CN104948902B - 燃料气体罐及其制造方法 - Google Patents

燃料气体罐及其制造方法 Download PDF

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CN104948902B
CN104948902B CN201510065121.9A CN201510065121A CN104948902B CN 104948902 B CN104948902 B CN 104948902B CN 201510065121 A CN201510065121 A CN 201510065121A CN 104948902 B CN104948902 B CN 104948902B
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liner
metal coil
fuel gas
composite material
molding
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CN104948902A (zh
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郑在旱
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Hyundai Motor Co
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Hyundai Motor Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
    • B60K15/03—Fuel tanks
    • B60K15/03006—Gas tanks
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
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    • F17C1/00—Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge
    • F17C1/02—Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge involving reinforcing arrangements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • F17C13/00—Details of vessels or of the filling or discharging of vessels
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    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/25—Solid
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    • B29K2105/258—Tubular
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
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    • B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
    • B60K15/03—Fuel tanks
    • B60K2015/03032—Manufacturing of fuel tanks
    • B60K2015/03046—Manufacturing of fuel tanks made from more than one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
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Abstract

本发明涉及一种燃料气体存储罐及其制造方法，其中燃料气体存储罐包括：形成罐壳体的复合材料；以及布置在复合材料内部的衬里，其中金属线圈一体地形成在衬里内部，以增大衬里在周向和径向上的刚度。此外，用于制造燃料气体存储罐的方法，包括以下步骤：利用注塑或挤压模具，使装备有金属线圈的金属线圈一体化衬里成型；以及利用绕丝装置，将复合材料长丝缠绕到金属线圈一体化衬里的表面上。

Description

燃料气体罐及其制造方法
技术领域
本发明涉及一种燃料气体存储罐及其制造方法，更具体涉及一种可安全存储高压气态燃料的罐及其制造方法。
背景技术
一般地，在诸如燃料电池车和压缩天然气车辆等可选的燃料气体车辆中，存储系统的构造基于燃料气体的存储方法而有所不同。目前，车辆制造商在考虑成本、重量以及存储方法简便性的同时，还关注压缩气体的存储方法。然而，由于气态燃料具有低能量存储密度，因此可能需要增大存储量或存储压力，来增加车辆的行驶距离。由于车辆中的气体存储系统安装空间有限，因此存储罐的尺寸也会受到限制，因此需要安全地存储更高压力的气体。
为了使燃料气体存储罐的复合罐承受由压缩气体带来的内压，利用具有高比强度和高比刚度的纤维加强复合材料来加固外层，并且将用来保持气密性的衬里布置在复合层内部。此外，燃料气体存储罐的形式根据衬里的材料而变化，并且被分成具有由诸如铝等金属制成的衬里的类型，和具有高密度聚合物衬里的类型，等等。具体地，当衬里由金属制成时，虽然衬里具有较高的安全属性，但是价格比较昂贵，并且具有较低的耐疲劳特性。
图5示出具有高密度聚合物衬里的传统燃料气体存储罐，附图标记100指代复合材料，附图标记110指代聚合物衬里。当衬里为高密度聚合物衬里时，价格相对便宜且耐疲劳特性优异，但是存在氢的耐渗透性能降低等安全问题(例如，聚合物衬里并不能完全防止氢渗透到衬里中)。
具体地，如图5所示，传送气体可停留在聚合物衬里110和复合材料100的界面处，并且在罐压下降时，气体会使复合材料层和聚合物衬里层分离。此外，气体可通过复合材料中的流动路径而泄漏到罐的外部。此外，停留在界面处的传送气体会使聚合物衬里110沿向内方向变形，并使聚合物衬里弯曲，如图6所示。
在该背景部分公开的上述信息仅用于增强对本发明背景的理解，因此可包含并不构成本国本领域普通技术人员已知的现有技术的信息。
发明内容
本发明提供一种燃料气体存储罐及其制造方法，其中通过利用在聚合物衬里本体部的注塑/挤压成型过程中与金属线圈一体形成而在衬里的周向和径向上具有增强刚度的燃料气体存储罐，可以防止复合材料与聚合物衬里分离，并且可防止因渗透的燃料气体的压力而导致聚合物衬里弯曲。
此外，本发明提供一种燃料气体存储罐及其制造方法，其可消除因气体的瞬间释放而引起的爆炸声，例如能够利用诸如复合材料和聚合物衬里之间的气体扩散层等多孔层暂时存储渗透的气体，利用多孔层中的气泡来去除和释放渗透的气体。
燃料气体存储罐可包括形成罐壳体的复合材料以及布置在复合材料内部(under)的衬里，其中衬里具有金属线圈一体形成在衬里内部的结构，该结构可增大衬里在周向和径向上的刚度。因此，燃料气体存储罐可通过嵌入的金属线圈一体化结构，来增大衬里在周向和径向上的刚度。
具体地，可以在衬里注塑成型时，将与衬里一体形成的金属线圈一体地成型或插入，并且在那时与衬里一体成型的金属线圈可形成到衬里的本体部上。此外，燃料气体存储罐还可包括形成在复合材料和衬里之间的气体扩散层，以允许气体在扩散和移动时被释放到外部。
制造燃料气体存储罐的方法可包括以下步骤：利用注塑或挤压模具使装备有金属线圈的金属线圈一体化衬里成型，以及利用绕丝机在金属线圈一体化衬里的表面上制造复合材料。该方法还可包括利用发泡模具，通过在金属线圈一体化衬里的表面上使多孔层材料发泡成型而使气体扩散层成型。此外，金属线圈一体化衬里的成型可包括，利用注塑或挤压模具使装备有金属线圈的金属线圈一体化衬里的本体部成型，使装备有金属凸起部的金属凸起一体化衬里圆顶部成型，并且通过熔化将衬里本体部和衬里圆顶部接合起来。
另外，该制造方法还可包括自紧工艺(autofrettage)，在复合材料和衬里之间形成残余应力。此外，利用绕丝机在金属线圈一体化衬里的表面上制造复合材料的步骤可包括：当长丝缠绕复合材料时，覆盖位于衬里两端处的凸起部的一部分。
本发明提供的燃料气体存储罐及其制造方法具有以下效果：
1)增大衬里的刚度
通过去除衬里与复合材料之间的层离区域(例如，分离的部分)，可以防止穿过衬里并停留在释放空间中的燃料气体被截留(trap)。
