A method for manufacturing a full-wrapped gas cylinder and the gas cylinder

Abstract

The present application relates to hydrogen storage cylinder preparation technical field, the present application provides a kind of preparation method and gas cylinder of full winding gas cylinder, preparation method includes: step S1: by rotomolding preparation plastic liner, and preset metal bottle mouth connector;Step S2: multiple rubber layers and winding layers are sequentially arranged on the outer surface of plastic liner;Step S3: setting connector sealing assembly, for cooperating with metal bottle mouth connector sealing;Wherein, the winding layer in step S2 is formed by winding machine winding, when winding, using rigid reinforcing component to enhance the rigidity of plastic liner, rigid reinforcing component is attracted by the magnetic force of inside and outside of plastic liner and is matched to enhance the rigidity of plastic liner.The present application is set by the setting of magnetic force auxiliary device of inside and outside cooperation, significantly increase the rigidity of plastic liner winding position, improve the winding effect of fiber layer, by the setting of rubber layer, the different elastic modulus and thermal expansion coefficient caused by plastic liner and winding layer can form compensation to delamination problem.

Description

Technical Field

[0001] This invention relates to the field of hydrogen storage cylinder technology, and more specifically, to a method for preparing a fully wound cylinder and the cylinder itself. Background Technology

[0002] In recent years, the high-pressure hydrogen storage container widely used internationally is the plastic-lined fiber-wound gas cylinder, which consists of a plastic liner, a nozzle connector, and a fiber winding layer. It has the advantages of being lightweight, having a large capacity, and being resistant to high pressure.

[0003] When the fiber layer is wound onto the plastic liner, the fiber material contains a certain pre-tension. Since the plastic liner itself is weakly rigid, it is easy to deform during the winding process. This results in the fiber layer not being able to fit effectively with the liner, and causes a large deviation in the ellipticity and straightness of the gas cylinder, resulting in a defective gas cylinder that cannot be used in high-pressure application environments.

[0004] Patent CN108790797A discloses an inner liner for a fully wound composite gas cylinder with a plastic inner liner, comprising an inner liner body with several annular protrusions spaced apart on its surface. This inner liner, by incorporating these annular protrusions, increases the inertial torque under stress, thereby increasing its strength, dispersing pressure, and preventing deformation. While this patent increases inner liner strength and reduces deformation to some extent, deformation still easily occurs when the winding is performed away from the annular protrusions. Furthermore, the annular protrusions increase the manufacturing difficulty of the plastic inner liner and can easily lead to uneven thickness in certain areas during production, severely affecting the gas cylinder's lifespan. Summary of the Invention

[0005] The technical problem solved by this invention is that, in the prior art, when the fiber layer is wound on the plastic inner liner, the fiber material contains a certain pre-tension. Since the material of the plastic inner liner itself is weakly rigid, it is easy to deform during the winding process, which leads to the fiber winding layer not being able to fit effectively with the inner liner, and causes a large deviation in the ellipticity and straightness of the gas cylinder, resulting in a defective gas cylinder that cannot be used in high-pressure application environments.

[0006] This invention discloses a method for preparing a fully wound gas cylinder, comprising the following steps:

[0007] Step S1: Prepare the plastic inner liner by rotational molding, and pre-install a metal bottle nozzle connector in the plastic inner liner;

[0008] Step S2: Sequentially apply a first rubber layer, a geodesic winding layer, a circumferential winding layer, a second rubber layer, and a glass fiber winding layer to the outer surface of the plastic inner liner;

[0009] Step S3: Set the connector sealing assembly, which is used to mate with the metal bottle nozzle connector for sealing;

[0010] In step S2, the geodesic winding layer, the circumferential winding layer, and the glass fiber winding layer are wound into shape by a winding machine. During winding, a rigid reinforcement component is used to enhance the rigidity of the plastic liner. A portion of the rigid reinforcement component is located on the inner side of the plastic liner, and another portion is located on the outer side of the plastic liner. The rigid reinforcement components on the inner and outer sides of the plastic liner are magnetically attracted to each other to enhance the rigidity of the plastic liner.

[0011] Furthermore, in step S1, the plastic liner is formed by rotational molding. The rotational molding equipment includes a first base, a first driving component, a second driving component, a first mold, a second mold, and a third driving component. The first driving component is rotatably mounted on the first base and has an upwardly extending support portion. The second driving component is rotatably mounted on the support portion and has a rotatable third driving component. The first mold and the second mold are mounted on the third driving component. The inner cavity after the first mold and the second mold are assembled together is used to prepare the plastic liner. The two metal bottle nipple connectors are respectively fixed to the first mold and the second mold by a screw.

[0012] Furthermore, step S1 includes:

[0013] Step S11: Fix the two metal bottle nipple connectors to the first mold and the second mold respectively;

[0014] Step S12: Place plastic granules in the first mold;

[0015] Step S13: Assemble the first mold and the second mold into one piece;

[0016] Step S14: Start the rotational molding equipment to prepare the plastic inner liner.

[0017] Furthermore, the rigidity enhancement component includes a magnetic auxiliary device and several metal balls. The metal balls are made of ferromagnetic material and are disposed on the inner side of the plastic liner. The magnetic auxiliary device is disposed on the outer side of the plastic liner. The magnetic auxiliary device can provide an electromagnetic field so as to cooperate with the metal balls on the inner side of the plastic liner to clamp the sidewall of the plastic liner, thereby enhancing the rigidity of the plastic liner during winding.

