High-pressure gas storage cylinder capable of reducing breathing effect and monitoring health and preparation method of high-pressure gas storage cylinder

Abstract

The invention discloses a high-pressure gas storage cylinder capable of reducing the breathing effect and monitoring health and a preparation method. The high-pressure gas storage cylinder comprises an inner container, a pressure-bearing framework, a bonding layer, a reinforcing layer, an outer protective layer and a health monitoring module. The pressure-bearing framework is arranged in an inner cavity of the inner container and is tightly connected with the inner container; the pressure-bearing framework comprises a supporting ring, an inclined supporting ring and a supporting shaft; the bonding layer is arranged on the outer surface of the inner container; the reinforcing layer wraps the outer side of the bonding layer in a winding manner; the outer protection layer is arranged on the outer side of the enhancement layer; the health monitoring module comprises a micro-deformation sensor, a temperature sensor and a data processor; the preparation method comprises the steps of core mold pretreatment, inner container forming, bonding layer coating, reinforcing layer winding and demolding and post-treatment. The gas storage bottle can effectively solve the problems that in the prior art, the breathing effect is prominent, interlayer combination is not firm, health monitoring is lack, and the deformation resistance is insufficient, the use safety is improved, and the service life is prolonged.

Description

Technical Field

[0001] This invention relates to the field of high-pressure gas cylinder technology, specifically to a high-pressure gas cylinder that can reduce respiratory effects and also has health monitoring capabilities, and its preparation method. Background Technology

[0002] High-pressure gas cylinders are widely used in key areas such as hydrogen energy storage and transportation, industrial gas supply, emergency respiratory protection, and on-board gas supply for new energy vehicles. Among them, composite material high-pressure gas cylinders have become the mainstream development direction due to their advantages of lightweight and high pressure resistance. However, the following specific and urgent technical problems exist in the existing technology: Technical Problem 1: Prominent Breathing Effect and Poor Structural Stability: Under repeated inflation and depressurization cycles, the internal pressure of existing high-pressure gas cylinders undergoes periodic and drastic changes, resulting in a significant "breathing effect." This causes frequent expansion and contraction deformation of the inner liner and the outer reinforcing structure. After long-term service, this deformation can directly lead to defects such as peeling of the interface between the inner liner and the reinforcing layer, delamination and loosening, and local bulging, significantly shortening the service life of the gas cylinder and reducing its pressure-bearing stability, posing a safety hazard.

[0003] Technical problem two: weak interlayer bonding force, prone to interface failure: The outer surface of the inner liner of traditional high-pressure gas cylinders is mostly a smooth and flat structure, and there is no effective mechanical interlocking structure at the interface with the adhesive layer and fiber reinforcement layer, resulting in insufficient bonding force. During the molding and long-term pressure bearing process, micro gaps are easily generated between the layers, which not only aggravates the structural damage caused by the breathing effect, but also causes local stress concentration, induces the initiation and propagation of microcracks, and further reduces the mechanical load-bearing capacity and airtight barrier effect of the cylinder.

[0004] The third technical problem is the lack of in-situ real-time health monitoring, leading to delayed hazard identification: Currently, high-pressure gas cylinders on the market are not equipped with effective in-situ health monitoring devices. They can only rely on offline sampling inspections such as periodic shutdowns and disassemblies, industrial CT scans, and ultrasonic testing to identify structural hazards. This method has strong detection lag, high detection costs, and low efficiency. It cannot capture key service parameters such as cylinder deformation, interface damage, and sudden changes in ambient temperature in real time. When hidden faults such as early micro-cracks, interface delamination, and overheating occur in the gas cylinder, there is no early warning, which can easily lead to major safety accidents such as leaks and cylinder explosions. Summary of the Invention

