Gas cylinder valve seat structure, type iv gas cylinder and manufacturing method

Abstract

The present application relates to the technical field of composite material gas cylinder, and particularly relates to a gas cylinder valve seat structure, a type IV gas cylinder and a manufacturing method. The gas cylinder valve seat structure comprises a valve seat body, an inner container body and an optical fiber sensor. The valve seat body comprises an interface part, a skirt part and at least one mounting channel. The mounting channel comprises a groove channel arranged on the outer surface of the skirt part on one side of the interface part and a through channel arranged in the wall of the interface part. The inner container body comprises an injection molded inner container and a plurality of fiber winding layers wound and fixed on the outer periphery of the injection molded inner container. The end surface of the injection molded inner container is provided with an embedded groove for integrally embedding and fixing the skirt part. The optical fiber sensor is provided with at least one lead end. The lead end is embedded in the groove channel and is led out of the outside along the groove channel and the through channel in sequence. The lead of the optical fiber sensor is arranged in the protected mounting channel, so that the shearing and crushing damage caused by the contact with the metal during the winding and curing process is avoided, and the reliable lead-out of the signal line is realized.

Description

Technical Field

[0001] This invention relates to the field of composite material gas cylinder technology, and in particular to a gas cylinder valve seat structure, a Type IV gas cylinder, and a manufacturing method thereof. Background Technology

[0002] Type IV fiber-wound composite gas cylinders are widely used in new energy vehicles, aerospace, and gas storage and transportation due to their lightweight and high strength characteristics. As special equipment, the safety of gas cylinders is of paramount importance. Traditional inspection methods (such as hydrostatic testing and ultrasonic testing) are all offline and periodic inspections, which cannot achieve real-time, online monitoring of the structural health status of gas cylinders throughout their entire life cycle.

[0003] Fiber optic sensors, such as FBGs (fiber gratings), have advantages such as resistance to electromagnetic interference, small size, light weight, easy integration, and the ability to achieve distributed measurement. Currently, composite material gas cylinders use fiber optic sensors for structural health monitoring.

[0004] However, current methods for embedding fiber optic sensors into composite gas cylinders still face the following challenges:

[0005] The challenge of interface lead-out: When the gas cylinder is under pressure, the connection area between the end caps and the valve seat of the inner liner is located near the end cap pole. Not only is there stress concentration, but the optical fiber is also very easy to slide and difficult to fix when it is wound through this area. How to safely and reliably lead the fragile optical fiber out of the gas cylinder from inside the fiber winding layer at one end of the gas cylinder and ensure its long-term survival rate is a major challenge.

[0006] Significant difference in coefficients of thermal expansion: The coefficients of thermal expansion of plastic and metal valve seats differ significantly. During temperature cycling, such as temperature changes (-40℃ to 85℃) caused by filling and discharging gas cylinders, this difference can generate enormous thermal stress, potentially leading to seal failure or fiber optic cable shearing.

[0007] Poor process compatibility: Traditional methods of bonding to the surface or directly embedding between fiber layers are prone to fiber damage, breakage or detachment from the substrate under winding tension, resin flow and curing pressure, resulting in a high risk of sensor failure. Summary of the Invention

[0008] The purpose of this invention is to provide a gas cylinder valve seat structure, a Type IV gas cylinder, and a manufacturing method to solve the problems of integration, protection, and reliable signal extraction in an online monitoring system using fiber optic sensors.

[0009] The technical solution adopted to solve the above-mentioned technical problems is as follows:

[0010] This invention provides a gas cylinder valve seat structure, comprising:

[0011] A valve seat body includes an interface portion, a skirt portion, and at least one mounting channel. The interface portion is a hollow columnar structure. The skirt portion is connected to one end of the interface portion and extends outward around the interface portion. The mounting channel includes a groove channel on the outer surface of the skirt portion located on one side of the interface portion and a through groove channel in the wall of the interface portion. One end of the groove channel extends to the outer edge of the skirt portion, and the other end extends between the skirt portion and the interface portion and communicates with the through groove channel. The end of the through groove channel away from the skirt portion extends to the end of the interface portion away from the skirt portion.

