CN104908334B - 离心力编织的无衬垫压力容器及其制造方法 - Google Patents

离心力编织的无衬垫压力容器及其制造方法 Download PDF

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CN104908334B
CN104908334B CN201410778884.3A CN201410778884A CN104908334B CN 104908334 B CN104908334 B CN 104908334B CN 201410778884 A CN201410778884 A CN 201410778884A CN 104908334 B CN104908334 B CN 104908334B
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fiber
mold
unit
resin
braiding
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CN104908334A (zh
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姜铉旻
李宗国
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Hyundai Motor Co
Kia Corp
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Kia Motors Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/32—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core
    • B29C70/323—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core on the inner surface of a rotating mould
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16J—PISTONS; CYLINDERS; SEALINGS
    • F16J12/00—Pressure vessels in general
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/56—Winding and joining, e.g. winding spirally
    • B29C53/58—Winding and joining, e.g. winding spirally helically
    • B29C53/72—Winding and joining, e.g. winding spirally helically using external forming surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/32—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core
    • B29C70/323—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core on the inner surface of a rotating mould
    • B29C70/326—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core on the inner surface of a rotating mould by rotating the mould around its axis of symmetry
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    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/07—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments otherwise than in a plane, e.g. in a tubular way
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • F17C2201/00—Vessel construction, in particular geometry, arrangement or size
    • F17C2201/05—Size
    • F17C2201/056—Small (<1 m3)
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
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    • F17C2203/00—Vessel construction, in particular walls or details thereof
    • F17C2203/06—Materials for walls or layers thereof; Properties or structures of walls or their materials
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    • F17C2203/0612—Wall structures
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F17C2203/06—Materials for walls or layers thereof; Properties or structures of walls or their materials
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  • Filling Or Discharging Of Gas Storage Vessels (AREA)

