A carbon fiber composite gas storage cylinder structure

Abstract

This utility model relates to the field of structural optimization design technology for gas storage devices, and particularly to a carbon fiber composite gas storage cylinder structure, comprising a first plastic shell, one end of which is connected to a second plastic shell. A weld is formed at the connection between the first and second plastic shells. Several nut fixing seats are provided on the surfaces of both the first and second plastic shells. This utility model achieves simultaneous improvement in the strength of the fixing structure and the injection molding quality by providing several nut fixing seats on the outer surfaces of the first and second plastic shells, and by providing thickened areas and surface colloid channels within them. The thickened areas can effectively bear the locking load of the nuts, while the colloid channels improve the uniformity of molten adhesive filling, prevent local shrinkage or structural defects, and significantly enhance the reliability of the insert fixing and the fatigue life of the connection parts.

Description

Technical Field

[0001] This utility model relates to the technical field of structural optimization design of gas storage devices, specifically a carbon fiber composite gas storage cylinder structure. Background Technology

[0002] In technological fields such as vehicle air suspension systems, which have high requirements for compressed gas energy storage, the air tank, as a key component, must possess excellent airtightness, pressure resistance, and structural stability. Existing air tanks are mainly made of aluminum alloy or aluminum-magnesium alloy, manufactured through processes such as spinning and welding to meet their pressure resistance requirements. However, in order to achieve lightweighting and cost reduction goals, the structural optimization of traditional metal cylinders is constrained by factors such as material density, welding stress concentration, and the inability to further reduce thickness, resulting in slow overall modernization progress and making it difficult to simultaneously achieve strength, quality, and cost control.

[0003] In recent years, some companies have attempted to introduce composite materials to replace traditional metal shells, using an inner liner injection-molded and outer carbon fiber winding layer to improve overall performance by leveraging the high specific strength of composite materials. However, in practical applications, it has been found that this type of structure is prone to damage or loosening in the nut insert fixing area due to insufficient local injection molding or stress concentration. At the same time, there is a lack of structural reinforcement methods for the insert positioning area, resulting in a high fatigue failure rate of the connectors, which affects the long-term reliability of the gas tank in high-frequency use scenarios. A mature and stable product structure system has not yet been formed. Utility Model Content

[0004] The purpose of this utility model embodiment is to provide a carbon fiber composite gas storage cylinder structure, which aims to solve the technical problems mentioned in the background art.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] A carbon fiber composite gas storage cylinder structure includes a first plastic shell, one end of which is connected to a second plastic shell. A weld is formed at the connection between the first and second plastic shells. Several nut fixing seats are provided on the surface of both the first and second plastic shells. Thickened areas are provided inside the first and second plastic shells at positions corresponding to the nut fixing seats. Colloidal flow channels are provided on the surface of the thickened areas.

[0007] Furthermore, the length of the colloidal flow channel is 10mm-40mm, and the depth is 0.25mm-2mm.

[0008] Furthermore, both the first and second plastic shells have pole holes at their ends, and a head reinforcement block is provided at the pole hole.

[0009] Furthermore, reinforcing ribs for the polar holes are provided inside both the first and second plastic shells near the polar holes.

[0010] Furthermore, the head reinforcement block is provided with a hot-swappable nut inside, and a quick-connect fitting is installed inside the hot-swappable nut.

[0011] Furthermore, the outer sides of the first and second plastic shells are wrapped with carbon fiber winding layers.

[0012] The carbon fiber composite gas storage cylinder structure provided by this utility model has the following beneficial effects:

[0013] This invention achieves simultaneous improvement in the strength of the fixing structure and the quality of injection molding by setting several nut fixing seats on the outer surfaces of the first and second plastic shells, and setting thickened areas and surface colloid channels inside them. The thickened areas can effectively bear the locking load of the nuts, while the colloid channels improve the uniformity of molten adhesive filling, prevent local shrinkage or structural defects, and significantly enhance the reliability of insert fixing and the fatigue life of the connection parts. The above structural design takes into account both the stress performance and the stability of the manufacturing process, improves the assembly strength and long-term reliability of the overall gas storage cylinder, and has good application value. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of a carbon fiber composite gas storage cylinder structure.

