Fiber-reinforced nylon composite materials have excellent resistance to chemical corrosion and hydrolysis, which completely solves the problems of iron air storage cylinders being easily rusted and easily corroded by water stored in compressed air, causing pollution and safety hazards. No additional anti-corrosion coating is required, reducing maintenance costs.

[0027] The injection molding process allows the cylinder and retaining ring to be formed in one piece, eliminating the complex welding process of traditional metal gas cylinders and significantly improving production efficiency and product consistency. The two-component elastic structural adhesive bonding method is simple and easy to automate, effectively absorbing vibrations and improving joint strength and sealing. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is a schematic diagram of the overall structure of the present invention.

[0029] Figure 2 It is a partial cross-sectional view of the present invention;

[0030] Figure 3 The test data table.

[0031] In the figure: 1. Left section of the cylinder; 2. Right section of the cylinder; 3. Middle fixing ring; 4. Reinforcement rib; 5. Threaded insert; 6. Drain valve. DETAILED DESCRIPTION

[0032] In the following description, numerous specific details are provided to provide a more thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced without one or more of these details. In other instances, certain technical features well known in the art are not described to avoid confusion with the present invention.

[0033] like Figure 1-2 As shown, the commercial vehicle air reservoir based on the fiber-reinforced nylon composite material of this embodiment includes:

[0034] Left section cylinder 1: Made of fiber-reinforced nylon composite material injection molding, it has a hemispherical head with at least two air inlet / outlet ports, a sensor port, and a drainage port. The ports are connected to external pipes using pre-buried metal inserts.

[0035] Right cylinder 2: Made of fiber-reinforced nylon composite material injection molding, it has a hemispherical head with at least two air inlet / outlet ports, a sensor port, and a drain port. The ports are connected to external pipes using pre-buried metal inserts.

[0036] Middle fixing ring 3: Made of fiber-reinforced nylon composite material injection molding, in a circular ring shape, used to connect the left section cylinder 1 and the right section cylinder 2;

[0037] Structural adhesive: used to bond the left section cylinder 1, the right section cylinder 2 and the middle fixing ring 3 into a closed container. The structural adhesive is a two-component elastic structural adhesive.

[0038] The inner walls of the left and right sections of the cylinder (1) and (2) are uniformly distributed with reinforcing ribs (4). The ribs (4) are 2-3 times the wall thickness, and the semicircular head is locally thickened. The fiber-reinforced nylon composite material contains an anti-light aging agent. A manual drain valve (6) is installed at the drainage port.

[0039] The manufacturing method of the commercial vehicle air reservoir based on the fiber-reinforced nylon composite material of this embodiment includes the following steps:

[0040] S1: Material preparation: nylon resin is mixed with fiber material impregnated with a special coupling agent, anti-light aging agent, toughening agent and other additives, and extruded to prepare fiber-reinforced nylon composite material long pellets with a length of 15-20 mm;

[0041] S2: Injection molding: Inject the fiber-reinforced nylon composite material into the molds of the left cylinder 1, the right cylinder 2, and the middle fixing ring 3, respectively, and perform injection molding to obtain the left cylinder 1, the right cylinder 2, and the middle fixing ring 3;

[0042] S3: Pre-embedded inserts: During the injection molding process, threaded metal inserts are pre-embedded at the end-sealing interface between the left cylinder 1 and the right cylinder 2. The surface of the inserts must be degreased and phosphated before being embedded. Before being placed in the mold, they must be preheated to above 90°C in an oven to improve the bonding strength with the plastic and enhance the sealing performance.

[0043] S4: Gluing and bonding: Apply two-component elastic structural adhesive to the joints of the left and right sections of the cylinder 1 and 2 and the middle fixing ring 3, insert the left and right sections of the cylinder 1 and 2 into the middle fixing ring 3, and allow the structural adhesive to solidify to form a closed container;

[0044] S5: Install the drain valve 6: Install the manual drain valve 6 at the drain interface of the cylinder.

[0045] S6: Air tightness test: Check whether the air cylinder is leaking by filling it with water.

[0046] Example 1

[0047] Material preparation: Nylon 66 resin was mixed with 40% chopped glass fiber, 0.5% anti-light aging agent, and 5% toughening agent, and then extruded and granulated to prepare a fiber-reinforced nylon composite material.

[0048] Injection molding: The fiber-reinforced nylon composite material is injected into the molds of the left cylinder 1, the right cylinder 2 and the middle fixing ring 3 respectively. The injection molding temperature is 290°C, the injection pressure is 80 MPa, the holding time is 10 seconds, and the cooling time is 30 seconds.

[0049] Embedded inserts: During the injection molding process, metal inserts with internal threads are embedded in the head interface between the left section cylinder 1 and the right section cylinder 2.

[0050] Glue coating and bonding: Use an automatic glue coating machine to apply two-component elastic structural adhesive at the joints between the left and right sections of the cylinder 1, 2 and the middle fixed ring 3. The ratio of the structural adhesive is component A: component B = 1:1, and the adhesive coating thickness is 1 mm. Insert the left and right sections of the cylinder 1, 2 into the middle fixed ring 3, and allow the structural adhesive to cure at room temperature for 24 hours to form a closed container.

[0051] Install the drain valve 6: Install the manual drain valve 6 at the drain interface of the cylinder.