[0012] The inner liner includes an injection-molded inner liner and a multi-layer fiber winding layer that is wound and fixed around the outer periphery of the injection-molded inner liner. The end face of the injection-molded inner liner is provided with an embedding groove for integrally injection-molding and fixing the skirt portion. The fiber winding layer covers the skirt portion.

[0013] The fiber optic sensor is provided at least one, which is disposed between the injection-molded inner liner and the multiple layers of fiber winding. The fiber optic sensor is provided with a lead end, which is embedded in the groove channel and led out to the outside in sequence along the groove channel and the through channel.

[0014] The beneficial effects of the gas cylinder valve seat structure of the present invention are:

[0015] In this invention, when leading out the fiber optic sensor, the lead end is embedded in the groove channel and led out to the outside in sequence along the groove channel and the through channel. This invention places the fragile fiber optic sensor lead in a protected mounting channel, avoiding shearing and crushing damage caused by contact with metal during winding and curing. The mounting channel provides a protected and clearly defined safe corridor for the fragile fiber optic sensor lead, greatly improving the survival rate of the fiber optic sensor, thereby achieving effective protection of the fiber optic sensor during winding and curing, and realizing reliable signal line lead-out.

[0016] As a further improvement to the above technical solution, the outer surface of the skirt portion located on one side of the interface portion is an arc-shaped conical structure, the through channel and the groove channel are smoothly intersected, the groove channel extends radially along the skirt portion, and the through channel extends axially along the interface portion.

[0017] As a further improvement to the above technical solution, the surface of the skirt portion is provided with an anchoring structure, which is used to form an anchoring connection with the injection-molded inner liner.

[0018] As a further improvement to the above technical solution, the mounting channel is filled with a sealing protective body, which is used to protect the fiber optic sensor and seal the mounting channel.

[0019] As a further improvement to the above technical solution, the groove channel is fitted with a flexible protective sleeve, the optical fiber sensor is inserted through the flexible protective sleeve, and a buffer pad is provided in the junction area between the skirt, the injection-molded inner liner and the multi-layer fiber winding layer.

[0020] As a further improvement to the above technical solution, the cross-section of the groove channel is an arc-shaped structure, and the cross-section of the through channel is a circular structure.

[0021] As a further improvement to the above technical solution, there are multiple installation channels, which are evenly distributed along the circumference of the valve seat body.

[0022] As a further improvement to the above technical solution, the inner peripheral wall of the interface portion is provided with an internal thread and a first sealing step surface, and the injection-molded inner liner is provided with a bottle mouth body fixedly sleeved in the interface portion. The end face of the bottle mouth body is in sealing contact with the first sealing step surface, and the inner diameter of the bottle mouth body is smaller than the inner diameter of the first sealing step surface, so as to form a second sealing step surface on the end face of the bottle mouth body.

[0023] This invention proposes a Type IV gas cylinder, including the aforementioned gas cylinder valve seat structure.

[0024] The present invention also proposes a method for manufacturing a Type IV gas cylinder, applicable to the aforementioned Type IV gas cylinder, the method comprising:

[0025] The valve seat body is processed according to the required number and layout of the fiber optic sensors to produce a preset number and preset distribution of the installation channels;

[0026] The valve seat body and the inner liner body are integrally injection molded together by embedded injection molding to form an assembly;

[0027] The fiber winding layers are sequentially wound onto the surface of the assembly, and the fiber optic sensor is simultaneously fixedly laid on the outer surface of the injection-molded inner liner and / or between two adjacent fiber winding layers. The lead end of the fiber optic sensor is embedded in the groove channel and sequentially led out to the outside along the groove channel and the through channel.

[0028] During the laying and installation of the fiber optic sensor, the fiber optic sensor is tested online in real time. If signal attenuation or interruption is detected, the winding process is stopped and repaired.