[0015] Figure 2 This is a schematic diagram of a carbon fiber composite gas storage cylinder structure in which the first plastic shell and the second plastic shell are in a split state.

[0016] Figure 3 This is a schematic diagram of the internal structure of the first plastic shell in a carbon fiber composite gas storage cylinder structure.

[0017] Figure 4 This is a schematic diagram of the internal structure of the second plastic shell in a carbon fiber composite gas storage cylinder structure.

[0018] Figure 5 This is a schematic diagram of a carbon fiber composite gas storage cylinder structure with a carbon fiber winding layer.

[0019] Figure 6 This is a schematic diagram of a partial structure of the carbon fiber winding layer in a carbon fiber composite gas storage cylinder structure.

[0020] In the figure: 1. First plastic shell; 2. Second plastic shell; 3. End cap reinforcing block; 4. Nut fixing seat; 5. First aluminum bracket; 6. Hot-swappable nut; 7. Quick-connect connector; 8. Weld; 9. Second aluminum bracket; 10. Support frame; 11. Thickened area; 12. Polar hole reinforcing rib; 13. Colloid flow channel; 14. Carbon fiber winding layer. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present utility model and are not intended to limit the present utility model.

[0022] The specific implementation of this utility model will be described in detail below with reference to specific embodiments.

[0023] like Figures 1-6 As shown, the present invention provides a carbon fiber composite gas storage cylinder structure, including a first plastic shell 1, and a second plastic shell 2 connected to one end of the first plastic shell 1. A weld 8 is formed at the connection between the first plastic shell 1 and the second plastic shell 2. A carbon fiber winding layer 14 is wound around the outer side of the first plastic shell 1 and the second plastic shell 2.

[0024] The surfaces of both the first plastic shell 1 and the second plastic shell 2 are provided with a plurality of nut fixing seats 4, and the interiors of both the first plastic shell 1 and the second plastic shell 2 are provided with thickened areas 11 at positions corresponding to the nut fixing seats 4, and the surfaces of the thickened areas 11 are provided with colloid flow channels 13. The length of the colloid flow channels 13 is 10mm-40mm and the depth is 0.25mm-2mm.

[0025] Both the first plastic shell 1 and the second plastic shell 2 have pole holes at their ends, and end cap reinforcing blocks 3 are provided at the pole holes. Both the first plastic shell 1 and the second plastic shell 2 have pole hole reinforcing ribs 12 located inside the pole holes.

[0026] The head reinforcement block 3 has a hot-swappable nut 6 inside, and a quick-connect connector 7 is installed inside the hot-swappable nut 6.

[0027] In one embodiment of this invention, the first plastic shell 1 and the second plastic shell 2 are connected by a weld 8 to form a sealed cavity, suitable for the storage and release of high-pressure gas, meeting the application requirements of high-pressure energy storage in air suspension systems. To enhance the overall welding strength of this connection, a thickened structure is provided in the weld 8 area, with a thickness ranging from 0.5mm to 2mm. The thickening curve is calculated based on the theory of isostatic end caps to ensure consistent stress throughout the end cap area, reducing the risk of deformation or cracking caused by stress mutations in the later stages of welding. This weld structure, together with the winding layer, constitutes an external continuous reinforcing band, contributing to the sealing and pressure resistance of the overall shell.

[0028] To enhance the overall structural strength and pressure resistance, carbon fiber winding layers 14 are wound onto the outer sides of the first plastic shell 1 and the second plastic shell 2. During the winding process, a composite strategy of small-angle (5°–30°) and large-angle (70°–90°) layups is employed, with the winding thickness controlled between 0.5 mm and 2 mm. A finite element model of the composite material is established using ABAQUS software for simulation and optimization calculations to achieve the optimal balance between structural pressure resistance and material utilization. Simulation results verify the strength requirements of this winding structure under the customer-specified operating conditions, avoiding material waste caused by redundant layups and improving winding efficiency and the overall lightweight level of the gas storage tank.