[0018] Furthermore, the magnetic auxiliary device includes an electromagnet, a crossbar, a vertical rod, and a second base. The vertical rod is fixedly connected to the second base. The crossbar is movably mounted on the vertical rod. The electromagnet is mounted on the crossbar at one end near the plastic inner liner. The crossbar is telescopic, and the electromagnet can move closer to or away from the plastic inner liner under the action of the crossbar.

[0019] Furthermore, the winding machine includes a machine body, a lower rotary clamp, an upper rotary clamp, a central shaft, a cross-sectional sealing ring, a shaft surface sealing ring, a rotary joint, an air pipe, and a fiber bundle starting point. The lower and upper rotary clamps are used to clamp the plastic inner liner, and the lower and upper rotary clamps can drive the plastic inner liner to rotate along its axis. The central shaft is provided with a first external thread, which engages with the internal thread of the metal bottle nozzle joint. When the threads are engaged, the central shaft simultaneously connects the lower or upper rotary clamp to the metal bottle nozzle. The connector is fixed in place. The cross-sectional sealing ring is set between the central shaft and the lower or upper rotary clamp. The axial sealing ring is set between the outer circumferential surface of the metal bottle nipple connector and the lower or upper rotary clamp. One end of the rotary connector is rotatably connected to the central shaft, and the other end of the rotary connector is connected to an air pipe. The air pipe communicates with the central hole of the central shaft and is used to inflate the plastic liner during winding. The fiber bundle starting point is set on the machine body and is used to provide fiber bundles towards the plastic liner. The fiber bundle has a certain pre-tension during winding.

[0020] Furthermore, step S2 includes:

[0021] Step S21: Apply a first rubber layer to the outer periphery of the plastic inner liner;

[0022] Step S22: Pour metal balls into the plastic inner liner;

[0023] Step S23: Rotatably mount the plastic inner liner on the winding machine;

[0024] Step S24: Inflate the plastic liner with air;

[0025] Step S25: Activate the magnetic auxiliary device to bring the electromagnet into contact with the outer surface of the plastic inner liner;

[0026] Step S26: Start the winding machine and wind it according to the preset winding pattern to form the preset geodesic winding layer and circumferential winding layer, then stop the machine;

[0027] Step S27: Apply a second rubber layer around the outer periphery of the circumferential winding layer;

[0028] Step S28: Start the winding machine and wind it according to the preset winding pattern to form the preset glass fiber winding layer, then stop the machine.

[0029] Furthermore, the joint sealing assembly includes a baffle, a compensating disc spring, a ring, a fillet weld, and a sealing ring. The metal bottle nozzle joint includes a frustum portion and a cylindrical portion. The frustum portion is disposed within the plastic inner liner, and the cylindrical portion is partially disposed within the plastic inner liner and partially extends out of the plastic inner liner. The baffle, compensating disc spring, and ring are all sleeved on the outer periphery of the portion of the metal bottle nozzle joint that extends out of the plastic inner liner. The inner end face of the baffle abuts against the inner liner shaft end of the plastic inner liner. One end of the compensating disc spring abuts against the outer end face of the baffle, and the other end abuts against the ring. The ring is fixedly connected to the metal bottle nozzle joint by a fillet weld. A cylindrical cavity is formed between the outer periphery of the cylindrical portion of the metal bottle nozzle joint and the plastic inner liner, and a sealing ring is disposed in the cylindrical cavity.

[0030] Furthermore, step S3 includes:

[0031] Step S31: Place the sealing ring in the cylindrical cavity;

[0032] Step S32: Place the baffle over the end of the gas cylinder body;

[0033] Step S33: Set the compensating disc spring on the outer end face of the baffle;

[0034] Step S34: Place the ring on the outer end face of the compensating disc spring;

[0035] Step S35: Weld the ring to the metal bottle nozzle connector, wherein the compensating disc spring maintains preload.

[0036] The present invention also discloses a fully wound gas cylinder, which is manufactured using the preparation method described above.

[0037] Compared with existing technologies, the method for preparing a fully wound gas cylinder and the gas cylinder described in this invention have the following advantages:

[0038] (1) By setting up a magnetic auxiliary device that coordinates the inner and outer parts of the plastic liner, the present invention significantly increases the rigidity of the winding position of the plastic liner, improves the winding effect of the fiber layer, and can also reduce the thickness of the plastic liner to a certain extent, thereby further reducing the weight of the gas cylinder.