[0029] The groove channel and the through channel are sealed and filled.

[0030] Heating and curing are performed according to the preset process curve.

[0031] Other features and advantages of the invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. Attached Figure Description

[0032] The present invention will be further described below with reference to the accompanying drawings and embodiments;

[0033] Figure 1 This is a schematic diagram of an embodiment of the gas cylinder valve seat structure provided by the present invention.

[0034] Figure 2 This is a flowchart of an embodiment of the manufacturing method of the Type IV gas cylinder provided by the present invention;

[0035] Icon labels:

[0036] Valve seat body 100; interface portion 110; internal thread 111; first sealing step surface 112; skirt portion 120; mounting channel 130; groove channel 131; through groove channel 132;

[0037] Inner liner 200; Injection-molded inner liner 210; Embedded groove 211; Bottle spout 212; Second sealing step surface 213; Carbon fiber composite winding layer 220; Glass fiber composite winding protective layer 230;

[0038] Fiber optic sensor 300; lead wire end 310;

[0039] Composite material protective cover 400. Detailed Implementation

[0040] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0041] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, etc., are based on the orientation or positional relationship shown in the drawings and are only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0042] In the description of this invention, "multiple" refers to two or more. The use of "first" and "second" is for distinguishing technical features only and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features or their sequential relationship.

[0043] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0044] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described below are some embodiments of the present invention, not all embodiments.

[0045] Currently, when embedding fiber optic sensors 300 into composite material structures, problems such as interface lead-out difficulties, large differences in thermal expansion coefficients, and poor process compatibility still exist. Therefore, there is an urgent need for a gas cylinder valve seat structure that can solve the problems of integration, protection, and reliable signal lead-out of fiber optic online monitoring systems while meeting the full life cycle requirements of static strength, fatigue strength, and sealing performance.

[0046] Reference Figure 1 The gas cylinder valve seat structure of the present invention is provided in the following embodiment:

[0047] The gas cylinder valve seat structure of the present invention includes: a valve seat body 100, an inner liner 200, and an optical fiber sensor 300.

[0048] The valve seat body 100 includes an interface portion 110, a skirt portion 120, and at least one mounting channel 130. The interface portion 110 and the skirt portion 120 are connected to each other along the axial direction. The valve seat body 100 is a specially designed metal insert and is one of the core load-bearing and sealing components of the gas cylinder. It is usually made of a metal material with good hydrogen compatibility and resistance to hydrogen embrittlement. Preferably, it is made of 6061 aluminum alloy or S31603 stainless steel, and is precision forged and machined.

[0049] Specifically, the interface part 110 has a hollow cylindrical structure. The inner peripheral wall of the interface part 110 is provided with internal threads 111 for threaded connection with bottle valves, combination valves or pipeline systems. It is also provided with a high-pressure sealing surface, which cooperates with the metal sealing ring of the bottle valve to form a line seal, ensuring the sealed delivery of high-pressure media.

[0050] In this embodiment, the skirt portion 120 is connected to the lower end of the interface portion 110. The skirt portion 120 extends outward around the interface portion 110. The skirt portion 120 is designed as a tapered transition structure. The outer surface of the skirt portion 120 on one side of the interface portion 110 is an arc-shaped tapered surface structure.

[0051] The mounting channel 130 of this embodiment includes a groove channel 131 on the outer surface of the skirt portion 120 located on the side of the interface portion 110 and a through channel 132 in the wall of the interface portion 110. The through channel 132 extends axially along the interface portion 110. The lower end of the groove channel 131 extends to the outer edge of the skirt portion 120, and the upper end extends between the skirt portion 120 and the interface portion 110 and communicates with the lower end of the through channel 132. The upper end of the through channel 132 extends to the upper end surface of the interface portion 110.