通过增加衬里的周向刚度，可以防止因被截留在衬里和复合材料之间的释放空间中的气体而使衬里弯曲。
2)被传送的燃料气体的排出
通过衬里的壁传送的燃料气体，可通过气体扩散层中的孔和孔与孔之间的流动路径，移动到罐两端处的凸起部，并且可通过形成由多孔层材料制成的气体扩散层而被释放到大气(例如，存储罐的外部)。
可防止出现已停留在衬里和复合材料之间的释放空间中的传送气体被立即释放到凸起部的现象，这样可防止爆炸声，并且气体可以经由复合材料流动路径而被释放到罐的表面上。
附图说明
现在参考在附图中示出的某些示例性的实施方式来详细描述本发明的上述和其它特征，仅仅以示例性的方式给出下文中的附图，因此其不构成对本发明的限制，其中：
图1是示出根据本发明示例性实施例的燃料气体存储罐的示例性剖视图；
图2是示出根据本发明示例性实施例的燃料气体存储罐的复合层与具有金属线圈(例如插入到聚合物衬里中的金属线圈)的聚合物衬里的应力曲线，以及二者之间的接触机构的示例性示意图；
图3是示出渗透气体从根据本发明示例性实施例的燃料气体存储罐排出的状态的示例性剖视图；
图4是示出根据本发明示例性实施例的燃料气体存储罐的制造方法的示例性示意图；
图5是示出根据现有技术的燃料气体存储罐的示例性剖视图；以及
图6是示出根据现有技术的燃料气体存储罐的弯曲的示例性视图。
应当理解的是，附图不必按比例绘制，而是呈现出说明本发明的基本原理的各种特征的简化表示。在此公开的本发明的特殊设计特征，包括，例如特殊的尺寸、取向、位置、以及形状，可部分地由特别意图的应用和使用环境决定。在附图中，贯穿附图中几幅图的附图标记涉及本发明的相同或等效部件。
具体实施方式
可以理解的是，本文所使用的术语“车辆”或“车辆的”或其它类似的术语包括一般而言的机动车辆，诸如包含运动型多用途车辆(SUV)、公共汽车、货车，各种商用车辆的客车、包含各种轮船和舰船的船只、飞行器等等，并且包括混合动力车、电动汽车、燃油式、混合动力电动汽车、氢动力汽车和其它替代燃料汽车(例如，从除了石油以外的资源中取得的燃料)。
本文所用的术语仅用于描述特定实施例，而并非对本发明进行限制。如本文所使用的，除非上下文另有明确指出，否则单数形式“一”、“一个”和“该”也旨在包括复数形式。还应该理解的是，在该说明中使用的术语“包括”和/或“其包括”，具体指存在所述特征、整体、步骤、操作、元件、和/或组件，但不排除存在或添加一个或多个其它特征、整体、步骤、操作、元件、组件和/或它们的群组。如本文所使用的，术语“和/或”包括一个或多个相关所列事项的任何组合和所有组合。
下文将详细地参考本发明的不同示例性实施例，其示例显示在附图中并在下文进行描述。尽管将结合示例性实施例对本发明进行描述，然而，应当理解的是，这些描述并非旨在将本发明限制到那些示例性实施例。相反地，本发明旨在不仅涵盖示例性实施例，并且还涵盖可包括在由所附权利要求限定的本发明的精神和范围内的各种替代、修正、等效形式以及其它实施例。
接下来，将参考附图详细地描述本发明。
图1是示出根据本发明示例性实施例的燃料气体存储罐的示例性剖视图。如图1所示，燃料气体存储罐可具有诸如管状的结构，其可通过将卷绕的金属加强件一体地装备到聚合物衬里的本体部内以增强刚度，从而防止不同材料界面之间发生层离(例如分离)。因此，燃料气体存储罐可包括形成罐的壳体的复合材料10，以及被布置在复合材料10内部的聚合物衬里11。
具体地，复合材料10和衬里11可向内、向外地双粘合到彼此，以便提供可安全存储高压燃料气体的空间并形成罐的形状。金属线圈12(例如具有由金属制成的螺旋弹簧形式的金属线圈12)，可形成在衬里11内部，以增大衬里11的周向和径向刚度。金属线圈12可由基于材料的延伸强度和屈服强度的各种材料制成，例如铝、不锈钢等。
金属线圈12可在衬里11的注塑成型过程中被一起插入并一体成型，以此方式被一体插入并成型的金属线圈12可完全地布置在本体部中，而不会暴露到外部，同时同心地布置在衬里11的衬里本体部11a上。另外，当衬里11包括衬里本体部11a和衬里圆顶部11b的一体结构时，衬里本体部11a和衬里圆顶部11b可以分别在注塑或挤压成型后，通过熔化，形成彼此粘合的一体化衬里。具体地，由于金属线圈12一体地构建于衬里11内，因此可增大衬里11的周向和径向刚度。
