CN111907151A - 一种具有多层结构的复合材料低温压力容器及制造方法 - Google Patents
一种具有多层结构的复合材料低温压力容器及制造方法 Download PDFInfo
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Abstract
本发明涉及复合材料压力容器制造技术，具体涉及一种具有多层结构的复合材料低温压力容器及制造方法，该复合材料低温压力容器具有重量轻、保温效果好等特点，可用于贮存低温液体介质，且可承受较高的内压；包括铝合金内胆(1)，所述铝合金内胆(1)上依次包覆有复合材料承力层(2)和保温层(3)和复合材料缓冲层(4)，所述复合材料承力层(2)和保温层(3)和复合材料缓冲层(4)依次包覆在铝合金内胆(1)上。
Description
技术领域
本发明涉及复合材料压力容器制造技术，具体涉及一种具有多层结构的复合材料低温压力容器及制造方法。
背景技术
随着工业生产的需要和国民经济的高速发展，低温介质在国民经济建设和国防现代化进程中有着不可替代的作用。常见的低温介质主要有液氮、液氩、液氦、液氧、液氢、液化天然气和液态二氧化碳等。随着我国低温液体介质产量的大幅提高，供应地区和范围的不断扩大，低温介质的应用也日趋广泛，同时低温液体介质的贮运市场也在逐步扩大。
目前用于贮存低温液体介质的贮罐均有金属材料制成，其自重较大，给液体介质的贮存和运输带来诸多不便，且所花费的运输成本高昂。碳纤维增强环氧树脂基复合材料由于高比强度、高比模量、低密度、低热导率、耐腐蚀耐疲劳等优点正在国民经济各个领域广泛应用。因此，如果将碳纤维增强环氧树脂基复合材料应用于低温液体介质贮罐，将大幅降低贮罐的自身重量，节约运输成本。
发明内容
本发明要解决的技术问题克服现有的缺陷，提供了一种具有多层结构的复合材料低温压力容器及制造方法，该复合材料低温压力容器具有重量轻、保温效果好等特点，可用于贮存低温液体介质，且可承受较高的内压。
为了解决上述技术问题，本发明提供了如下的技术方案：一种具有多层结构的复合材料低温压力容器，包括铝合金内胆，所述铝合金内胆上依次包覆有复合材料承力层和保温层和复合材料缓冲层，所述复合材料承力层和保温层和复合材料缓冲层依次包覆在铝合金内胆上。
作为优选，还包括基座，所述基座与铝合金内胆连通并依次穿过复合材料承力层和保温层和复合材料缓冲层。
作为优选，所述基座包括内胆固定层、真空抽气口、压力真空表、真空阀门和尾部顶针固定槽，所述内胆固定层与铝合金内胆连接，所述真空抽气口与内胆固定层连接且与铝合金内胆连通，所述真空抽气口还分别与压力真空表和真空阀门连通，所述压力真空表和真空阀门位于复合材料缓冲层外部，所述尾部顶针固定槽设在内胆固定层的底部。
为了解决上述技术问题，本发明提供了如下的技术方案：一种具有多层结构的复合材料低温压力容器的制造方法，包括如下步骤：
步骤一：根据复合材料低温压力容器的容积、尺寸、重量、工作温度和工作内压，设计铝合金内胆、复合材料承力层的厚度及纤维铺层方式、保温层厚度、复合材料缓冲层的厚度及纤维铺层方式、基座的尺寸参数，并利用有限元软件进行数值模拟和强度、刚度的校核；
步骤二：按照步骤一的设计要求制作铝合金内胆和底部的基座，并用环氧胶黏剂将基座粘接在铝合金内胆底部；
步骤三：按照步骤一设计的复合材料承力层在螺旋向和环向缠绕，并根据要求进行角度和层数的调整，然后放入烘箱中加热固化成型；
步骤四：按照步骤一设计的保温层结构，将保温材料包覆在固化成型后的复合材料承力层外部；
步骤五：按照步骤一设计的复合材料缓冲层在螺旋向和环向缠绕，并根据要求进行角度和层数的调整，然后放入烘箱中加热固化成型，从而完成具有多层结构的复合材料压力容器的制造；
