CN101780632B - 高压罐及其组装方法 - Google Patents

高压罐及其组装方法 Download PDF

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CN101780632B
CN101780632B CN2009102259344A CN200910225934A CN101780632B CN 101780632 B CN101780632 B CN 101780632B CN 2009102259344 A CN2009102259344 A CN 2009102259344A CN 200910225934 A CN200910225934 A CN 200910225934A CN 101780632 B CN101780632 B CN 101780632B
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CN101780632A (zh
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R·M·克勒伯
H·G·基亚
J·E·卡斯利
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Abstract

本发明涉及高压罐及其组装方法。提供了一种高压罐的一个示例性实施例和组装该高压罐的方法，该方法包括提供高压罐的衬套。衬套有至少一个开口端，该开口端具有第一内径及第一外径。本方法还包括提供端盖，其所具有的第二外径大于第一内径。本方法还包括提供套环，其所具有的第二内径小于第一外径。使衬套达到第一温度，端盖达到低于第一温度的第二温度，面套环达到高于第一温度的第三温度。端盖的至少一部放置在开口端内而套环的至少一部分套在开口端上。

Description

高压罐及其组装方法
技术领域
本发明总的涉及的领域包括高压罐，以及高压罐的组装方法及其端部的组装方法。
背景技术
高压罐通常用来储存燃料电池车辆(如汽车)使用的加压的气体和液体，如压缩氢气。高压罐使用的压力范围一般在真空至10,000psi之间，或更高。成本及重量正好是高压罐面临的问题。
发明内容
一个示例性实施例包括一种提供高压罐的衬套的方法。衬套具有一个或多个开口端，该开口端具有第一内径和第一外径。本方法还可包括提供端盖，该端盖的第二外径大于第一内径。本方法还包括提供套环，该套环的第二内径小于第一外径。本方法可包括使衬套达到第一温度，使端盖达到小于第一温度的第二温度，和使套环达到大于第一温度的第三温度。本方法还包括在衬套处于第一温度或第一温度附近时且端盖处于第二温度或第二温度附近时将端盖的一部分或更多部分放置在开口端内。本方法还可包括在衬套处于第一温度或第一温度左右且套环处于第三温度或第三温度左右时将套环的一部分或更多部分套在开口端上。
另一示例性实施例包括一种用挤压工艺形成高压罐衬套的方法。衬套可具有第一开口端和第二开口端且其内径从第一开口端到第二开口端基本保持不变。本方法还包括形成端盖。本方法还包括形成套环。本方法包括将端盖的一部分或更多部分放置在第一开口端内，且包括将套环的一部分或更多部分套在第一开口端及端盖上。本方法还包括从第一开口端到第二开口端将纤维层卷绕在衬套及套环之上。
另一示例性实施例包括一种产品，它本身包括高压罐。该高压罐包括衬套、端盖、套环和纤维层。衬套有第一开口端和第二开口端，且其内径从第一开口端至第二开口端基本不变。端盖定位在第一开口端内且有助于密封第一开口端。端盖可具有一条或更多条肋，该肋环绕端盖延伸，从端盖外表面突出并在装配时贴紧衬套。套环定位在第一开口端及端盖之上，有利于第一开口端的密封。而纤维层定位在衬套及套环之上。
本发明其它示例性实施例将从下文提供的详细说明清楚起来，应当明白，虽然在此公开了本发明的示例性实施例，其详细说明及特例只是为了举例说明，并不试图限制本发明的范围。
附图说明
本发明的示例性实施例可从详细说明和附图中获得充分了解，附图中：
图1是高压罐的示例性实施例的剖视图。
图2是图1的高压罐使用的端部组件的示例性实施例的分解图。