[0005] The purpose of this invention is to provide a high-pressure gas cylinder that can reduce the breathing effect and has health monitoring capabilities, as well as a method for its preparation. This gas cylinder solves the technical problems of existing gas cylinders, such as prominent breathing effect, poor structural stability, weak interlayer bonding, easy interface failure, lack of in-situ real-time health monitoring, and delayed hazard investigation.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A high-pressure gas cylinder that can reduce respiratory effects and also has health monitoring functions includes an inner liner, a pressure-bearing frame, an adhesive layer, a reinforcing layer, an outer protective layer, and a health monitoring module. The pressure-bearing skeleton is disposed in the inner cavity of the inner liner, and the pressure-bearing skeleton is tightly connected to the inner liner; The pressure-bearing frame includes a support ring, a diagonal brace ring, and a support shaft. Multiple support rings and multiple diagonal brace rings are fixedly mounted on the support shaft. The outer surfaces of the support rings and diagonal brace rings are all attached to the inner wall of the inner liner. The adhesive layer is disposed on the outer surface of the inner liner; The reinforcing layer is wrapped around the outside of the adhesive layer by a winding method; The outer protective layer is disposed on the outside of the reinforcing layer; The health monitoring module includes a micro-deformation sensor, a temperature sensor, and a data processor. The micro-deformation sensor is located on the outside of the adhesive layer and is used to detect the deformation of the reinforcing layer. The temperature sensor is located at the bottleneck of the gas cylinder and is used to detect the ambient temperature. The data processor is located on the outside of the gas cylinder and is used to process the signals measured by the micro-deformation sensor and the temperature sensor. A wireless transmission module is provided on the data processor, which sends the electrical signal generated by the data processor to the terminal device.

[0007] Preferably, an interface roughness is integrally formed on the outer surface of the inner liner to improve the adhesion of the adhesive layer.

[0008] Preferably, the interface roughness includes a plurality of alternating protrusions and depressions; the top surface of the adhesive layer is flush with the top of the protrusions.

[0009] Preferably, the inner liner is made of thermoplastic resin.

[0010] Preferably, the reinforcing layer is formed by impregnating a resin matrix with fiber filaments and then winding them around the surface of the adhesive layer.

[0011] Preferably, the height of the protrusion is 0.1 to 0.5 mm, and the depth of the depression is 0.1 to 0.3 mm.

[0012] Preferably, the adhesive layer is composed of epoxy resin and silane coupling agent, wherein the mass fraction of the silane coupling agent is 3% to 8%.

[0013] Preferably, the thickness of the reinforcing layer is 2–10 mm.

[0014] Preferably, the thermoplastic resin is one or more of polyamide, polybutylene terephthalate, and polycarbonate.

[0015] A method for preparing a high-pressure gas cylinder that can reduce respiratory effects and also has health monitoring capabilities includes the following steps: Step 1, core mold pretreatment; select a demoldable core mold and splice the support ring and diagonal brace ring with the core mold. After splicing, the support ring and diagonal brace ring are flush with the outer surface of the core mold. Step 2, Inner Liner Molding: The thermoplastic resin is heated to a molten state, extruded and coated onto the core mold surface, and simultaneously pressed into one piece to form protrusions and depressions. Heat preservation treatment is then applied to initially shape the inner liner. Step 3: Apply adhesive layer. Apply adhesive layer material to the outer surface of the inner liner under high pressure, so that the material fills the depressions and is flush with the top of the protrusions, and let it stand to soak. Attach multiple micro-deformation sensors to the outside of the adhesive layer. Step 4: Reinforcing layer winding. After impregnating the fiber filaments with the resin matrix, they are wound around the outside of the adhesive layer; the signal lines of the micro-deformation sensor are exposed. Step 5: Demolding and post-processing, remove the core mold, spray the outer protective layer; install the temperature sensor and data processor.

[0016] This invention specifically addresses the problems of prominent breathing effects and poor structural stability: It incorporates a pressure-bearing skeleton composed of a support ring, a diagonal brace ring, and a support shaft within the cylinder's inner cavity. The outer wall of the skeleton closely fits the inner wall of the inner liner, providing all-around rigid support and significantly offsetting the periodic expansion and contraction stress generated by high-pressure cyclic filling and depressurization. This substantially reduces deformation, delamination, and bulging caused by breathing effects. The diagonal brace ring is adapted to the stress concentration area on the cylinder shoulder, further optimizing the stress distribution, avoiding localized overload damage, ensuring long-term structural stability of the cylinder, and extending its service life.