[0039] (2) By setting the rubber layer on the outside of the plastic liner, the delamination problem caused by the different elastic modulus and thermal expansion coefficients of the plastic liner, fiber winding layer and glass fiber winding layer can be compensated;

[0040] (3) By setting a compensating disc spring on the bottle nozzle joint, dynamic compensation of displacement and force between the bottle nozzle joint and the plastic inner liner is realized. This overcomes the problem in the prior art that the plastic inner liner and the metal bottle nozzle joint material have large differences in modulus and thermal expansion coefficient, which causes cracks or even fissures in the joint when subjected to cyclic loads due to discontinuity in stiffness. This extends the service life of the metal bottle nozzle joint, thereby extending the overall service life of the gas cylinder. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the fully wound gas cylinder according to an embodiment of the present invention;

[0042] Figure 2 for Figure 1 A magnified view of part A in the middle;

[0043] Figure 3 This is a schematic diagram of the rotational molding equipment described in an embodiment of the present invention;

[0044] Figure 4 This is a schematic cross-sectional view of the rotational molding equipment described in an embodiment of the present invention;

[0045] Figure 5 for Figure 4 A magnified view of part B in the middle;

[0046] Figure 6 This is a three-dimensional structural diagram of the winding machine described in an embodiment of the present invention;

[0047] Figure 7 This is a top view of the winding machine described in an embodiment of the present invention;

[0048] Figure 8 for Figure 7 A partially enlarged schematic diagram of the cross-sectional structure of the CC region.

[0049] Explanation of reference numerals in the attached figures:

[0050] 1. Gas cylinder; 101. Plastic inner liner; 102. First rubber layer; 103. Geodesic winding layer; 104. Circumferential winding layer; 105. Second rubber layer; 106. Glass fiber winding layer; 107. Baffle; 108. Compensating disc spring; 109. Ring; 110. Fillet weld; 111. Metal nozzle connector; 113. Sealing ring; 114. Cylinder body; 115. Cylinder shoulder; 116. Frustum hole; 117. Cylindrical cavity; 118. Inner liner shaft end; 2. Rotational molding equipment; 201. First base; 202. First driving component; 203. Second driving component; 204. First mold; 205. Second mold; 206. Screw; 3. Winding machine; 301. Machine body; 302. Lower rotary clamp; 303. Upper rotary clamp; 304. Central hole shaft; 305. Cross-section sealing ring; 306. Shaft surface sealing ring; 307. Rotary joint; 308. Air pipe; 309. Fiber bundle; 310. Fiber bundle starting point; 311. Electromagnet; 312. Crossbar; 313. Vertical rod; 314. Second base. Detailed Implementation

[0051] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the described embodiments are only some, not all, of the embodiments of this invention. The specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. It should be noted that, unless otherwise specified, the embodiments and features described in these embodiments can be combined with each other.

[0052] During long-term and high-pressure use throughout the entire life cycle of a fully wound gas cylinder, the different elastic moduli and coefficients of thermal expansion of the plastic inner liner, fiber winding layer, and nozzle connector substrate can easily lead to delamination and fatigue microcracks at the joints, resulting in hydrogen leakage. This reduces the high-pressure sealing performance of the gas cylinder, creating safety hazards and seriously affecting its service life.

[0053] The following describes in detail, with reference to the accompanying drawings, a method for preparing a fully wound gas cylinder and the gas cylinder itself, according to an embodiment of the present invention.

[0054] Example 1

[0055] This embodiment provides a method for preparing a fully wound gas cylinder, including the following steps:

[0056] Step S1: Prepare the plastic inner liner 101 by rotational molding, and pre-install a metal bottle nozzle connector 111 in the plastic inner liner 101;

[0057] Step S2: Sequentially arrange a first rubber layer 102, a geodesic winding layer 103, a circumferential winding layer 104, a second rubber layer 105, and a glass fiber winding layer 106 on the outer surface of the plastic inner liner 101.

[0058] Step S3: Set the connector sealing assembly, which is used to cooperate with the metal bottle nipple connector 111 for sealing;

[0059] In step S2, the geodesic winding layer 103, the circumferential winding layer 104, and the glass fiber winding layer 106 are wound and formed by the winding machine 3. During winding, a rigid reinforcement component is used to enhance the rigidity of the plastic inner liner 101. A portion of the rigid reinforcement component is located on the inner side of the plastic inner liner 101, and another portion is located on the outer side of the plastic inner liner 101. The rigid reinforcement components on the inner and outer sides of the plastic inner liner 101 are magnetically attracted to each other to enhance the rigidity of the plastic inner liner 101.

[0060] It should be noted that existing hydrogen storage cylinders are relatively long. When winding the fiber layer onto the surface of their plastic inner liner 101, the ends are typically fixed only by the winding machine 3. During winding, a certain pre-tension force needs to be applied to the fibers. Under these circumstances, when the winding reaches a position a certain distance from the ends, the plastic inner liner 101 is prone to deformation and collapse, severely affecting the cylinder's forming effect. In this example, by setting up a rigidity reinforcement component, the rigidity of the winding position of the plastic inner liner 101 is significantly increased. This ensures the winding effect while also reducing the thickness of the plastic inner liner 101 to a certain extent, further reducing the cylinder's weight. The actual reduction in thickness of the plastic inner liner 101 can be obtained through calculation or simulation based on the specific material properties of the plastic inner liner 101 and the location and intensity of the magnetic force applied; therefore, it is not limited here. Furthermore, the plastic inner liner 101 and the fiber winding layer often deform due to changes in thermal stress. However, because their deformation amounts differ, their deformations cannot be coordinated, making them prone to separation during use. Separation of the two layers poses a safety hazard to the gas cylinder. The fiber winding layer includes a geodesic winding layer 103 and / or a circumferential winding layer 104 and / or a glass fiber winding layer 106. In this example, the first rubber layer 102 and the second rubber layer 105 enable corresponding elastic deformation compensation even when the elastic modulus and thermal expansion coefficients of the plastic inner liner 101, geodesic winding layer 103, circumferential winding layer 104, and glass fiber winding layer 106 differ. This prevents delamination, ensures the stability of the outer structure of the gas cylinder 1, and extends the service life of the gas cylinder 1. It should be noted that the attached diagram only shows the case of one geodesic winding layer 103 and one circumferential winding layer 104. In actual production, multi-layer combination full winding can be carried out according to the gas cylinder design requirements, strength analysis software, winding software and other existing technologies, which will not be elaborated here.