[0052] The inner liner 200 of this embodiment includes an injection-molded inner liner 210 and a multi-layer fiber winding layer that is wound and fixed around the outer periphery of the injection-molded inner liner 210. The end face of the injection-molded inner liner 210 is provided with an embedding groove 211 for integrally injection-molded and fixed the skirt portion 120. The fiber winding layer covers the skirt portion 120. The fiber winding layer includes a carbon fiber composite winding layer 220 and a glass fiber composite winding protective layer 230.

[0053] In this embodiment, the fiber optic sensor 300 is disposed between the injection-molded inner liner 210 and the multilayer fiber winding layer. The fiber optic sensor 300 is provided with a lead end 310, which is embedded in the groove channel 131 and led out to the outside in sequence along the groove channel 131 and the through channel 132.

[0054] In this invention, when leading out the fiber optic sensor 300, the lead end 310 is embedded in the groove channel 131 and led out to the outside in sequence along the groove channel 131 and the through channel 132. This invention places the fragile fiber optic sensor 300 lead in the protected mounting channel 130, avoiding shearing and crushing damage caused by contact with metal during winding and curing. The mounting channel 130 provides a protected and clearly defined safe corridor for the fragile fiber optic sensor 300 lead, greatly improving the survival rate of the fiber optic sensor 300, thereby achieving effective protection of the fiber optic sensor 300 during winding and curing, and realizing reliable lead-out of the signal line.

[0055] Furthermore, the through channel 132 and the groove channel 131 are smoothly intersected. The groove channel 131 extends radially along the skirt edge 120. The design of the mounting channel 130 avoids the fiber being sheared at the edge of the channel or creating unnecessary gaps during the winding process, ensuring the continuity of fiber accumulation and the stability of load transfer.

[0056] The groove channel 131 in this embodiment has an arc-shaped cross-section to prevent the fiber optic sensor 300 from being scratched when it is embedded. The arc-shaped groove has the best stress dispersion characteristics, which can minimize the stress concentration on the metal valve seat body 100 caused by the groove and prevent it from becoming the origin of fatigue cracks. The groove channel 131 is opened on the outer surface of the skirt portion 120 and extends axially from the lower end of the skirt portion 120 to the root of the skirt portion 120. The cross-section is semi-circular. Preferably, the diameter is 0.8 mm and the depth is 0.4 mm. The surface finish of the groove wall is Ra≤1.6μm.

[0057] The smooth arc transition design of the groove channel 131 minimizes the weakening of the valve seat body 100 strength by the slotting and ensures that the composite material can form good wetting and wrapping in this area, providing a protected and well-defined "safe corridor" for the fragile optical fiber lead, which greatly improves the survival rate of the optical fiber sensor 300.

[0058] The through channel 132 has a circular cross-section and is located inside the interface portion 110. The axis of the through channel 132 is strictly parallel to the axis of the valve seat body 100, with a coaxiality of ≤0.05mm and a diameter of 0.8mm. One end is smoothly connected to the groove channel 131 through a R1.0mm transition fillet without steps, reducing stress concentration. The other end extends to the upper end face of the interface portion 110, forming a fiber optic lead-out hole with a diameter of 0.9mm, ensuring that the fiber optic cable can pass through the through channel 132 without obstruction after entering from the groove channel 131 through the root of the skirt portion 120.

[0059] The number of fiber optic sensors 300 can be set according to monitoring requirements, therefore there are multiple mounting channels 130. The number of mounting channels 130 matches the number of fiber optic sensors 300. The multiple mounting channels 130 are evenly distributed around the circumference of the valve seat body 100. Usually, two or more mounting channels 130 are set. The multiple mounting channels 130 should preferably be symmetrically distributed around the axis of the interface part 110, such as being evenly distributed on the circumference. For example, when two mounting channels 130 are set, they are 180° symmetrical; when four mounting channels 130 are set, they are 90° symmetrical. The symmetrical layout helps to maintain the mechanical balance of the valve seat body 100 and prevents unbalanced loads caused by asymmetrical slotting.