[0017] To specifically address the issues of weak interlayer bonding and susceptibility to interface failure: The alternating protrusions and depressions on the integrally molded outer surface of the inner liner form an interface roughness. Combined with the design of limited dimensional parameters, the adhesive layer can fully fill the depressions and align with the protrusions, forming a strong mechanical interlocking structure. At the same time, a special adhesive layer formula using epoxy resin composite silane coupling agent is adopted to achieve chemical cross-linking between the inner liner and the reinforcing layer, doubly enhancing the interlayer adhesion, completely eliminating interlayer micro-gaps, preventing peeling and delamination, and effectively improving the gas cylinder's airtightness and overall integral molding quality.

[0018] This system specifically addresses the issues of lacking in-situ real-time health monitoring and delayed hazard identification: It integrates a micro-deformation sensor, a temperature sensor, a data processor, wireless transmission, and an alarm module. The micro-deformation sensor collects reinforcement layer deformation data in real time, accurately reporting early hidden defects such as interface delamination and micro-cracks. The temperature sensor monitors the bottleneck environment temperature in real time. Both types of signals are simultaneously transmitted to the data processor for analysis and processing, and then uploaded to the terminal device via the wireless module. When parameters exceed the threshold, an audible and visual alarm is automatically triggered. This eliminates the need for offline disassembly and testing, enabling 24 / 7 uninterrupted in-situ health monitoring, completely resolving the problem of delayed hazard identification, improving the convenience and safety of use and management, and preventing major safety accidents such as leaks and bottle explosions.

[0019] To specifically address the issues of insufficient internal rigid support and deformation resistance: An internal pressure-bearing skeleton significantly enhances the inner liner's resistance to radial deformation, mitigating the negative impact of the breathing effect. Simultaneously, optimized molding processes limit the thickness of the reinforcing layer, the carbon fiber impregnation ratio, and winding parameters. A stepped vacuum co-curing process ensures simultaneous curing and bonding of the inner liner, adhesive layer, and reinforcing layer, guaranteeing a seamless, wrinkle-free, and stable multi-layered structure, thus improving overall integrity. The outer polyurethane protective layer effectively resists corrosion, wear, and impact, further extending the overall service life of the gas cylinder. It is suitable for various high-pressure operating environments, reducing maintenance and repair costs, and promoting the safe industrialization and widespread adoption of high-pressure gas cylinders. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a partial structural diagram of the present invention; In the diagram: 1. Inner liner; 2. Pressure-bearing frame; 3. Adhesive layer; 4. Reinforcing layer; 5. Outer protective layer; 6. Micro-deformation sensor; 7. Temperature sensor; 8. Data processor; 9. Protrusion; 10. Depression; 20. Support ring; 21. Diagonal brace ring; 22. Support shaft. Detailed Implementation

[0021] The present invention will be further described below with reference to the accompanying drawings: like Figure 1 and Figure 2 The high-pressure gas cylinder shown can reduce respiratory effects and has health monitoring capabilities, including an inner liner 1, a pressure-bearing frame 2, an adhesive layer 3, a reinforcing layer 4, an outer protective layer 5, and a health monitoring module.

[0022] The inner liner 1 is made of thermoplastic resin. The thermoplastic resin is one or more of polyamide, polybutylene terephthalate, and polycarbonate. The inner liner 1 can be integrally formed by blow molding or by rotational molding.

[0023] An interface roughening body is integrally formed on the outer surface of the inner liner 1. The interface roughening body is used to improve the adhesion of the adhesive layer 3. The interface roughening body includes a number of alternately arranged protrusions 9 and depressions 10; the top surface of the adhesive layer 3 is flush with the top of the protrusions 9. The height of the protrusions 9 is 0.1 to 0.5 mm; the depth of the depressions 10 is 0.1 to 0.3 mm.

[0024] The pressure-bearing frame 2 is disposed within the inner cavity of the inner liner 1 and is tightly connected to the inner liner 1. The pressure-bearing frame 2 includes support rings 20, diagonal bracing rings 21, and a support shaft 22. Multiple support rings 20 are fixedly mounted on the support shaft 22 via support rods, and two diagonal bracing rings 21 are fixedly mounted on the support shaft 22 via support rods. The outer surfaces of the support rings 20 and the diagonal bracing rings 21 are both attached to the inner wall of the inner liner 1. The two diagonal bracing rings 21 are located at the shoulders of the gas cylinder at both ends, and the multiple support rings 20 are located at the body of the cylinder between the two diagonal bracing rings 21.