[0061] Specifically, the rigidity enhancement component includes a magnetic auxiliary device and several metal balls. The metal balls are made of ferromagnetic material and are disposed inside the plastic inner liner 101. The magnetic auxiliary device is disposed outside the plastic inner liner 101 and provides an electromagnetic field to cooperate with the metal balls inside the plastic inner liner 101 to clamp the sidewalls of the plastic inner liner 101, thereby enhancing the rigidity of the plastic inner liner 101 during winding. The ferromagnetic material can be iron and / or steel and / or other known ferromagnetic materials, and is not limited thereto.

[0062] Specifically, the diameter of the metal ball is smaller than the diameter of the metal bottle nozzle connector 111. This arrangement facilitates the insertion of the metal ball into the plastic inner liner 101 after molding and the removal of the metal ball after winding, ensuring ease of operation. Preferably, during the winding process, the plastic inner liner 101 is filled with metal balls. This arrangement significantly improves the rigidity of the plastic inner liner 101 during winding and also facilitates the clamping of the metal ball with the magnetic auxiliary device.

[0063] As one example, such as Figure 7 As shown, the magnetic auxiliary device includes an electromagnet 311, a crossbar 312, a vertical rod 313, and a second base 314. The vertical rod 313 is fixedly connected to the second base 314. The crossbar 312 is movably mounted on the vertical rod 313. The electromagnet 311 is mounted on the crossbar 312 near one end of the plastic inner liner 101, and the crossbar 312 is a telescopic structure. The electromagnet 311 can move closer to or away from the plastic inner liner 101 under the influence of the crossbar 312. This configuration allows the electromagnet 311 to move radially and / or axially along the plastic inner liner 101 under the influence of the crossbar 312. This facilitates rigidity reinforcement of the areas closer to the liner during winding at different positions along the length of the plastic inner liner 101, effectively reducing the risk of collapse of the plastic inner liner 101 during winding and improving the production qualification rate of the gas cylinder 1. Optionally, the second base 314 is mounted on the body 301 of the winding machine 3.

[0064] Preferably, during winding, the electromagnet 311 is tangent to the outer surface of the plastic inner liner 101, and the tangent point is located behind the tangent point between the winding fiber bundle 309 and the outer surface of the plastic inner liner 101. It should be understood that during winding, the surface of the fiber bundle 309 is impregnated with resin. Setting the tangent point of the electromagnet 311 behind the tangent point of the fiber bundle 309 avoids the electromagnet 311 affecting the resin on the fiber bundle 309, ensuring the winding effect. It should be noted that "behind" refers to the same position on the surface of the plastic inner liner 101 being tangent to the fiber bundle 309 during the rotational winding process, and then tangent to the electromagnet 311 after winding. The distance between the two tangent points can be calculated or simulated based on data such as the material and thickness of the plastic inner liner 101, the magnetic field strength of the electromagnet 311, and the pre-tension of the fiber bundle 309. Ideally, the rigidity reinforcement component should enhance the rigidity of the winding position; however, this is not further limited here.

[0065] In this example, such as Figures 6-8As shown, the winding machine 3 includes a machine body 301, a lower rotary clamp 302, an upper rotary clamp 303, a central shaft 304, a cross-sectional sealing ring 305, a shaft surface sealing ring 306, a rotary joint 307, an air pipe 308, and a fiber bundle starting point 310. The lower rotary clamp 302 and the upper rotary clamp 303 are used to clamp the plastic inner liner 101, and the lower rotary clamp 302 and the upper rotary clamp 303 can drive the plastic inner liner 101 to rotate along its axis. The central shaft 304 is provided with a first external thread, which is engaged with the internal thread of the metal bottle nozzle joint 111. When the threads are engaged, the central shaft 304 simultaneously connects the lower rotary clamp 302 or the upper rotary clamp 303 to the metal bottle nozzle joint. The 111 joint is fixed in place. The cross-sectional sealing ring 305 is disposed between the central shaft 304 and the lower rotary clamp 302 or the upper rotary clamp 303. The axial sealing ring 306 is disposed between the outer circumferential surface of the metal bottle nipple joint 111 and the lower rotary clamp 302 or the upper rotary clamp 303. One end of the rotary joint 307 is rotatably connected to the central shaft 304. The other end of the rotary joint 307 is connected to the air pipe 308. The air pipe 308 communicates with the central hole of the central shaft 304 and is used to inflate the plastic inner liner 101 with air during winding. The fiber bundle starting point 310 is disposed on the machine body 301 and is used to provide fiber bundles 309 in the direction of the plastic inner liner 101. The fiber bundles 309 have a certain pre-tension during winding. It should be noted that a metal bottle nozzle connector 111 is provided at each end of the plastic inner liner 101. In this case, there are two sets of the central shaft 304, cross-sectional sealing ring 305, shaft surface sealing ring 306, rotary connector 307, and air pipe 308. One set is connected to the upper metal bottle nozzle connector 111 and the upper rotary clamp 303, and the other set is connected to the lower metal bottle nozzle connector 111 and the lower rotary clamp 302. Optionally, the lower rotary clamp 302 is at least partially disposed in the second base 314, and the lower rotary clamp 302 can rotate relative to the second base 314. With the above arrangement, the plastic inner liner 101 can be fixedly mounted on the winding machine 3 and rotated and wound under the drive of the lower rotary clamp 302 and the upper rotary clamp 303. With the addition of the rigidity reinforcement component, the rigidity of the winding part is significantly improved, avoiding the risk of the plastic inner liner 101 collapsing during winding, and significantly improving the product qualification rate. The air tube 308 is designed to deliver gas into the plastic inner liner 101, increasing its internal air pressure and thus improving the overall rigidity of the plastic inner liner 101, ensuring the winding effect. It should be noted that the fiber bundle 309 is impregnated with a resin matrix and pre-tensioned during winding.