Abstract

本发明提供用于制造无衬垫压力容器的方法和装置，其可以通过将连续纤维在离心方向上挤出以制造高压罐。

Description

离心力编织的无衬垫压力容器及其制造方法
技术领域
本公开内容涉及通过在离心方向上对连续纤维进行挤出来制造可用于高压罐的无衬垫压力容器的方法和装置。
背景技术
由于对无衬垫容器例如高压罐的需求，使用形状记忆泡沫制造上述容器的方法正处于开发中。作为复合材料技术发展公司(Composite Technology Development Inc.)(USA)与美国空军研究实验室(U.S.Air Force Research Laboratory)和得克萨斯大学合作开发的技术，通过多用途精确提取加工(Multiple Use Precision ExtractableTooling，MUPET)技术，使用KIBOKO的韧化环氧树脂和Toray的T700碳纤维，制造出中空型罐(1.9L，直径：152mm，长度：203mm，0.2kg)，其安装在FASTRAC 1卫星上，工作压力为138巴，耐受压力为690巴，爆破压力范围在1,300至1,700巴。该技术通过以下方式进行：首先，进行单纤维缠绕，然后，将其用形状记忆泡沫支持，以在室温下保持形状，并为热固化提供压力。完成固化以后，使形状记忆泡沫在真空和冷却条件下收缩，并从罐中取出，然后罐可以再利用(参见图1和图2)。
作为高压容器制造方法的另一参考文献，美国专利公开第2005-0258575号公开了一种通过将制成的容器用纤维缠绕并对模具内部施加压力以进行膨胀成型的制造方法。
韩国专利登记第10-0857170号公开了一种用于制造设置在高压容器上的衬垫的吹塑成型装置，其构造成在型坯翼部的底面上涂有粘合剂，用于将整体设置的410粘附在可以前后移动的喷嘴400上。
而且，美国专利公开第3900355号公开了以下构造的装置：具有树脂排出孔32的喷嘴管33通过电机43转动，树脂溶液通过离心力喷射在圆筒30的壁上。
另一方面，韩国专利登记第10-1271454号公开了通过将混合材料挤压至混合材料输出管并通过喷嘴喷射至模具，同时通过单独的玻璃纤维喷嘴喷射切成预定长度的短切原丝形式的玻璃纤维而制造的容器，其中混合材料可以在混合材料输出管中移动。
但是，任何上述技术均没有公开缠绕容器内部、同时控制缠绕形状和物理性质、制造无衬垫压力容器并具有连续制造工艺的结构。
该背景部分公开的上述信息仅仅用于增强对本发明背景的理解，因此，其可以含有不构成在该国家中本领域普通技术人员已经知晓的现有技术的信息。
发明内容
本发明提供一种通过内部缠绕技术制造用于储存CNG、LPG、H2等的轻质无衬垫高压罐的方法以及用于该方法的装置。
在一方面，本发明提供一种设置有用树脂浸渍纤维编织的三维中空型纤维结构的高压罐的制造方法，其中将树脂浸渍纤维在中空成型的模具中挤出，并安置在模具的内表面中。方法包括以下步骤：将挤出纤维的挤出单元沿着模具中的移动轴移动并转动；通过离心力在圆周方向上进行挤出；并沿着模具的内轮廓编织三维中空型纤维结构。并提供一种进行该方法的装置。
在优选的实施方式中，在圆周方向上挤出的角速度可以加速至挤出的纤维到达模具的内表面。
在另一优选的实施方式中，在挤出单元处的作为纤维被挤出的单元的喷嘴可以是倾斜的。
在另一优选的实施方式中，中空型纤维结构的编织形状及其密度可以通过以下估计：挤出纤维的路径、作为在挤出单元中的纤维被挤出的单元的喷嘴的倾斜角、挤出单元的移动速度和模具的内部形状。
在另一优选的实施方式中，随着挤出单元沿着移动轴反复前后移动，中空型纤维结构的编织厚度可以变厚。
在另一优选的实施方式中，本发明还可以包括，在编织后将织物压缩到模具中，或者在脱模后通过加热、UV或脱水而固化。
在另一优选的实施方式中，树脂可以是选自以下的至少一种热固性树脂：异邻苯二甲酸聚酯、乙烯基酯、环氧树脂、聚酯和聚氨酯。
在另一优选的实施方式中，纤维可以是碳纤维、玻璃纤维、聚芳酰胺纤维或其混合物。
在另一优选的实施方式中，通过广角X-射线散射(WAXS)测量，碳纤维的结晶粒度可以为约1～6nm以及平均单纤维直径为约1～20μm。
在另一优选的实施方式中，纤维浸渍的树脂的粘度可以为0.01～100Pa·s。
以下对本发明的其他方面和优选实施方式加以讨论。
附图说明
现将参考附图示出的其某些示例性实施方式对本发明的上述和其他特征进行详细说明，上述实施方式在下文中仅通过示例说明的方式给出，因此并非对本发明进行限定，其中：
图1(现有技术)是示出MUPET技术中使用的形状记忆泡沫随温度变化而变化的图；
图2(现有技术)是示出复合材料技术发展公司等人开发的无衬垫压力容器的制造方法的图；
图3是通过类型对压力容器进行分类的表格；
图4是简要描述本发明的无衬垫高压罐的制造原理的图；以及
图5是本发明的用于制造无衬垫高压罐的装置的图。
应当理解到，附图不必要成比例，而是对说明本发明基本原理的各种优选特征的略微简化的呈现。在本文公开的本发明的特定设计特征，包括，例如，特定的尺寸、方向、位置和形状将部分地由具体的既定应用和使用环境所决定。
在附图中，附图标记在附图的几张图中通篇指代本发明的相同或等同部件。
具体实施方式
应理解，本文使用的术语“车辆”或“车辆的”或其他类似术语包括通常的机动车，例如，包括多功能运动车(SUV)、公共汽车、卡车、各种商务车的客车，包括各种船只和船舶的水运工具，飞行器等等，并且包括混合动力车、电动车、插入式混合电动车、氢动力车和其他代用燃料车(例如，来源于石油以外的资源的燃料)。本文中提到的混合动力车是具有两种或更多种动力来源的车，例如同时为汽油动力和电动力的车。