[0025] The adhesive layer 3 is disposed on the outer surface of the inner liner 1. The adhesive layer 3 is composed of epoxy resin and silane coupling agent, with the mass fraction of the silane coupling agent being 3% to 8%.

[0026] The reinforcing layer 4 is wrapped around the outside of the adhesive layer 3 by a winding method. The reinforcing layer 4 is formed by impregnating carbon fiber filaments with a resin matrix and then winding them around the surface of the adhesive layer 3. The thickness of the reinforcing layer 4 is 2 to 10 mm.

[0027] The outer protective layer 5 is placed on the outside of the reinforcing layer 4. A polyurethane outer protective layer is applied to the outside of the reinforcing layer 4 using a spraying process, with a coating thickness of 0.2-0.3 mm. After coating, it is cured at room temperature for 24 hours to ensure that the outer protective layer is uniform, free of bubbles and cracks, and to achieve comprehensive protection for the reinforcing layer 4.

[0028] The health monitoring module includes a micro-deformation sensor 6, a temperature sensor 7, and a data processor 8. All three components—micro-deformation sensor 6, temperature sensor 7, and data processor 8—are commercially available and their structures are not described in detail in this specification. The micro-deformation sensor 6 is located on the outside of the adhesive layer 3 and is used to detect the deformation of the reinforcing layer 4, indirectly reflecting potential problems such as interface delamination and microcracks. Specifically, when delamination or microcracks occur at the interface, the deformation of the reinforcing layer 4 will change abnormally, and the micro-deformation sensor 6 will transmit the deformation signal to the data processor 8.

[0029] Temperature sensor 7 is installed at the bottleneck of the gas cylinder to detect the ambient temperature and transmit the detected temperature signal to data processor 8 in real time.

[0030] The data processor 8 is located on the outside of the gas cylinder and is used to process the signals measured by the micro-deformation sensor 6 and the temperature sensor 7.

[0031] A wireless transmission module is provided on the data processor 8. The wireless transmission module sends the electrical signals generated by the data processor 8 to the terminal device, which can be a monitoring host or a mobile APP.

[0032] An alarm module is also provided on the data processor 8. When the ambient temperature is higher or lower than a preset threshold, and / or when the deformation of the reinforcement layer 4 changes abnormally, the alarm module will issue a warning light or sound.

[0033] like Figure 1 and Figure 2 The method for preparing a high-pressure gas cylinder that can reduce respiratory effects and also has health monitoring capabilities includes the following steps: Step 1: Core mold pretreatment; Select a demoldable core mold, grind and polish the surface of the core mold to remove surface impurities and burrs, then apply a release agent to the surface of the core mold. The thickness of the release agent should be controlled between 0.01 and 0.02 mm. After even application, let it dry for later use. The core mold is composed of several pieces. During assembly, the support ring 20 and the diagonal brace ring 21 are integrally assembled with the core mold. After assembly, the support ring 20 and the diagonal brace ring 21 are smooth and flush with the outer surface of the core mold.

[0034] Step 2: Molding of the inner liner 1. The thermoplastic resin is heated to a molten state at a temperature of 180–220°C. The molten thermoplastic resin is uniformly coated onto the surface of the pretreated core mold and the pressure-bearing frame 2 using a vacuum-assisted extrusion molding method. The coating thickness is 1–3 mm. At the same time, protrusions 9 and depressions 10 are formed on the surface of the molten resin by pressing with a mold. During the pressing process, the pressure is controlled at 0.5–1.0 MPa, the temperature is maintained at 180–200°C, and the temperature is held for 30–60 minutes to initially form the inner liner 1. At this time, the inner liner 1 is in an incompletely cured state, and the protrusions 9 and depressions 10 on the outer surface remain active.

[0035] Step 3: Apply adhesive layer 3. Apply adhesive layer 3 material to the outer surface of the inner liner 1 under high pressure, so that the material fills the depression 10 and is flush with the top of the protrusion 9, and let it stand to soak. Attach multiple micro-deformation sensors 6 to the outside of adhesive layer 3.