[0066] Optionally, step S2 includes:

[0067] Step S21: A first rubber layer 102 is fitted around the outer periphery of the plastic inner liner 101;

[0068] Step S22: Pour metal balls into the plastic inner liner 101;

[0069] Step S23: Rotatably mount the plastic inner liner 101 on the winding machine 3;

[0070] Step S24: Inflate the plastic inner liner 101 with air;

[0071] Step S25: Activate the magnetic auxiliary device to bring the electromagnet 311 into contact with the outer surface of the plastic inner liner 101;

[0072] Step S26: Start the winding machine 3 and make it wind according to the preset winding pattern to form the preset geodesic winding layer 103 and circumferential winding layer 104, then stop the machine;

[0073] Step S27: A second rubber layer 105 is fitted around the outer periphery of the circumferential winding layer 104;

[0074] Step S28: Start the winding machine 3 and wind it according to the preset winding pattern to form the preset glass fiber winding layer 106, then stop the machine.

[0075] Through the above settings, a corresponding rubber layer and winding layer can be formed on the outer periphery of the plastic inner liner 101, ensuring the strength and airtightness of the plastic inner liner 101. In step S27, the plastic inner liner 101 needs to be removed after the machine is stopped, and then installed into the winding machine 3 after the second rubber layer 105 is applied. This will not be elaborated further here.

[0076] Optionally, step S23 includes:

[0077] Step S231: Connect the metal bottle nipple connectors 111 at both ends of the plastic inner liner 101 to the lower rotary clamp 302 and the upper rotary clamp 303 respectively through the central hole shaft 304. When connecting, the cross-sectional sealing ring 305 and the shaft surface sealing ring 306 are set simultaneously.

[0078] Step S232: Connect a rotary joint 307 to the central hole shaft 304 at both ends of the plastic inner liner 101, and then connect an air tube 308 to each rotary joint 307.

[0079] With the above settings, the plastic inner liner 101 can be smoothly rotated and wound on the winding machine 3, and air can be injected into the plastic inner liner 101 to increase its rigidity and further improve its winding effect.

[0080] Optionally, in step S2, the first rubber layer 102 and the second rubber layer 105 are two semi-encasing structures, which are formed by bonding. It should be understood that since the cylinder shoulders 115 at both ends of the gas cylinder 1 are contracted structures, the structures of the first rubber layer 102 and the second rubber layer 105 need to be adapted to them. Therefore, the integrally formed first rubber layer 102 and the second rubber layer 105 cannot be fitted onto the plastic inner liner 101. The semi-encasing structure refers to a structure that covers the general length of the gas cylinder 1. The two semi-encasing structures can be fitted onto the plastic inner liner 101 from both ends for easy installation. Optionally, the semi-encasing structure is prepared by compression molding. With prolonged high-pressure and variable-pressure use of the gas cylinder 1, due to the different elastic moduli and coefficients of thermal expansion of the plastic inner liner 101, the fiber winding layer, and the glass fiber winding layer 106, the different deformations generated between the above structures can be compensated by the elastic deformation of the first rubber layer 102 and the second rubber layer 105, thereby effectively preventing delamination and fatigue microcracks, and ensuring the service life of the gas cylinder 1. Optionally, the first rubber layer 102 and the second rubber layer 105 are fluororubber.

[0081] Optionally, in step S1, the plastic inner liner 101 is formed by rotational molding. Generally, the plastic inner liner 101 can be prepared by blow molding or rotational molding. However, in this example, since the metal bottle nozzle connector 111 needs to be partially embedded within the plastic inner liner 101, the corresponding plastic inner liner 101 structure can only be prepared by rotational molding.