另一方面，可通过被插入来代替金属线圈12，以堆叠形式制造管状薄膜金属，但是由于材料之间的渗透性存在差异，而会在聚合物和金属层之间发生层离。然而，当根据本发明示例性实施例应用金属线圈12时，在增大刚度的同时，被传送的氢气可在线圈之间(例如，聚合物基体材料之间)移动。因此，不会发生如同管状薄膜金属那样在不同材料界面之间发生分离。
此外，气体扩散层13可形成在复合材料10和衬里11之间的界面处。具体地，气体扩散层13可工作，以便在允许自然扩散和移动的同时，使已穿过衬里11的气体被释放到外部。例如，当由多孔层材料(例如，聚氨酯类泡沫)制成的气体扩散层13形成在复合材料10和衬里11之间时，移动到气体扩散层13中的气体(例如穿过衬里11的气体)，可以在通过多孔层的孔扩散并移动的同时，被暂时地存储在气体扩散层13的多孔层中，并且可被释放到外部。
图2是示例性示意图，示出根据本发明示例性实施例的燃料气体存储罐中的复合层和聚合物衬里的应力曲线，以及复合层和聚合物衬里之间的接触结构。如图2所示，金属线圈12可以在注塑/挤压成型过程中，一体地形成在聚合物衬里11的本体部11a中，以增大衬里的周向和径向刚度。当利用复合材料(例如，长丝缠绕filament winding)加强衬里11的表面时，也就是说，在衬里11和复合材料10形成在内层和外层上之后，可通过自紧工艺(autofrettage)，产生复合材料10与衬里11之间的残余应力。因此，在复合材料10中产生拉伸应力，而在衬里11中产生压应力，并且由于彼此相反作用的应力作用在两层上，因此在两层之间不会产生凹陷。
此外，即使处于压应力状态下的金属线圈12在填充过程中被拉伸时，应力在负(－)状态下也会增加，因此屈服强度内的最大应力会受到限制，因此增加耐用性。在此时插入的线圈可由基于金属材料的延伸强度和屈服强度的各种金属材料制成。
图3是根据本发明示例性实施例的示例性剖视图，示出传送气体从燃料气体存储罐排出的状态。如图3所示，燃料气体存储罐的层结构可包括从内到外布置的聚合物衬里层、气体扩散层、以及复合材料层。
由于燃料气体存在内压，因此燃料气体可渗入聚合物衬里层并流到气体扩散层中，以此方式暂时聚集于气体扩散层的燃料气体，可以在穿过气体扩散层的多孔层内的气泡而被扩散的同时，通过沿着两个凸起部的方向(例如，沿衬里圆顶部的凸起的方向)移动而被释放到外部。由于连续地释放燃料气体，因此不会产生因瞬间释放燃料气体而产生的爆炸声。此外，因为燃料气体不是沿着复合材料层被释放到罐的外部，因此可防止气体泄漏。
图4是示例性示意图，示出根据本发明示例性实施例的燃料气体存储罐的制造方法。具体地，金属线圈一体化衬里11的成型可采用注塑法或挤压法，气体扩散层13的成型可采用发泡法，复合材料10的成型可采用长丝缠绕法(filament winding method)。此外，由于用于注塑法或挤压法、发泡法、以及长丝缠绕法的注塑/挤压模具14、注塑机/挤压机15、发泡模具17、绕丝机16等，具有本领域技术人员已知的各种方法的一般结构，因此在此省略对其的详细描述。
燃料储罐的制造方法可包括利用注塑或挤压模具14和注塑机/挤压机15，来使装备有金属线圈12的金属线圈一体化衬里11成型。也就是说，在使衬里11成型时，可以将装备有金属线圈12的一体化衬里11与被插入到模具中的金属线圈12一起成型。
金属线圈一体化衬里的形成可包括利用注塑或挤压模具14，使装备有金属线圈12的金属线圈一体化衬里的本体部11a成型，利用注塑或挤压模具14使装备有金属凸起(未示出)的金属凸起一体化衬里的圆顶部11b成型，并且通过熔化，将衬里圆顶部11b与衬里本体部11a的两端部接合起来。
此外，该方法还可包括利用发泡模具17，通过在金属线圈一体化衬里的表面上使多孔层材料发泡而形成气体扩散层13。也就是说，在使衬里成型之后，可通过将多孔层材料涂布到外表面上，暂时将气体存储到多孔层中，气体可通过多孔层的孔而被扩散和移动，可通过将衬里放入发泡模具中，使诸如聚氨酯类泡沫等材料发泡(例如形成泡沫状结构)，该发泡模具具有与气体扩散层13的厚度近似大小的空间。
由于在复合材料成型时，气体扩散层会因长丝缠绕的拉伸而被压缩，并且气体流动会堵塞，因此通过混合适于基于缠绕拉伸的多孔层材料(例如，玻璃纤维)的加强件，可以增大刚度。此外，在长丝缠绕时，可不覆盖衬里两端处的凸起部。也就是说，当将复合材料长丝缠绕到气体扩散层的外表面上时，在利用长丝缠绕的树脂并未完全覆盖两侧的凸起部时，气体扩散层可完全地形成，直到罐两端的凸起部，并且移动的传送气体可被释放。