图3是图2的端部组件的剖视图，示出组装后的端部组件。
图4是纤维层卷绕工艺的示例性实施例的透视图。
具体实施方式
下面对实施例的描述实际上只是示例性的(举例说明)，决非试图限制本发明、其用途和使用。
附图图示了高压罐10的示例性实施例，该容器用来储存流体，例如液体及压缩气体，如燃料电池车辆(如汽车)中使用的压缩氢气，但不局限这些。高压罐10设计为降低制造与装配成本，同时保持结构完整性且重量合适。在一实施例中，高压罐10包括衬套12、端部组件14及纤维层16。
作为旁白，在本文中使用的术语“轴向”、“径向”及“周向”，指的是相对于高压罐10的大致圆柱形的方向，因此所谓径向是大致沿该圆柱形任何一条假想半径延伸的方向，轴向是大致平行于该圆柱形中心轴线的方向，而周向是大致沿圆柱形任一个假想圆周延伸的方向。
衬套12也叫护板，可用作防止气体和液体穿过的屏障，且作为高压罐10的芯结构部件。参看图1及图2，衬套12具有大致圆柱形。在所选的实施例中，衬套12可用铝、铝合金或其它合适的材料制造，且可由挤压成形工艺制作，从而在其全长有固定的截面轮廓，其它成型工艺，包括机加工工艺，可与挤压工艺一起使用，或取代挤压工艺。衬套12具有一壳体18，该壳体限定盛装被储存流体的内部空间20。壳体18从第一开口端22沿轴向延伸到第二开口端24。衬套12还有接触被储存流体的第一内表面26，并具有第一外表面28。固定截面形状限定的第一内径ID1，沿衬套12的整个轴向长度是不变的，因此，在第一和第二开口端22，24处测得的内径与在衬套轴向中点处测得的内径是一样的。第一外径OD1在衬套12的整个轴向长度上也是恒定值。
端部组件14可密封高压罐10的端部，以防流体泄漏并克服储存流体产生的作用力，如果有的话。端部组件14可封闭第一开口端22，第二开口端24，或同时封闭二者。当只有一个开口端以端部组件14封闭时，另外的端部构件可起高压罐10的进口及/或出口的作用而且封闭另一端。另外或作为替代，端部组件14本身也可包含用于高压罐10的进口及/或出口的功能。参看图2，端部组件14可包括端盖30和套环32。
端盖30可套叠地被放置在第一开口端22内，以便于密封第一开口端。端盖30可完全插入第一开口端22内(见图3)，或只将一部分插入第一开口端内。参看图2，端盖30大致呈盘形。在所选的实施例中，端盖30可用铝、铝合金或其它合适的材料制造，且可通过铸造、锻压或其它成形工艺，包括机加工制作，后者可与铸造与锻压工艺一起使用，也可取代铸造与锻压工艺。端盖30的本体34可以形成有一装配部36(图上所示为一开孔)，用来安装进、出口构件如阀门，或者本体也可以是一没有装配部的实心的单件结构。端盖30还有第二外表面38，其限定第二外径OD2。第二外径OD2略大于衬套12的第一内径ID1。一条或多条肋40从第二外表面38沿径向突出，并周向地环绕第二外表面延伸。在一实施例中，就一条肋横跨整个第二外表面38，因此构成端盖30的外表面。在所示实施例中，有三条肋40在轴向上互相分开，在相邻两肋之间形成间隙42。每条肋40限定的第三外径OD3略大于第一内径ID1。在端盖30有肋40的情况下，第二外径OD2可略小于第一内径ID1，而第三外径OD3仍略大于第一内径ID1。端盖30的准确尺寸，包括轴向厚度，尤其取决于储存流体产生的预计力，如果有的话。
套环32可套叠地放置第一开口端22上，以利于密封第一开口端并可起压缩环的作用。套环32可完全插在第一开口端22上(见图3)，或者也可只部分地插在第一开口端22上。参看图2，套环32大体呈环形。在所选的实施例中，套环32可以是用铝、铝合金或其他合适的材料制造，且可用挤压工艺、锻造工艺或其它成形工艺制作，后者包括机加工工艺，可与挤压及锻造工艺结合使用，或替代它们单独使用。套环32是一坚固的单件体44，它有第三外表面46和第二内表面48。在截面上看，第三外表面46和第二内表面48在轴向构成平面。第三外表面46限定第四外径OD4，第二内表面48限定第二内径ID2，后者略小于衬套12的第一外径OD1。套环32的准确尺寸，包括径向宽度和轴向厚度，尤其由端盖30的尺寸及组装时由储存流体产生的及由端盖产生的预计力决定。