[0082] Specifically, such as Figures 3-5As shown, the rotational molding equipment 2 includes a first base 201, a first driving component 202, a second driving component 203, a first mold 204, a second mold 205, and a third driving component (not shown in the figure). The first driving component 202 is rotatably mounted on the first base 201 and has an upwardly extending support portion. The second driving component 203 is rotatably mounted on the support portion and has a rotatable third driving component on the second driving component 203. The first mold 204 and the second mold 205 are mounted on the third driving component. The inner cavity of the first mold 204 and the second mold 205 after assembly is used to prepare the plastic inner liner 101. The two metal bottle nipple connectors 111 are respectively fixed to the first mold 204 and the second mold 205 by a screw 206. Specifically, a first driving device is provided in the first base 201 to drive the first driving member 202 to rotate around its axis. A second driving device is provided in the support part to drive the second driving member 203 to rotate around its connecting axis with the support part as the central axis. A third driving device is provided in the second driving member 203 to drive the assembly of the first mold 204 and the second mold 205 to rotate along their axes. During rotational molding, plastic granules are placed in the first mold 204, and the metal bottle nozzle connector 111 is fixedly set on the first mold 204 and the second mold 205. Then, by means of the above three-axis rotation, the spatial orientation of the mold assembly can be arbitrarily changed to complete the preparation of the plastic inner liner 101.

[0083] Optionally, step S1 includes:

[0084] Step S11: Fix the two metal bottle nipple connectors 111 to the first mold 204 and the second mold 205 respectively;

[0085] Step S12: Place plastic granules inside the first mold 204;

[0086] Step S13: Assemble the first mold 204 and the second mold 205 into one piece;

[0087] Step S14: Start the rotational molding equipment 2 to prepare the plastic inner liner 101.

[0088] With the above settings, the metal bottle nipple connector 111 can be pre-installed into the plastic inner liner 101 during the preparation of the plastic inner liner 101, which facilitates the subsequent winding of the fiber layer and the setting of the connector sealing assembly.

[0089] Specifically, such as Figure 2As shown, the joint sealing assembly includes a baffle 107, a compensating disc spring 108, a ring 109, a fillet weld 110, and a sealing ring 113. The metal bottle nipple joint 111 includes a frustum portion and a cylindrical portion. The frustum portion is disposed within the plastic inner liner 101, and the cylindrical portion is partially disposed within the plastic inner liner 101 and partially extends out of the plastic inner liner 101. The baffle 107, the compensating disc spring 108, and the ring 109 are all sleeved on the metal bottle nipple joint 111 extending out of the plastic inner liner 101. On the outer periphery of the portion, the inner end face of the baffle 107 abuts against the inner liner shaft end 118 of the plastic inner liner 101. One end of the compensating disc spring 108 abuts against the outer end face of the baffle 107, and the other end abuts against the ring 109. The ring 109 is fixedly connected to the metal bottle nozzle connector 111 by a fillet weld 110. A cylindrical cavity 117 is formed between the outer periphery of the cylindrical portion of the metal bottle nozzle connector 111 and the plastic inner liner 101. A sealing ring 113 is provided in the cylindrical cavity 117. The metal bottle nozzle connector 111 is provided with a threaded hole penetrating its cylindrical portion and frustum portion. In the prior art, due to the large difference in modulus and thermal expansion coefficient between the plastic material of the plastic inner liner 101 and the metal material of the metal bottle nozzle connector 111, cracks may appear at the joint due to stiffness discontinuity when subjected to cyclic loads. In addition, thermal stress will be generated under the action of ambient temperature, which will also cause cracks at the joint, resulting in gas leakage from the gas cylinder 1. In this example, the above-mentioned configuration allows the frustum of the metal nozzle connector 111 to form a partially inclined connection with the frustum holes 116 at both ends of the plastic inner liner 101. Although the two are connected by rotational molding, the metal nozzle connector 111 and the plastic inner liner 101 are prone to relative sliding under long-term use and pressure changes. At this time, the compensating disc spring 108 can perform dynamic compensation for displacement and pressure. Combined with the baffle 107 and the sealing ring 113, the sealing effect of the gas cylinder 1 is effectively guaranteed, ensuring its safety in use. It should be understood that the partially inclined connection structure formed by the frustum of the metal nozzle connector 111 and the frustum holes 116 at both ends of the plastic inner liner 101 is insufficient to withstand the pressure changes experienced by the gas cylinder 1 during long-term use, resulting in relative sliding between them. In this case, the compensation disc spring 108 and the sealing ring 113 effectively compensate for the displacement of the metal nozzle connector 111 and ensure the sealing performance of the baffle 107 and the bottle shoulder 115, achieving dynamic sealing of the gas cylinder 1 and extending its service life. The inner end face refers to the end face facing the center of the gas cylinder 1 along its length, and the outer end face refers to the end face facing away from the center of the gas cylinder 1 along its length. Furthermore, in the existing plastic inner liner 101 gas cylinder, the most frequently damaged location during use is the nozzle connector. In this example, the nozzle sealing component compensates for the displacement of the metal nozzle connector 111, significantly reducing the risk of nozzle connector damage and extending the service life of the gas cylinder 1.