步骤六：通过步骤一所述基座的真空抽气口将保温层内真空度抽至-1个标准大气压，之后关闭真空阀门，通过基座上连接的压力真空表实时监测保温层中的真空度。
作为优选，所述步骤三和步骤五中的固化成型条件均依次为：80～100℃保温1～2h，110～130℃保温1～2h，150～160℃保温4～6h。
作为优选，所述步骤四中的保温材料为具有连通孔道的聚氨酯保温材料，通过环氧胶黏剂将保温材料固定在复合材料承力层外部。
本发明有益效果：本发明的具有多层结构的复合材料低温压力容器及制造方法制造的低温压力容器具有质量轻、耐高压、保温效果好、成本低等优点，通过优化复合材料承力层和缓冲层的厚度和纤维缠绕角度及保温层的结构形式，可满足贮存不同低温介质以及不同贮存条件所需的高压、保温、长时效等工作要求。
附图说明
图1为本发明的压力容器的结构示意图；
图2为本发明的压力容器的局部放大示意图；
图3为本发明的压力容器的基座的结构示意图。
附图说明：1、铝合金内胆；2、复合材料承力层；3、保温层；4、复合材料缓冲层；5、基座；5-1、内胆固定层；5-2、真空抽气口；5-3、压力真空表；5-4、真空阀门；5-5、尾部顶针固定槽。
具体实施方式
以下结合附图对本发明的优选实施例进行说明，应当理解，此处所描述的优选实施例仅用于说明和解释本发明，并不用于限定本发明。
一种具有多层结构的复合材料低温压力容器，包括铝合金内胆1，所述铝合金内胆1上依次包覆有复合材料承力层2和保温层3和复合材料缓冲层4，所述复合材料承力层2和保温层3和复合材料缓冲层4依次包覆在铝合金内胆1上；还包括基座5，所述基座5与铝合金内胆1连通并依次穿过复合材料承力层2和保温层3和复合材料缓冲层4；所述基座5包括内胆固定层5-1、真空抽气口5-2、压力真空表5-3、真空阀门5-4和尾部顶针固定槽5-5，所述内胆固定层5-1与铝合金内胆1连接，所述真空抽气口5-2与内胆固定层5-1连接且与铝合金内胆1连通，所述真空抽气口5-2还分别与压力真空表5-3和真空阀门5-4连通，所述压力真空表5-3和真空阀门5-4位于复合材料缓冲层4外部，所述尾部顶针固定槽5-5设在内胆固定层5-1的底部。
一种具有多层结构的复合材料低温压力容器的制造方法，包括如下步骤：
步骤一：根据复合材料低温压力容器的容积、尺寸、重量、工作温度和工作内压，设计铝合金内胆1、复合材料承力层2的厚度及纤维铺层方式、保温层厚度、复合材料缓冲层4的厚度及纤维铺层方式、基座5的尺寸参数，并利用有限元软件进行数值模拟和强度、刚度的校核；
步骤二：按照步骤一的设计要求制作铝合金内胆1和底部的基座5，并用环氧胶黏剂将基座5粘接在铝合金内胆1底部；
步骤三：按照步骤一设计的复合材料承力层2在螺旋向和环向缠绕，并根据要求进行角度和层数的调整，然后放入烘箱中加热固化成型；
步骤四：按照步骤一设计的保温层3结构，将保温材料包覆在固化成型后的复合材料承力层2外部；
步骤五：按照步骤一设计的复合材料缓冲层4在螺旋向和环向缠绕，并根据要求进行角度和层数的调整，然后放入烘箱中加热固化成型，从而完成具有多层结构的复合材料压力容器的制造；
步骤六：通过步骤一所述基座5的真空抽气口5-2将保温层3内真空度抽至-1个标准大气压，之后关闭真空阀门5-4，通过基座5上连接的压力真空表5-3实时监测保温层中的真空度。
所述步骤三和步骤五中的固化成型条件均依次为：80～100℃保温1～2h，110～130℃保温1～2h，150～160℃保温4～6h。
所述步骤四中的保温材料为具有连通孔道的聚氨酯保温材料，通过环氧胶黏剂将保温材料固定在复合材料承力层2外部。
在具体实施时，以实施例一和实施例二为例：
实施例一
图1所示为具有多层结构的复合材料低温压力容器的结构示意图，结构层主要包括铝合金内胆1、复合材料承力层2、保温层3、复合材料缓冲层4和位于容器底部的基座5。图2所示为复合材料压力容器结构层局部放大图。