[0060] In some other embodiments, alternatives to the cross-section of the groove channel 131 may include a rectangular or trapezoidal groove, but its corners must be rounded to reduce the stress concentration factor. The size design must strike a balance between accommodating the fiber optic sensor 300 and not excessively weakening the strength of the valve seat 100. The depth is typically between 0.3 mm and 1.0 mm, and the depth must be greater than the cladding diameter of the fiber optic sensor 300, typically 0.125 mm or 0.25 mm, to ensure that the fiber optic sensor 300 can be fully embedded in the groove 211 and protected. The width is typically between 0.8 mm and 2.0 mm, and the width must be able to accommodate one or two fiber optic sensors 300 and an appropriate amount of sealant, while also facilitating operator installation.

[0061] In this embodiment, the surface of the skirt portion 120 is provided with an anchoring structure. The anchoring structure is used to form an anchoring connection with the injection-molded inner liner 210. When the injection-molded inner liner 210 is injection-molded, the valve seat body 100 is directly placed into the mold as an insert, so that it is integrated with the injection-molded inner liner 210 in one injection. After the plastic cools and shrinks, it will tightly wrap around the anchoring structure of the skirt portion 120, forming a strong mechanical interlock. The anchoring structure can be knurled, barbed, or annular groove.

[0062] In this embodiment, the skirt portion 120 serves as a conical or cylindrical transition area, which is the main bonding and load transfer area between the valve seat body 100, the injection-molded inner liner 210, and the composite winding layer. The surface of the skirt portion 120 is usually specially pretreated to enhance the bonding strength with the composite material. The pretreatment methods include: macroscopic mechanical locking: turning circumferential grooves, barbs, or knurling; microscopic roughening treatment: sandblasting to form a uniform, clean, and active surface with a certain roughness; and chemical bonding promotion: coating with a special silane coupling agent or epoxy primer.

[0063] Furthermore, in this embodiment, the mounting channel 130 is filled with a sealing protector. The sealing protector is used to protect the fiber optic sensor 300 and seal the mounting channel 130 to ensure the airtightness of the interface. The sealing protector includes high-temperature sealant, flexible sealing gasket, or low-shrinkage resin.

[0064] This invention uses sealant / resin to fill and cure the mounting channel 130, which, while fixing the fiber optic sensor 300, forms a strong bond with the composite material body and the metal interface. Together with the filling sealant and other sealing and protective materials, it constitutes a reliable sealing barrier. The mechanical structure of the mounting channel 130 transforms the stress on the sealant from simple interfacial bonding to a more reliable "mechanical interlocking + adhesive" composite form, greatly enhancing the sealing reliability under high pressure and cyclic loads.

[0065] In this embodiment, a flexible protective sleeve is embedded in the groove channel 131. The fiber optic sensor 300 passes through the flexible protective sleeve. The flexible protective sleeve can be made of high-performance fluororubber or perfluoroether rubber. The flexible protective sleeve can effectively absorb and compensate for stress and displacement caused by the difference in thermal expansion coefficient, protect the fiber optic sensor 300 from being broken, and pre-position the fiber optic sensor 300.

[0066] A buffer layer is provided in the junction area between the skirt 120, the injection-molded inner liner 210 and the fiber winding layer, which reduces the abrupt change in stiffness from soft material to hard material, effectively disperses shear stress, and protects the fiber optic sensor 300.

[0067] In this embodiment, the inner peripheral wall of the interface portion 110 is provided with a first sealing step surface 112, and the injection-molded inner liner 210 is provided with a bottle mouth body 212 fixedly sleeved inside the interface portion 110. The end face of the bottle mouth body 212 is in sealing contact with the first sealing step surface 112. The inner diameter of the bottle mouth body 212 is smaller than the inner diameter of the first sealing step surface 112, so as to form a second sealing step surface 213 on the end face of the bottle mouth body 212, thereby further improving the sealing performance.

[0068] This invention proposes a Type IV gas cylinder, including the gas cylinder valve seat structure described above.