[0090] Optionally, the baffle 107 is a metal plate, the ring 109 is a metal part, and the cylindrical cavity 117 is formed by the cylindrical part of the metal bottle nozzle connector 111, the cylindrical holes of the shoulders at both ends of the plastic inner liner 101, and the inner end face of the baffle 107. The sealing ring 113 is disposed in the cylindrical cavity 117, and the sealing ring 113 cooperates with the metal bottle nozzle connector 111, the plastic inner liner 101, and the baffle 107 to seal. Through the above arrangement, the gas cylinder 1 forms a dual compensation mechanism. A rubber layer 102 and a second rubber layer 105 compensate for the deformation difference between the winding layer and the plastic liner 101. The compensating disc spring 108 compensates for the movement of the metal nozzle connector 111 relative to the plastic liner 101. Even with prolonged high-pressure and variable-pressure use, despite differences in the elastic modulus and coefficient of thermal expansion of the plastic liner 101, the fiber winding layer, and the metal nozzle connector 111 substrate, delamination and fatigue microcracks will not occur at the joint, preventing hydrogen leakage and maintaining the high-pressure sealing of the gas cylinder 1. The fillet weld 110 can be either an intermittent weld or a continuous weld; this is not limited here.

[0091] Specifically, step S3 includes:

[0092] Step S31: Place the sealing ring 113 in the cylindrical cavity 117;

[0093] Step S32: Cover the end of the gas cylinder 1 with the baffle 107;

[0094] Step S33: Set the compensating disc spring 108 on the outer end face of the baffle 107;

[0095] Step S34: Set the ring 109 on the outer end face of the compensating disc spring 108;

[0096] Step S35: Weld the ring 109 to the metal bottle nozzle connector 111, wherein the compensating disc spring 108 maintains preload.

[0097] By setting the pre-pressure of the compensating disc spring 108, the compensating disc spring 108 can timely compensate for the deformation of the metal bottle nozzle connector 111, avoiding cracks at the bottle nozzle and ensuring the stability of the gas cylinder 1 in use. The magnitude of the pre-pressure is determined according to the specific specifications of the gas cylinder 1, and will not be elaborated here.

[0098] Example 2

[0099] This embodiment provides a fully wound gas cylinder, which is prepared using the preparation method described in Embodiment 1.

[0100] like Figure 1As shown, the gas cylinder 1 includes a cylinder body 114 and cylinder shoulders 115 disposed at both ends thereon. A metal nozzle connector 111 is disposed at the end of each of the two cylinder shoulders 115. The metal nozzle connector 111 cooperates with the connector sealing assembly to seal.

[0101] The advantages of the fully wound gas cylinder compared to the prior art are the same as those in Embodiment 1, and will not be repeated here.

[0102] It should be noted that all directional and positional terms used in this invention, such as "up," "down," "left," "right," "front," "back," "vertical," "horizontal," "inner," "outer," "top," "lower," "tail end," "head end," and "center," are only used to explain the relative positional relationships and connection situations between components in a specific state. They are merely for the convenience of describing the invention and do not require the invention to be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on the invention. Furthermore, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Additionally, the meaning of "and / or" throughout the text includes three parallel solutions. Taking "A and / or B" as an example, it includes solution A, solution B, or a solution where both A and B are satisfied simultaneously.

[0103] In this invention, unless otherwise explicitly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0104] 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 method for preparing a fully wound gas cylinder, characterized in that, Includes the following steps: Step S1: Prepare a plastic inner liner (101) by rotational molding, and pre-install a metal bottle nozzle connector (111) in the plastic inner liner (101). Step S2: Sequentially arrange a first rubber layer (102), a geodesic winding layer (103), a circumferential winding layer (104), a second rubber layer (105), and a glass fiber winding layer (106) on the outer surface of the plastic inner liner (101). Step S3: Set the connector sealing assembly, which is used to cooperate with the metal bottle nipple connector (111) for sealing; In step S2, the geodesic winding layer (103), the circumferential winding layer (104), and the glass fiber winding layer (106) are wound and formed by a winding machine (3). During winding, a rigid reinforcement component is used to enhance the rigidity of the plastic liner (101). A part of the rigid reinforcement component is located on the inner side of the plastic liner (101), and another part is located on the outer side of the plastic liner (101). The rigid reinforcement components on the inner and outer sides of the plastic liner (101) are attracted by magnetic force to enhance the rigidity of the plastic liner (101). The rigidity enhancement component includes a magnetic auxiliary device and several metal balls. The metal balls are made of ferromagnetic material and are disposed inside the plastic inner liner (101). The magnetic auxiliary device is disposed outside the plastic inner liner (101). The magnetic auxiliary device can provide an electromagnetic field so as to cooperate with the metal balls inside the plastic inner liner (101) to clamp the side wall of the plastic inner liner (101), thereby enhancing the rigidity of the plastic inner liner (101) during winding. The joint sealing assembly includes a baffle (107), a compensating disc spring (108), a ring (109), a fillet weld (110), and a sealing ring (113). The metal bottle nozzle joint (111) includes a frustum and a cylindrical portion. The frustum is disposed within the plastic inner liner (101), and the cylindrical portion is partially disposed within the plastic inner liner (101) and partially extends out of the plastic inner liner (101). The baffle (107), the compensating disc spring (108), and the ring (109) are all fitted onto the portion of the metal bottle nozzle joint (111) that extends out of the plastic inner liner (101). On the outer periphery, the inner end face of the baffle (107) abuts against the inner liner shaft end (118) of the plastic inner liner (101). One end of the compensating disc spring (108) abuts against the outer end face of the baffle (107), and the other end abuts against the ring (109). The ring (109) is fixedly connected to the metal bottle nipple connector (111) by fillet weld (110). A cylindrical cavity (117) is formed between the outer periphery of the cylindrical part of the metal bottle nipple connector (111) and the plastic inner liner (101). A sealing ring (113) is provided in the cylindrical cavity (117).