本文使用的术语仅为说明具体实施方式，而不是意在限制本发明。如本文所使用的，单数形式“一个、一种、该”也意在包括复数形式，除非上下文中另外明确指明。还应当理解的是，在说明书中使用的术语“包括、包含、含有”是指存在所述特征、整数、步骤、操作、元素和/或部件，但是不排除存在或添加一个或多个其他特征、整数、步骤、操作、元素、部件和/或其群组。如本文所使用的，术语“和/或”包括一个或多个相关所列项的任何和所有结合。
此外，本发明的控制逻辑可以具体表现为，在含有由处理器、控制器等执行的可执行程序指令的计算机可读介质上的非瞬时性计算机可读介质。计算机可读介质的例子包括但不限于ROM、RAM、光盘(CD)-ROM、磁带、软盘、闪存驱动器、智能卡和光数据存储装置。计算机可读记录介质也可以在连接网络的计算机系统中分布，从而计算机可读介质可以通过例如远程信息处理服务器或控制器局域网络(CAN)以分布方式进行存储并执行。
本发明的以上和其他特征将在下文中讨论。
以下将详细参考本发明的各种实施方式，其实施例在附图中加以图示，并在下文加以说明。尽管本发明将结合示例性实施方式进行说明，但应当明白，本文的说明无意于将本发明限定于这些示例性实施方式。相反地，本发明不仅要涵盖示例性的实施方式，还要涵盖各种变化方式、修改方式、等同方式和其他实施方式，其均包括在由所附权利要求所定义的本发明的构思和范围之内。
压力容器可以通过类型加以分类，如图3所示。
US 8,074,826 B2中公开的全复合式压力容器可以属于V型(将该文献通过引用并入本文)，因为使在施加爆炸排量以上的压力时对细裂缝有耐受性的聚合物树脂(KIBOKO的韧化环氧树脂)进行纤维缠绕或编织。
US 2010/0230417 A1中公开的非圆柱型压力容器可以属于IV型(将该文献通过引用并入本文)，因为分成若干部分的衬垫被纤维加强衬垫包裹。
US 3,765,557中公开的通过连续纤维缠绕而加强的压力容器的制造方法(将该文献通过引用并入本文)，是一种通过使用复丝编织加强压力容器的提高耐疲劳特性的技术，其可以应用于制造III型和IV型。
本发明提供的技术可以通过转动浸渍纤维挤出单元，使得挤出的纤维通过离心力在圆周方向上移动，以沿着模具的内部形状缠绕或编织纤维，从而制造出无衬垫中空型罐(参见图4)。
制造图3所示的V型高压罐的核心技术是不使用任何金属或聚合物衬垫的情况下通过使玻璃纤维或碳纤维进行纤维缠绕或编织以中空的形式进行制造。上述现有专利保护的方法(MUPET)进行如下：使用形状记忆泡沫作为衬垫进行纤维缠绕，然后通过冷却使形状记忆泡沫收缩，并从内部将其取出。
通过在挤出浸渍纤维的过程中转动挤出单元，以对纤维产生离心力，从而将织成或纺成的纤维安置在罐形模具的内部，本发明能够在不使用单独的衬垫的情况下制造V型高压罐。
更具体地，参考图5，A表示用于编织或纤维缠绕的纤维，其在从喷嘴B挤出之前的步骤中进行树脂浸渍。
B表示用于挤出纤维的喷嘴，其与1或2的自由度与C结合，以在C的端部单轴或双轴倾斜。
C表示与B结合的挤出单元，其中心是中空的，且其可以前后移动并在中心轴上转动，其中纤维通过其中空部而移动至B。
并且D和E表示用于制造中空型部件的模具，其由上部D和下部E组成，其中从B挤出的纤维沿着模具D和E的内部形状缠绕或编织。
在图中，“I”部分是用于使最初挤出纤维的路径稳定化的部分，然后在I部分之后纤维可以从II部分挤出成具有所设计形状的部件。
通过C的旋转而挤出纤维的角速度可以加速至挤出的纤维到达模具的内表面。
中空型纤维结构的编织形状及其密度可以通过以下估计：挤出纤维的路径、作为在挤出单元C处的纤维被挤出的单元的喷嘴B的倾斜角、挤出单元的移动速度和模具的内部形状，并且中空型纤维结构的编织厚度可以通过将挤出单元C反复前后移动来控制。
由于模具中纤维到达的点可以通过前后移动“C”来控制，通过同时控制“B”和“C”的运动，模具的内壁可以用从“B”挤出的纤维密集填充。
基本上，纤维路径可以很容易地基于例如有关“B”和“C”的运动和模具形状的信息来估计。因此，反过来，纤维挤出速度以及“B”和“C”的运动函数可以基于有关模具形状的信息来计算。
因此，当使用本发明的装置制造高压罐时，在开始时，用于编织或缠绕的“B”和“C”的运动函数基于模具形状信息而自动计算，并且装置根据函数操作以制成最终产品。
而且，编织壁或缠绕壁的厚度可以通过反复进行“C”的前后运动来控制，在完成编织或缠绕之后，使模具闭合，并通过用空气压施加内部压力而固化，或者编织或缠绕的产品可以在脱模后单独地固化，以制成最终产品。
为使用离心挤出来制造中空型高压罐，需要用热固性树脂浸渍的纤维束，热固性树脂可以是异邻苯二甲酸聚酯、乙烯基酯、环氧树脂、聚酯和聚氨酯。优选地，这些聚合物树脂含有的量可以是20～70wt％，优选地，浸渍有纤维的树脂的粘度可以是0.01～100Pa·s(根据KS M3822标准方法测量)。用热固性树脂浸渍的纤维束应当以固化之前的状态进行挤出，在固化之前的状态下，其可以具有足以紧密粘附于模具并由于粘附模具而保持的粘附力。
为产生额外的功能，热固性树脂可以进一步包括阻燃剂、抗氧化剂、热稳定剂、润滑剂、染料、颜料和无机填料。
优选地，纤维可以是碳纤维，通过广角X-射线散射(WAXS)测量，碳纤维的结晶粒度可以是约1～6nm，且平均单纤维直径为约1～20μm，就机械特性而言，最合适于高压容器。
特征在于，也可以使用玻璃纤维或聚芳酰胺纤维来代替碳纤维，并且可以结合使用其中的两种。
在无衬垫高压罐的制造中，本发明简化了制造工艺，降低了成本，并同时体现了轻质罐。
本发明已参考其优选实施方式进行了详细说明。但是，本领域技术人员将会意识到，可以在不偏离本发明原则和构思的情况下对这些实施方式进行改变，本发明的范围由所附权利要求及其等同方式限定。