[0036] Specifically, during the coating process, a high-pressure spraying method is used, with a spraying pressure of 1.5 to 2.0 MPa, to ensure that the adhesive layer 3 material is fully filled into the recess 9 of the inner liner 1 and is flush with the top of the protrusion 10. After coating, let it stand naturally for 10 to 20 minutes to allow the adhesive layer 3 to fully wet the surface of the inner liner 1.

[0037] Step 4: Reinforcing layer 4 is wound by impregnating the fiber filaments with the resin matrix and then winding them around the outside of the adhesive layer 3; the signal lines of the micro-deformation sensor 6 are exposed.

[0038] Specifically, using the inner liner 1 coated with adhesive layer 3 as the mandrel, a fiber winding machine is used for fiber winding. During the winding process, carbon fiber filaments are impregnated with a resin matrix, with the impregnation amount controlled at 30%–40%. The winding tension is 50–100 N, and the winding angle is adjusted to 20°–90° according to the pressure requirements of the gas cylinder. The number of winding layers is determined according to the thickness requirements of the fiber reinforcement layer. During the winding process, the mandrel rotation speed is maintained at 100–200 r / min to ensure that the fiber layer is wound evenly, without wrinkles, and without loosening. After winding, the reinforcement layer 4 and adhesive layer 3 are tightly bonded together without any gaps. The signal lines of the micro-deformation sensor 6 are pressed layer by layer into the reinforcement layer 4 and finally exposed and electrically connected to the data processor 8. The signal lines of the micro-deformation sensor 6 are high-temperature resistant lines and will not be damaged during subsequent co-curing treatment.

[0039] The preform is placed in a curing oven and vacuum co-cured using a stepped heating method. The vacuum level is controlled between -0.09 and -0.1 MPa; the stepped heating process is: room temperature → 80~100℃ → 120~140℃ → 160~180℃, and the cooling rate is 5~10℃ / h.

[0040] The specific heating process is as follows: heat from room temperature to 80-100℃ and hold for 60-90 minutes; then heat to 120-140℃ and hold for 120-180 minutes; finally heat to 160-180℃ and hold for 60-90 minutes, and then slowly cool down to room temperature at a rate of 5-10℃ / h. During the co-curing process, the inner liner 1, adhesive layer 3, and reinforcing layer 4 are cured simultaneously. Adhesive layer 3 achieves chemical cross-linking between the inner liner 1 and reinforcing layer 4. At the same time, the protrusions 10 and depressions 9 form a mechanical interlock with adhesive layer 3, forming a gapless integrated structure.

[0041] Step 5, demolding and post-processing: remove the core mold, spray the outer protective layer 5; install the temperature sensor 7 and data processor 8.

[0042] Specifically, after co-curing, the gas cylinder blank is removed from the curing oven, cooled to room temperature, and then demolded to remove the core mold. Next, both ends of the gas cylinder are sealed, valve interfaces are installed, and finally, the surface of the gas cylinder is polished and cleaned to remove impurities and defects. A polyurethane outer protective layer is applied to the outside of the reinforcing layer 4 using a spraying process, with a coating thickness of 0.2–0.3 mm. After coating, it is cured at room temperature for 24 hours to ensure the outer protective layer is uniform, bubble-free, and crack-free, achieving comprehensive protection for the reinforcing layer 4. The temperature sensor 7 and data processor 8 are fixed to the surface of the outer protective layer 5.

[0043] The above embodiments are merely illustrative of the concept and implementation of the present invention and are not intended to limit it. Under the concept of the present invention, technical solutions without substantial changes are still within the scope of protection.