[0052] Performance testing:

[0053] The gas cylinder prepared in Example 1 was subjected to a pressure test. The results showed that the gas cylinder weighed 4 kg, which was 50% and 33% lighter than traditional iron gas cylinders (8 kg) and aluminum alloy gas cylinders (6 kg), respectively.

[0054] like Figure 3 , air tightness test (pressure drop method) and data

[0055] 1. Slowly fill with water: Turn on the water source and slowly fill the test medium (pure water) into the gas cylinder until the specified test pressure is reached.

[0056] 2. Test pressure: usually 1.1 to 1.5 times the maximum working pressure, or according to the standard. For example, if the design working pressure is 1.0 MPa, the test pressure can be 1.5 MPa. (According to the embodiment of the present invention, the pressure resistance is 3 MPa, here it is assumed that the working pressure is 1.0 MPa and the airtightness test pressure is 1.5 MPa)

[0057] 3. Pressure stabilization: After reaching the test pressure, shut off the water supply and disconnect the air reservoir from the water source. Allow the pressure to stabilize for 5-10 minutes until the liquid temperature inside the air reservoir reaches equilibrium with the ambient temperature. Record the initial pressure and initial temperature at this time.

[0058] 4. Holding pressure: Maintain the pressure state and start timing. The holding time is determined according to the standard or product requirements, such as 30 minutes or 60 minutes.

[0059] 5. Record data: After the holding time is over, record the final pressure and final temperature at this time.

[0060] 6. Calculate pressure drop

[0061] 7. Local leak detection (optional / if necessary): If the pressure drop exceeds the allowable range, or as a routine inspection, during or after the pressure maintenance period, apply soapy water or a special leak detection fluid to the gas cylinder's adhesive seams, interface welds (where the insert and nylon meet), valves, and other parts to observe whether there are bubbles. You can also use the immersion method to completely immerse the pressurized gas cylinder in a water tank and observe whether there is continuous bubble escape.

[0062] Result judgment:

[0063] According to the test data:

[0064] At a test pressure of 1.5 MPa, after maintaining the pressure for 30 minutes, the pressure dropped to 0.003 MPa (2 kPa).

[0065] This pressure drop is less than the maximum allowable pressure drop of 0.01 MPa (10 kPa).

[0066] Local leak detection did not reveal any obvious leak points.

[0067] Conclusion: The air tightness test results of the sample are qualified.

[0068] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be included therein. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

Claims

1. A commercial vehicle air reservoir based on fiber-reinforced nylon composite material, characterized in that: include: Left section cylinder: Made of fiber-reinforced nylon composite material injection molding, it has a hemispherical head with at least two air inlet / outlet interfaces, a sensor interface, and a drainage interface. The interfaces are connected to external pipelines using pre-buried metal inserts. Right section cylinder: Made of fiber-reinforced nylon composite material injection molding, it has a hemispherical head with at least two air inlet / outlet interfaces, a sensor interface, and a drainage interface. The interfaces are connected to external pipelines using pre-buried metal inserts. Middle fixing ring: Made of fiber-reinforced nylon composite material injection molding, in a circular ring shape, used to connect the left and right sections of the cylinder; Structural adhesive: used to glue the left and right sections of the cylinder and the middle fixing ring together to form a closed container. The structural adhesive is a two-component elastic structural adhesive with a core-shell structure.

2. The commercial vehicle air reservoir according to claim 1, characterized in that: The inner walls of the left section cylinder and the right section cylinder are provided with uniformly distributed reinforcing ribs, the height of the reinforcing ribs is 2-3 times the thickness of the cylinder wall, and the semicircular head parts are locally thickened.

3. The commercial vehicle air reservoir according to claim 1, characterized in that: The fiber-reinforced nylon composite material is added with an anti-light aging additive, a toughening agent, and the like.

4. The commercial vehicle air reservoir according to claim 1, characterized in that: A manual drain valve is installed at the drain interface.

5. A method for manufacturing a commercial vehicle air tank based on fiber-reinforced nylon composite material, characterized in that: The following steps are involved: S1: Material preparation: nylon resin is mixed with a fiber material impregnated with a special coupling agent, an anti-light aging agent, a toughening agent and other additives, and extruded to prepare fiber-reinforced nylon composite material long pellets with a length of 15-20 mm; S2: Injection molding: injecting the fiber-reinforced nylon composite material into the molds of the left section cylinder, the right section cylinder and the middle fixing ring respectively, and performing injection molding to obtain the left section cylinder, the right section cylinder and the middle fixing ring; S3: Pre-embedded inserts: During the injection molding process, threaded metal inserts are pre-embedded at the end-sealing interface between the left and right cylinders. The surface of the inserts must be degreased and phosphated before being embedded. They must also be preheated to above 90°C in an oven before being placed in the mold to improve bonding strength with the plastic and enhance sealing. S4: Gluing and bonding: Use an automatic glue coating machine to apply two-component elastic structural glue at the joints of the left and right sections of the cylinder and the middle fixing ring, insert the left and right sections of the cylinder into the middle fixing ring, and allow the structural glue to cure to form a closed container; S5: Install the drain valve: Install a manual drain valve at the drain interface of the cylinder. S6: Air tightness test: Place the air cylinder in the testing machine and fill the cylinder with water to test whether the air cylinder is leaking.

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