[0069] This invention also proposes a method for manufacturing a Type IV gas cylinder, applicable to the aforementioned Type IV gas cylinder, such as... Figure 2 As shown, the manufacturing method of this embodiment includes:

[0070] Step S100: The valve seat body 100 is processed according to the required number and layout of the fiber optic sensors 300 to process the preset number and preset distribution of installation channels 130.

[0071] Step S200: The valve seat body 100 and the inner liner body 200 are integrally injection molded together by embedded injection molding to form an assembly;

[0072] Step S300: Control the sequential winding of multiple fiber winding layers onto the surface of the assembly, simultaneously fix and lay fiber optic sensors 300 on the outer surface of the injection-molded inner liner 210 and / or between two adjacent fiber winding layers, control the lead end 310 of the fiber optic sensor 300 to be embedded in the groove channel 131, and sequentially lead out to the outside along the groove channel 131 and the through channel 132.

[0073] Step S400: During the laying and installation of the fiber optic sensor 300, perform online real-time signal testing on the fiber optic sensor 300. If signal attenuation or interruption is detected, stop the winding process and repair it.

[0074] Step S500: Perform sealing and filling treatment on the groove channel 131 and the through channel 132.

[0075] Step S600: Heat and cure according to the preset process curve.

[0076] In step S100, S31603 stainless steel or 6061 aluminum alloy is precision machined using hot forging and CNC lathes, etc., and a network layout scheme for the fiber optic sensor 300 is designed according to the test requirements. The number of fiber optic sensors 300 is determined, and the valve seat body 100 is designed according to the required number and layout of the fiber optic sensors 300. The number of installation channels 130 is determined, while ensuring that the valve seat body 100 meets the full life cycle requirements of static strength, fatigue strength, and sealing performance.

[0077] In this embodiment, the skirt portion 120 is designed as a tapered transition structure, and its outer surface is processed with an anchoring structure. This structure is a macroscopic mechanical locking unit, specifically including annular grooves, barbs, or knurling, which is used to form a mechanical interlock with the injection-molded inner liner 210 during embedded injection molding. At the same time, the surface of the anchoring structure needs to be pretreated: it is sandblasted with 80-mesh white corundum to form a micro-rough surface; a silane coupling agent is coated with a coating thickness of 5μm and cured at room temperature for 24 hours. Through chemical bonding, the bonding force with the inner liner material is enhanced, and the peel strength between the pretreated skirt portion 120 and the injection-molded inner liner 210 is greatly improved.

[0078] The mounting channel 130 can be machined in one go during the final finishing stage of the valve seat body 100 using precision milling, fine grinding and other processes, to ensure accurate dimensions, high surface finish, and no burrs or micro-cracks.

[0079] In step S200, embedded injection molding is selected: the injection-molded inner liner 210 is made of high-density polyethylene (HDPE) and thermoplastic composite material. The valve seat body 100 is used as a metal insert and is directly placed into the mold, making it an integral part of the plastic during injection molding of the inner liner 210. After the plastic cools and shrinks, it tightly wraps around the special structures on the metal insert, such as barbs and knurling. By designing complex microstructures, such as large knurling, deep grooves, and anchoring holes, on the surface of the valve seat body 100, the mechanical interlocking ability with the plastic is maximized. This invention forms a "groove-plastic" mechanical interlock through one-time injection molding, solving the loosening problem caused by the difference in thermal expansion coefficients in traditional connection methods.

[0080] The multi-layer fiber winding layer in this embodiment includes a carbon fiber composite winding layer 220 and a glass fiber composite winding protective layer 230. In step S300, the assembly is installed onto a CNC fiber winding machine, and the following steps are performed sequentially: winding the carbon fiber composite winding layer 220: T700 carbon fiber and epoxy resin matrix are laid synchronously, and the winding tension is controlled at 50N~80N to ensure that the fiber tightly wraps the injection-molded inner liner 210 and the skirt 120; winding the glass fiber composite winding protective layer 230: at least two layers of glass fiber are wound outside the carbon fiber composite winding layer 220 to enhance impact resistance.