2. The method for preparing a fully wound gas cylinder as described in claim 1, characterized in that, In step S1, the plastic inner liner (101) is formed by rotational molding. The rotational molding equipment (2) includes a first base (201), a first driving component (202), a second driving component (203), a first mold (204), a second mold (205), and a third driving component. The first driving component (202) is rotatably mounted on the first base (201). The first driving component (202) is provided with an upwardly extending support portion. The second driving component (203) is rotatably mounted on the support portion. The second driving component (203) is provided with a rotatable third driving component. The first mold (204) and the second mold (205) are mounted on the third driving component. The inner cavity after the first mold (204) and the second mold (205) are assembled together is used to prepare the plastic inner liner (101). The two metal bottle nipple connectors (111) are respectively fixed on the first mold (204) and the second mold (205) by a screw (206).

3. The method for preparing a fully wound gas cylinder as described in claim 2, characterized in that, Step S1 includes: Step S11: Fix the two metal bottle nipple connectors (111) to the first mold (204) and the second mold (205) respectively; Step S12: Place plastic granules inside the first mold (204); Step S13: Assemble the first mold (204) and the second mold (205) into one piece; Step S14: Start the rotational molding equipment (2) to prepare the plastic inner liner (101).

4. The method for preparing a fully wound gas cylinder as described in claim 1, characterized in that, The magnetic auxiliary device includes an electromagnet (311), a crossbar (312), a vertical rod (313), and a second base (314). The vertical rod (313) is fixedly connected to the second base (314). The crossbar (312) is movably mounted on the vertical rod (313). The electromagnet (311) is mounted on the crossbar (312) at one end near the plastic inner liner (101). The crossbar (312) is a telescopic structure. The electromagnet (311) can move closer to or away from the plastic inner liner (101) under the action of the crossbar (312).

5. The method for preparing a fully wound gas cylinder as described in claim 4, characterized in that, The winding machine (3) includes a machine body (301), a lower rotary clamp (302), an upper rotary clamp (303), a central shaft (304), a cross-sectional sealing ring (305), a shaft surface sealing ring (306), a rotary joint (307), an air pipe (308), and a fiber bundle starting point (310). The lower rotary clamp (302) and the upper rotary clamp (303) are used to clamp the plastic inner liner (101), and the lower rotary clamp (302) and the upper rotary clamp (303) can drive the plastic inner liner (101) to rotate along its axis. The central shaft (304) is provided with a first external thread, which is engaged with the internal thread of the metal bottle nozzle joint (111). When the threads are engaged, the central shaft (304) simultaneously connects the lower rotary clamp (302) or the upper rotary clamp (303) with the metal bottle nozzle joint (111). 111) The cross-sectional sealing ring (305) is set between the central shaft (304) and the lower rotary clamp (302) or the upper rotary clamp (303). The axial sealing ring (306) is set between the outer circumferential surface of the metal bottle nipple connector (111) and the lower rotary clamp (302) or the upper rotary clamp (303). One end of the rotary connector (307) is rotatably connected to the central shaft (304). The other end of the rotary connector (307) is connected to the air pipe (308). The air pipe (308) is connected to the central hole of the central shaft (304) and is used to inflate the plastic inner liner (101) with air during winding. The fiber bundle starting point (310) is set on the machine body (301) and is used to provide fiber bundles (309) to the direction of the plastic inner liner (101). The fiber bundles (309) have a certain pre-tension during winding.

6. The method for preparing a fully wound gas cylinder as described in claim 5, characterized in that, Step S2 includes: Step S21: A first rubber layer (102) is fitted around the outer periphery of the plastic inner liner (101); Step S22: Pour metal balls into the plastic inner liner (101); Step S23: Rotatably mount the plastic inner liner (101) on the winding machine (3); Step S24: Inflate the plastic inner liner (101) with air; Step S25: Activate the magnetic auxiliary device to make the electromagnet (311) contact the outer surface of the plastic inner liner (101); Step S26: Start the winding machine (3) and make it wind according to the preset winding pattern to form the preset geodesic winding layer (103) and circumferential winding layer (104) and then stop the machine; Step S27: Apply a second rubber layer (105) around the outer periphery of the circumferential winding layer (104); Step S28: Start the winding machine (3) and wind it according to the preset winding pattern to form the preset glass fiber winding layer (106) and then stop the machine.

7. The method for preparing a fully wound gas cylinder as described in claim 1, characterized in that, Step S3 includes: Step S31: Place the sealing ring (113) in the cylindrical cavity (117); Step S32: Place the baffle (107) over the end of the gas cylinder (1); Step S33: Set the compensating disc spring (108) on the outer end face of the baffle (107); Step S34: Place the ring (109) on the outer end face of the compensating disc spring (108); Step S35: Weld the ring (109) to the metal bottle nozzle connector (111), wherein the compensating disc spring (108) maintains preload.

8. A fully wound gas cylinder, characterized in that, The gas cylinder (1) is manufactured using the preparation method described in any one of claims 1-7.

Images