如上所述，第二端部组件50可封闭第二开口端24。参看图1，和端部组件14一样，第二端部组件50可包括第二端盖52及第二套环54。第二端盖52和第二套环54与端盖30和套环32一样，包括具有一样的相应内径与外径，因此就不在此作详细说明。此外，每个端部组件都可包括未在此示出和描述的其它部件。
纤维层16给予高压罐10以抗内部压力的能力及抗外部损伤的能力。纤维层16的材料包括碳纤维、玻璃纤维或同时包括二者，也可以是另外适用的复合纤维增强材料。纤维彼此交错编织并可加入粘合剂，如环氧树脂。纤维层16可以为pre-peg单向片材或卷筒形状。此外，纤维层16可包括单层或多层，例如，包括碳纤维的中间层和玻璃纤维的外层。参看图1，纤维层16有第三内表面56和第四外表面58。纤维层的准确尺寸，包括径向宽度在内，及采用的实际材料特别由储存流体产生的预计力决定，如果有的话。
高压罐10的制造与装配是成本可行的。当各分别的部件制成后，就可将端部组件14装入衬套12内。在一实施例中，衬套12、端盖30及套环32在套在一起前应处于要求的温度下。除别的以外，准确的温度尤其取决于特定部件使用的材料，及组装所需的物理膨胀或收缩。在一实施例中，衬套12加热到约为200至250℃的第一温度，使得第一内径ID1和第一外径OD1尺寸膨胀，或者停留在室温(如25℃或别的值)。在一个例子中，加热工艺使用工业连续炉，炉中衬套12被架设在传送装置上，而另一例子是采用感应加热。端盖30及其附属的肋40可以冷却到低于室温的第二温度，约为-20至10℃，或者冷却到约-196℃，这样，肋的第三外径OD3收缩至小于膨胀后的第一内径ID1此刻的尺寸。在一例子中，冷却工艺采用冷却槽，如液氮槽，视具体冷却温度而定。而套环32加热到的第三温度约为350～400℃的高温，因此，第二内径ID2膨胀到大于膨胀后的第一外径OD1的尺寸。此外，尚有涉及工业连续炉和感应加热炉的例子。在其它实施例中，第一、第二、第三温度可以具有其他不同的值。
当衬套12、端盖30及套环32分别处于第一、第二、第三温度时便可将它们安放在一起。当然，各部件不必严格处在第一、第二和第三温度，因为各部件一旦特殊处理完毕它们的温度便开始改变，而是各部件处在其各自温度的附近。在一实施例中，当各部件安放就位时就用夹具(未示)将其夹住并将各部件定位。由于物理膨胀与收缩，衬套12、端盖30及套环32可滑配合到一起而不必花力气且部件之间不接触或几乎不接触，不然不可能如此。然后使所有部件达到室温。在一实施例中，通过热传导使各部件达到室温，即各部件在静止状态下从衬套12及从套环32向端盖30导热。在各部件达到室温时，夹具仍然夹住并定位各部件，接下来便可拆除夹具。
一旦达到室温，各内外径均恢复其原始尺寸。参看图3，衬套12的第一外表面28与套环32的第二内表面48直接接触并紧靠。套环32与衬套12于是便相互施以相反的力。每条肋40的外表面与衬套12的第一内表面26直接接触并紧靠。端盖30及衬套12于是彼此施以相反的力。肋40便嵌入衬套12内，它们之间形成相应的第一、第二和第三道密封。由于套环32可防止材料作径向向外的运动，所以衬套12的移位材料可填充间隙42。作为一种选择方案，可将衬套12与端盖30之间形成的周向接触面焊在一起，从而提供附加的密封和使端部组件14装到衬套中的补充手段。作为另一选择方案，可将机械紧固件应用至端盖30、套环32及/或衬套12上，以便提供附加密封和使端部组件14装到衬套中的补充手段。
安装完毕后将纤维层16绕衬套12并绕端部组件14卷绕。参看图4，利用高速运转的卷绕机可使纤维层16的卷形物60展开。将纤维层16按螺旋线卷绕在衬套12的圆周上及套环32上。纤维层16的第三内表面56直接与衬套12的第一外表面28接触，并直接与套环32的第三外表面46接触。卷料60上的纤维层16具有预定尺寸的轴向宽度W，该轴向宽度W等于带有装上的端部组件14的衬套12的轴向宽度。卷绕完毕的纤维层16作固化处理，使其永久粘附在衬套12与端部组件14上。在一实施例中，在端部组件14的轴向暴露的端部部分上不进行另外的单独缠绕处理。在另一实施例中，可进行另外单独的缠绕处理。
本发明的上述说明实际上仅仅是示例性的，因此其改变形式并不认为是脱离了本发明的实质与范围。