[0081] Before laying the fiber optic sensor 300, the installation channel 130 is cleaned by wiping the inner walls of the groove channel 131 and the through channel 132 with isopropyl alcohol and drying them with compressed air to ensure that there is no oil or dust.

[0082] Before winding, fiber optic sensors 300 are pre-laid on the outer surface of the injection-molded inner liner 210 to monitor the strain, temperature, and hydrogen content of the gas cylinder inner liner. The path of the fiber optic sensors 300 is fixed. On the outer surface of the injection-molded inner liner 210, biodegradable adhesive is used to temporarily fix the fiber optic sensors 300 along the axial direction to prevent displacement during winding. In the junction area between the skirt 120 and the injection-molded inner liner 210, a modified epoxy resin flexible transition adhesive with a thickness of less than 100μm is first coated, and then the fiber optic sensors 300 are pressed onto the adhesive layer. This adhesive layer can buffer the thermal expansion difference between the valve seat 100 and the injection-molded inner liner 210 to prevent the optical fiber from being cut. The lead end 310 of the fiber optic sensor 300 is embedded in the groove channel 131 and led out to the outside in sequence along the groove channel 131 and the through channel 132, leaving sufficient length after passing through the optical fiber lead-out hole.

[0083] During the winding process, fiber optic sensors 300 for detecting the strain, temperature and hydrogen content of the carbon fiber composite winding layer 220 are laid out in sequence. Using a fiber feed head with fiber guide groove, the fiber optic sensors 300 are synchronously guided to the groove channel 131 to avoid fiber crushing of optical fiber, realize synchronous delivery and laying of fiber and optical fiber, and ensure positional accuracy and consistency.

[0084] In step S400, after each layer of winding is completed, a portable optical time domain reflectometer (OTDR) or optical frequency domain reflectometer (OFDR) is used to perform online real-time signal testing on the fiber optic sensor 300 embedded in the installation channel 130. If signal attenuation is found to be greater than 0.1 dB / km or interruption is detected, the test should be stopped and repaired immediately, such as by replacing the local fiber segment, to avoid irreversible damage once the defect is covered up.

[0085] In step S500, modified epoxy resin sealant (model E-44, with 10% added silica powder) is injected into the installation channel 130. Vacuum injection process is used to remove air bubbles, ensuring that the sealant completely fills the groove channel 131 and the through channel 132. After curing at room temperature for 24 hours, the tensile strength of the sealant reaches 60MPa, which both fixes the fiber optic sensor 300 and seals the installation channel 130.

[0086] In step S600, the assembly of the valve seat-injection molded inner liner 210, which is wrapped with carbon fiber composite winding layer 220 and glass fiber composite winding protective layer 230, is sent into a hot air circulating curing oven and cured according to the corresponding process curve below. After curing, the sealant in the installation channel 130 is checked and found to be free of cracks.

[0087] Process the lead end 310 by cleaning its end face and polishing it with a fiber optic polisher to ensure that the end face roughness Ra≤0.02μm, and then connect it to the ST type fiber optic quick interface.

[0088] A composite material protective cover 400 is installed on the outside of the gas cylinder to further protect the gas cylinder and fiber optic detection system from mechanical damage such as impact and wear.

[0089] By connecting the fiber optic interface to the FBG demodulator, the demodulator is connected to the cloud data platform to form an online monitoring system. It can collect characteristic parameters such as strain, temperature, and hydrogen content of the plastic inner end and the carbon fiber composite winding layer 220 in real time. Specific application scenarios can be diversified depending on the way the demodulator and data processing system are connected.

[0090] The manufacturing method of this invention is perfectly compatible with existing fiber winding processes, requires no major equipment modifications, and is easy to implement for industrial application.