Claims

1. A high-pressure gas cylinder that can reduce respiratory effects and also provides health monitoring, characterized in that: It includes an inner liner (1), a pressure-bearing frame (2), an adhesive layer (3), a reinforcing layer (4), an outer protective layer (5), and a health monitoring module; The pressure-bearing frame (2) is disposed in the inner cavity of the inner liner (1), and the pressure-bearing frame (2) is tightly connected to the inner liner (1); The pressure-bearing frame (2) includes a support ring (20), a diagonal brace ring (21) and a support shaft (22). Multiple support rings (20) and multiple diagonal brace rings (21) are fixedly arranged on the support shaft (22). The outer surfaces of the support rings (20) and the diagonal brace rings (21) are attached to the inner wall of the inner liner (1). The adhesive layer (3) is disposed on the outer surface of the inner liner (1); The reinforcing layer (4) is wrapped around the outside of the adhesive layer (3) by a winding method; The outer protective layer (5) is disposed on the outside of the reinforcing layer (4); The health monitoring module includes a micro-deformation sensor (6), a temperature sensor (7), and a data processor (8). The micro-deformation sensor (6) is located on the outside of the adhesive layer (3) and is used to detect the deformation of the reinforcing layer (4). The temperature sensor (7) is located at the bottleneck of the gas cylinder and is used to detect the ambient temperature. The data processor (8) is located on the outside of the gas cylinder and is used to process the signals measured by the micro-deformation sensor (6) and the temperature sensor (7). A wireless transmission module is provided on the data processor (8), and the wireless transmission module sends the electrical signal generated by the data processor (8) to the terminal device.

2. The high-pressure gas cylinder that reduces respiratory effects and provides health monitoring according to claim 1, characterized in that: An interface roughness is integrally provided on the outer surface of the inner liner (1) to improve the adhesion of the adhesive layer (3).

3. The high-pressure gas cylinder that reduces respiratory effects and provides health monitoring according to claim 2, characterized in that: The interface roughness includes several alternating protrusions (9) and depressions (10); the top surface of the adhesive layer (3) is flush with the top of the protrusions (9).

4. The high-pressure gas cylinder that reduces respiratory effects and provides health monitoring according to claim 1 or 3, characterized in that: The inner liner (1) is made of thermoplastic resin.

5. The high-pressure gas cylinder that reduces respiratory effects and provides health monitoring according to claim 4, characterized in that: The reinforcing layer (4) is formed by impregnating a resin matrix with fiber filaments and then winding them around the surface of the adhesive layer (3).

6. The high-pressure gas cylinder that reduces respiratory effects and provides health monitoring according to claim 3, characterized in that: The height of the protrusion (9) is 0.1 to 0.5 mm; the depth of the depression (10) is 0.1 to 0.3 mm.

7. The high-pressure gas cylinder that reduces respiratory effects and provides health monitoring according to claim 1 or 5, characterized in that: The adhesive layer (3) is composed of epoxy resin and silane coupling agent, with the mass fraction of silane coupling agent being 3% to 8%.

8. The high-pressure gas cylinder that reduces respiratory effects and provides health monitoring according to claim 7, characterized in that: The thickness of the reinforcing layer (4) is 2 to 10 mm.

9. The high-pressure gas cylinder that reduces respiratory effects and provides health monitoring according to claim 5, characterized in that: The thermoplastic resin is one or more of polyamide, polybutylene terephthalate, and polycarbonate.

10. A method for preparing a high-pressure gas cylinder that reduces respiratory effects and provides health monitoring, as described in any one of claims 1 to 9, characterized in that: Includes the following steps: Step 1, core mold pretreatment; select a demoldable core mold and splice the support ring (20) and the inclined support ring (21) with the core mold. After splicing, the support ring (20) and the inclined support ring (21) are flush with the outer surface of the core mold. Step 2, Inner liner (1) molding: The thermoplastic resin is heated to a molten state, extruded and coated on the core mold surface, and at the same time, protrusions (9) and depressions (10) are formed by pressing. Heat preservation treatment makes the inner liner (1) initially formed. Step 3: Apply adhesive layer (3). Apply adhesive layer (3) material to the outer surface of the inner liner (1) under high pressure, so that the material fills the depression (10) and is flush with the top of the protrusion (9), and let it stand to soak. Attach multiple micro-deformation sensors (6) to the outside of the adhesive layer (3). Step 4, reinforcing layer (4) winding: After impregnating the fiber filaments with the resin matrix, they are wound around the outside of the adhesive layer (3); the signal lines of the micro-deformation sensor (6) are exposed; Step 5, demolding and post-processing: remove the core mold and spray the outer protective layer (5); install the temperature sensor (7) and data processor (8).

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