[0029] The outer surfaces of both the first plastic housing 1 and the second plastic housing 2 are provided with several nut fixing seats 4 for connecting external accessories. At the positions of the nut fixing seats 4 are fitted with a first aluminum bracket 5, a second aluminum bracket 9, and a support frame 10. The rigid support of the aluminum components enhances the installation strength and fatigue resistance of the overall connection area, making it suitable for repeated installations or long-term load-bearing conditions. The nut fixing seats 4 have a thickened area 11 inside the injection molding process, forming a colloid flow channel 13. This channel has a length of 10mm to 40mm and a depth of 0.25mm to 2mm, optimizing the plastic melt filling path and improving the fixing strength of the embedded parts. This structural design effectively alleviates the strength weakness in the cold injection molding area and enhances the overall bonding ability between the insert and the plastic housing.

[0030] Both the first plastic shell 1 and the second plastic shell 2 have end holes for pipe or connector connections. A head reinforcement block 3 is installed at each end hole, with a hot-swappable nut 6 inside for installing a quick-connect connector 7. Due to limitations in the coverage of the end holes caused by the winding process, the head reinforcement block 3 and the surrounding reinforcing ribs 12 together form a reinforcement structure to counteract potential local deformation, thinning, or uneven strength in areas where the winding layer is missing. The structural profile of the head reinforcement block 3 is also designed based on the equal tension theory to ensure uniform stress distribution under pressure and prevent cracking caused by force concentration.

[0031] Regarding the bracket connection, the first aluminum bracket 5 is connected to the plastic shell via bolts. To absorb dimensional tolerance variations caused by injection molding and welding, one side is designed with a slotted hole structure, allowing for a certain range of floating adjustment when the bolts are tightened, thereby improving the assembly compatibility and stress buffering capacity of the components. In addition, other auxiliary material mounting points use self-tapping screws for direct connection to the inner plastic shell, facilitating quick assembly and disassembly and adapting to diverse vehicle accessory installation needs.

[0032] This invention achieves higher structural strength and molding quality for the entire air tank structure while ensuring lightweight design by using thickened flow channels in the nut fixing area, introducing simulation optimization parameters into the winding layer structure, setting end cap reinforcing blocks and pole hole reinforcing ribs at the connection interface, and constructing the contour of key parts of the shell using isotension curves. It is suitable for scenarios where the air tank is subjected to high-frequency inflation and deflation conditions for a long time in automotive air suspension systems, and has good sealing performance, stability and engineering manufacturability.

[0033] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A carbon fiber composite gas storage cylinder structure, comprising a first plastic shell (1), wherein one end of the first plastic shell (1) is connected to a second plastic shell (2), and a weld (8) is formed at the connection between the first plastic shell (1) and the second plastic shell (2), characterized in that: The first plastic shell (1) and the second plastic shell (2) are provided with a plurality of nut fixing seats (4), and the interior of the first plastic shell (1) and the second plastic shell (2) are provided with thickened areas (11) at positions corresponding to the nut fixing seats (4), and the surface of the thickened areas (11) is provided with colloid flow channels (13).

2. The carbon fiber composite gas storage cylinder structure according to claim 1, characterized in that, The length of the colloidal flow channel (13) is 10mm-40mm and the depth is 0.25mm-2mm.

3. The carbon fiber composite gas storage cylinder structure according to claim 1, characterized in that, Both the first plastic shell (1) and the second plastic shell (2) are provided with pole holes at their ends, and a head reinforcement block (3) is provided at the pole hole.

4. The carbon fiber composite gas storage cylinder structure according to claim 3, characterized in that, Both the first plastic shell (1) and the second plastic shell (2) have reinforcing ribs (12) for the polar holes located inside the polar holes.

5. The carbon fiber composite gas storage cylinder structure according to claim 3, characterized in that, The head reinforcement block (3) is provided with a hot-plug nut (6) inside, and a quick-connect connector (7) is installed inside the hot-plug nut (6).

6. The carbon fiber composite gas storage cylinder structure according to claim 1, characterized in that, The outer sides of the first plastic shell (1) and the second plastic shell (2) are wrapped with carbon fiber winding layer (14).

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