Claims (14)

1.一种用于制造无衬垫高压罐的方法，所述无衬垫高压罐具有用树脂浸渍纤维编织的三维中空型纤维结构，所述方法包括以下步骤：
将所述树脂浸渍纤维在中空型模具中挤出，并安置在所述模具的内表面中；
将挤出所述纤维的挤出单元沿着所述模具中的移动轴移动并转动；
通过离心力在圆周方向上进行挤出；以及
沿着所述模具的内轮廓编织三维中空型纤维结构，
其中所述树脂是选自异邻苯二甲酸聚酯、乙烯基酯、环氧树脂、聚酯和聚氨酯中的至少一种热固性树脂，
其中所述浸渍有纤维的树脂的粘度为0.01～100Pa·s。
2.根据权利要求1所述的方法，其中，
将在圆周方向上进行挤出的角速度加速至使挤出的纤维到达所述模具的内表面。
3.根据权利要求1所述的方法，其中，
在所述挤出单元处的作为所述纤维被挤出的单元的喷嘴是倾斜的。
4.根据权利要求1所述的方法，其中，
所述中空型纤维结构的编织形状及其密度通过挤出纤维的路径、在所述挤出单元处的作为所述纤维被挤出的单元的喷嘴的倾斜角、所述挤出单元的移动速度和所述模具的内部形状而估计。
5.根据权利要求1所述的方法，其中，
所述中空型纤维结构的编织厚度随着所述挤出单元沿着所述移动轴反复前后移动而变厚。
6.根据权利要求1所述的方法，还包括以下步骤：
在编织后，将织物压缩到所述模具中，或者在脱模后，通过加热、UV或脱水而固化。
7.根据权利要求1所述的方法，其中，
所述纤维是碳纤维、玻璃纤维、聚芳酰胺纤维或其混合物。
8.根据权利要求7所述的方法，其中，
通过广角X-射线散射(WAXS)测量，所述碳纤维的结晶粒度为1～6nm以及平均单纤维直径为1～20μm。
9.一种用于制造无衬垫高压罐的装置，所述无衬垫高压罐具有用树脂浸渍纤维织物构成的中空型纤维结构，所述装置包含：
纤维，其用于编织或纤维缠绕，且在由喷嘴挤出之前以树脂浸渍状态存在；
所述喷嘴，其用于挤出所述纤维，以1或2的自由度与挤出单元结合以能够在所述挤出单元的端部单轴或双轴倾斜；
所述挤出单元，其配置成在中心轴上前后移动并转动，所述纤维经由中空部移动至所述喷嘴；以及
模具，其用于制造中空型部件，包含上部和下部，并且由所述喷嘴挤出的纤维沿着所述模具的内部形状缠绕或编织，
其中所述树脂是选自异邻苯二甲酸聚酯、乙烯基酯、环氧树脂、聚酯和聚氨酯中的至少一种热固性树脂，
其中所述浸渍有纤维的树脂的粘度为0.01～100Pa·s。
10.根据权利要求9所述的装置，其中，
由所述挤出单元的旋转引起的纤维的角速度被加速至使所挤出的纤维到达所述模具的内表面。
11.根据权利要求9所述的装置，其中，
所述中空型纤维结构的编织形状及其密度通过挤出纤维的路径、在所述挤出单元处的作为所述纤维被挤出的单元的所述喷嘴的倾斜角、所述挤出单元的移动速度和所述模具的内部形状而估计。
12.根据权利要求9所述的装置，其中，
所述中空型纤维结构的编织厚度通过反复前后移动所述挤出单元而控制。
13.根据权利要求9所述的装置，其中，
所述纤维是碳纤维、玻璃纤维、聚芳酰胺纤维或其混合物。
14.根据权利要求13所述的装置，其中，
通过广角X-射线散射(WAXS)测量，所述碳纤维的结晶粒度为1～6nm以及平均单纤维直径为1～20μm。
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