[0091] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0092] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A gas cylinder valve seat structure, characterized in that, include: A valve seat body includes an interface portion, a skirt portion, and at least one mounting channel. The interface portion is a hollow columnar structure. The skirt portion is integrally connected to one end of the interface portion. The skirt portion extends outward around the interface portion. The mounting channel includes a groove channel on the outer surface of the skirt portion located on one side of the interface portion and a through groove channel in the wall of the interface portion. One end of the groove channel extends to the outer edge of the skirt portion, and the other end extends between the skirt portion and the interface portion and communicates with the through groove channel. The end of the through groove channel away from the skirt portion extends to the end of the interface portion away from the skirt portion. The inner liner includes an injection-molded inner liner and a multi-layer fiber winding layer that is wound and fixed around the outer periphery of the injection-molded inner liner. The end face of the injection-molded inner liner is provided with an embedding groove for integrally injection-molding and fixing the skirt portion. The fiber winding layer covers the skirt portion. The fiber optic sensor is provided at least one, which is disposed between the injection-molded inner liner and the multiple layers of fiber winding. The fiber optic sensor is provided with a lead end, which is embedded in the groove channel and led out to the outside in sequence along the groove channel and the through channel.

2. The gas cylinder valve seat structure according to claim 1, characterized in that: The outer surface of the skirt portion located on one side of the interface portion is an arc-shaped conical structure. The through channel and the groove channel are smoothly intersected. The groove channel extends radially along the skirt portion, and the through channel extends axially along the interface portion.

3. The gas cylinder valve seat structure according to claim 1, characterized in that: The surface of the skirt is provided with an anchoring structure, which is used to form an anchoring connection with the injection-molded inner liner.

4. The gas cylinder valve seat structure according to claim 1, characterized in that: The mounting channel is filled with a sealing protector, which is used to protect the fiber optic sensor and seal the mounting channel.

5. The gas cylinder valve seat structure according to claim 1, characterized in that: The groove channel is fitted with a flexible protective sleeve, the optical fiber sensor passes through the flexible protective sleeve, and a buffer pad is provided in the junction area between the skirt, the injection-molded inner liner and the multi-layer fiber winding layer.

6. The gas cylinder valve seat structure according to claim 1, characterized in that: The groove channel has an arc-shaped cross-section, while the through channel has a circular cross-section.

7. The gas cylinder valve seat structure according to claim 1, characterized in that: The installation channels are multiple, and the multiple installation channels are evenly distributed along the circumference of the valve seat body.

8. The gas cylinder valve seat structure according to claim 1, characterized in that: The inner peripheral wall of the interface portion is provided with an internal thread and a first sealing step surface. The injection-molded inner liner is provided with a bottle mouth body fixedly sleeved in the interface portion. The end face of the bottle mouth body is in sealing contact with the first sealing step surface. The inner diameter of the bottle mouth body is smaller than the inner diameter of the first sealing step surface, so as to form a second sealing step surface on the end face of the bottle mouth body.

9. A type IV gas cylinder, characterized in that, Includes the gas cylinder valve seat structure as described in any one of claims 1 to 8.

10. A method for manufacturing a Type IV gas cylinder, characterized in that, The manufacturing method applicable to the Type IV gas cylinder of claim 9 includes: The valve seat body is processed according to the required number and layout of the fiber optic sensors to produce a preset number and preset distribution of the installation channels; The valve seat body and the inner liner body are integrally injection molded together by embedded injection molding to form an assembly; The fiber winding layers are sequentially wound onto the surface of the assembly, and the fiber optic sensor is simultaneously fixedly laid on the outer surface of the injection-molded inner liner and / or between two adjacent fiber winding layers. The lead end of the fiber optic sensor is embedded in the groove channel and sequentially led out to the outside along the groove channel and the through channel. During the laying and installation of the fiber optic sensor, the fiber optic sensor is tested online in real time. If signal attenuation or interruption is detected, the winding process is stopped and repaired. The groove channel and the through channel are sealed and filled. Heating and curing are performed according to the preset process curve.

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