可利用绕丝机16将复合材料成型到金属线圈一体化衬里的表面上。也就是说，可利用绕丝机16，通过将树脂浸渍的加强纤维缠绕在气体扩散层13的外表面上，来制造复合材料。在将复合材料长丝缠绕到金属线圈一体化衬里表面上之后，可通过执行自紧工艺，将复合材料和衬里之间的残余应力施加到复合材料和衬里。因此，燃料气体存储罐可利用一体化金属线圈来增大衬里的刚度，并可通过衬里外表面扩散层自然地排出燃料气体。
例如，可通过将金属材料和聚合物混合来获得混合衬里。也就是说，聚合物可形成基体材料，金属线圈可形成加强材料，并且可通过由聚合物基体材料来补充衬里的耐疲劳特性，并可利用金属线圈来补充聚合物的刚性。
另一方面，两层被接合以防止衬里与复合材料之间发生层离，然而会产生如下问题：例如接触层分离，以及由于燃料气体渗透到层离的界面所导致的界面分离的更快分散。本发明通过一体地形成金属线圈和衬里并自紧工艺，可防止界面层离。
由于燃料气体可渗透到聚合物层，因此可防止因气体而导致不同材料间较大程度的层离。此外，根据现有的聚合物衬里，聚合物衬里和复合材料之间的界面因不同材料之间的接合特性不同而产生层离，并且当燃料气体停留在层离空间之后瞬间泄漏到罐凸起部时，或者被误认为是复合材料流通路径之间的气体泄漏时，渗入聚合物衬里的厚度方向中的燃料气体会产生爆炸声。
为了防止这个问题，可通过将粘结剂(例如粘合材料)涂布到衬里的表面上来尝试接合复合材料，来防止燃料气体的截留(trap)，或者渗透的燃料气体可沿着所产生的流动路径被排出到两个凸起侧，其中通过在衬里和复合材料之间局部地插入不同的材料来产生流动路径。然而，粘结工艺会使粘结层易于因充入和排出所导致的疲劳而破损。此外，形成流动路径会限制流动路径的数量，并且在流动路径破裂过程中更易于形成层离的起点。
在本发明中，衬里和复合材料之间的气体扩散层允许渗透的气体通过扩散层的孔而快速地扩散，并且扩散的气体会逃逸到罐两端处的凸起部。由于渗透的气体不会停留在界面之间，而是通过扩散层的孔连续逃逸，因此不会产生爆炸声，并且由于在逃逸到复合材料流量之前，气体会通过扩散层排出，因此气体不会泄漏到罐的表面上，并可防止误判为罐泄漏。因此，通过增大衬里的刚度，可防止多层之间的层离和弯曲，并且渗透的燃料气体可以移动并通过气体扩散层自然地排出到外部。
上面已参考本发明的示例性实施例对本发明进行详细说明。然而，本领域技术人员应该清楚，在不背离本发明的原理和精神的情况下，还可对这些示例性实施例进行修改，本发明的范围由所附权利要求及其等效形式限定。

Claims (7)

1.一种燃料气体存储罐，包括：
形成罐壳体的复合材料；
布置在所述复合材料内部的衬里；以及
气体扩散层，形成在所述复合材料与所述衬里之间，使得所述气体在扩散和移动的同时被释放到外部，
其中金属线圈一体地形成在所述衬里内部，以增大所述衬里在周向和径向上的刚度，
其中所述气体扩散层通过与加强件混合来防止气流堵塞的多孔层材料的发泡成型而形成在所述衬里的外表面上。
2.如权利要求1所述的燃料气体存储罐，其中与所述衬里一体形成的所述金属线圈，能够在衬里注塑成型时被插入而一体地成型。
3.如权利要求2所述的燃料气体存储罐，其中与所述衬里一体成型的所述金属线圈形成在衬里本体部上。
4.一种用于制造燃料气体存储罐的方法，包括以下步骤：
利用注塑或挤压模具，使装备有金属线圈的金属线圈一体化衬里成型；
利用发泡模具，通过在所述金属线圈一体化衬里的外表面上使与加强件混合来防止气流堵塞的多孔层材料发泡成型，来使气体扩散层成型；以及
利用绕丝装置，将复合材料长丝缠绕到所述气体扩散层的表面上。
5.如权利要求4所述的方法，其中所述金属线圈一体化衬里的成型步骤包括以下步骤：
利用注塑或挤压模具，使装备有所述金属线圈的金属线圈一体化衬里本体部成型；
使装备有金属凸起部的金属凸起一体化衬里圆顶部成型；以及
通过熔化，将所述衬里本体部和所述衬里圆顶部接合起来。
6.如权利要求4所述的方法，还包括以下步骤：
利用自紧工艺，在所述复合材料和所述衬里之间形成残余应力。
7.如权利要求4所述的方法，其中使复合材料成型在所述气体扩散层的表面上的步骤包括以下步骤：
在使所述复合材料成型时，覆盖位于所述金属线圈一体化衬里两端处的凸起部的一部分。
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