Claims (10)

1.一种组装高压罐的方法，包括：
提供高压罐的衬套，该衬套具有至少一个开口端，该开口端具有第一内径和第一外径；
提供端盖，该端盖具有限定第二外径的外表面，该外表面具有多个沿径向突出的肋，第二外径略小于第一内径，由所述肋限定的第三外径略大于第一内径；
提供套环，该套环具有小于所述第一外径的第二内径；
使衬套达到第一温度，使端盖达到低于第一温度的第二温度，并使套环达到高于第一温度的第三温度，其中第一温度为200至250℃，第二温度为-20到10℃或约-196℃，第三温度为350至400℃；
当衬套处于第一温度或第一温度附近时且当端盖处于第二温度或第二温度附近时将端盖的至少一部分放置在开口端内；
当衬套处于第一温度或第一温度附近时且当套环处于第三温度或第三温度附近时将套环的至少一部分套在开口端上；
使衬套、端盖及套环达到低于第三温度且高于第二温度的室温；
在衬套上及套环上卷绕交错编织的pre-peg单向片材的纤维层，该纤维层包括碳纤维的中间层和玻璃纤维的外层并包括粘合剂，该纤维层具有预定尺寸的轴向宽度，该轴向宽度等于带有装上的端部组件的衬套的轴向宽度，该端部组件包括端盖和套环，该纤维层的内表面接触衬套和端部组件的外表面；以及
将卷绕好的纤维层作固化处理以便将纤维层永久粘附在衬套与端部组件上。
2.权利要求1所述的方法，其特征在于，衬套由铝或铝合金做成，端盖由铝或铝合金做成，以及套环由铝及铝合金做成。
3.权利要求1所述的方法，其特征在于，第一内径及第一外径基本上分别与衬套主体的内径及该主体的外径是同一值。
4.权利要求1所述的方法，还包括用挤压工艺提供衬套。
5.权利要求4所述的方法，还包括用铸造或锻造工艺提供端盖。
6.权利要求5所述的方法，还包括用挤压或锻造工艺提供套环。
7.权利要求1所述的方法，还包括将衬套与端盖之间形成的接触面焊接。
8.权利要求1所述的方法，还包括：
提供具有第二外径的第二端盖；
提供具有第二内径的第二套环；
使第二端盖达到第二温度且使第二套环达到第三温度；
当衬套处于第一温度或第一温度附近时且当第二端盖处于第二温度或第二温度附近时将第二端盖的至少一部分放置在第二开口端内；及
当衬套处于第一温度或第一温度附近当且当第二套环处于第三温度或第三温度附近时将第二套环的至少一部分套在第二开口端上。
9.一种高压罐，该高压罐包括；
衬套，它有第一开口端及第二开口端且其内径从第一开口端到第二口端基本上不变；
端盖，位于第一开口端内且密封第一开口端，该端盖具有围绕端盖延伸且从端盖的外表面突出的至少一条肋，该肋紧靠衬套；
套环，定位在第一开口端之上及在端盖之上，以便于密封第一开口端；及
交错编织的pre-peg单向片材或卷筒形状的纤维层，位于衬套之上及套环之上，该纤维层包括碳纤维的中间层和玻璃纤维的外层并包括粘合剂，该纤维层具有预定尺寸的轴向宽度，该轴向宽度等于带有装上的端部组件的衬套的轴向宽度，该端部组件包括端盖和套环。
10.权利要求9所述的高压罐，其特征在于，所述衬套具有第一内表面及第一外表面，所述肋具有紧靠第一内表面且施力于第一内表面的第二外表面，套环具有紧靠第一外表面且施力于第一外表面的第二内表面，以及纤维层直接接触第一外表面和套环的第三外表面。
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US20100126999A1 (en) 2010-05-27
DE102009053831A1 (de) 2010-06-10

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