该具有多层结构的复合材料压力容器用于贮存低温介质，主要技术指标为：容器容积200L，贮存介质液态CO2，工作压力15MPa。具体制备方法包括以下步骤：
(1)根据复合材料压力容器的主要技术指标，设计铝合金内胆1的尺寸为直径500mm，高度1100mm，壁厚3mm；复合材料承力层2的厚度为7mm，缠绕层数20层；保温层3的厚度为30mm；复合材料缓冲层4的厚度为2.8mm，缠绕层数8层；
(2)根据铝合金内胆1的尺寸，基座5采用铝合金加工成型，主要包括内胆固定层5-1、真空抽气口5-2、压力真空表5-3、真空阀门5-4和尾部顶针固定槽5-5；
(3)利用爱牢达环氧胶黏剂将基座5粘接在铝合金内胆1的底部，室温下固化24h后使用；
(4)复合材料承力层2的缠绕采用纱片宽度为3.5mm的T300碳纤维丝束，封头采用扩孔缠绕方式，封头缠绕包络圆直径逐渐扩大，纤维铺层顺序为：±90o2/±22o2/±90o2/±24o2/±90o2；
(5)按照100℃保温2h，130℃保温2h，160℃保温4h的固化工艺进行升温固化，固化完成后自然降温至室温；
(6)采用分瓣组装的方式将聚氨酯保温泡沫包覆在复合材料承力层外部，并用爱牢达环氧胶黏剂将其与承力层粘接牢固，特别地，聚氨酯泡沫表面和内部均加工出连通的孔道用于保温层的抽真空处理；
(7)复合材料缓冲层4的缠绕采用纱片宽度为3.5mm的T300碳纤维丝束，封头采用扩孔缠绕方式，封头缠绕包络圆直径逐渐扩大，纤维铺层顺序为：±22o2/±24o/±90o；
(8)按照100℃保温2h，130℃保温2h，160℃保温4h的固化工艺进行升温固化，固化完成后自然降温至室温；
(9)通过容器底部基座5上的真空抽气口5-2将保温层内的真空度抽至-1个标准大气压，之后关闭真空阀门5-4，完成具有保温功能且可承受15MPa内压的复合材料低温压力容器的成型制造。
实施例二
一种用于贮存低温介质的多层结构复合材料压力容器，其结构同实施例1，主要技术指标为：容器容积130L，贮存介质液氮，工作压力2MPa。具体制备方法包括以下步骤：
(1)根据复合材料压力容器的主要技术指标，设计铝合金内胆1的尺寸为直径373mm，高度1460mm，壁厚2mm；复合材料承力层2的厚度为3.5mm，缠绕层数10层；保温层3的厚度为50mm；复合材料缓冲层4的厚度为2.8mm，缠绕层数8层；
(2)根据铝合金内胆1的尺寸，采用铝合金加工成型基座5；
(3)利用爱牢达环氧胶黏剂将基座5粘接在铝合金内胆1的底部，室温下固化24h后使用；
(4)复合材料承力层2的缠绕采用纱片宽度为3.5mm的T300碳纤维丝束，封头采用扩孔缠绕方式，封头缠绕包络圆直径逐渐扩大，纤维铺层顺序为：±90o/±12o2/±16o/±90o；
(5)按照100℃保温2h，130℃保温2h，160℃保温4h的固化工艺进行升温固化，固化完成后自然降温至室温；
(6)采用分瓣组装的方式将50mm厚的聚氨酯保温泡沫包覆在复合材料承力层外部，并用爱牢达环氧胶黏剂将其与承力层粘接牢固，特别地，聚氨酯泡沫表面和内部均加工出连通的孔道用于保温层的抽真空处理；
(7)复合材料缓冲层4的缠绕采用纱片宽度为3.5mm的T300碳纤维丝束，封头采用扩孔缠绕方式，封头缠绕包络圆直径逐渐扩大，纤维铺层顺序为：±12o2/±16o/±90o；
(8)按照100℃保温2h，130℃保温2h，160℃保温4h的固化工艺进行升温固化，固化完成后自然降温至室温；
(9)通过容器底部基座5上的真空抽气口5-2将保温层内的真空度抽至-1个标准大气压，之后关闭真空阀门5-4，完成用于贮存液氮且可承受2MPa内压的复合材料压力容器的成型制造。
以上为本发明较佳的实施方式，本发明所属领域的技术人员还能够对上述实施方式进行变更和修改，因此，本发明并不局限于上述的具体实施方式，凡是本领域技术人员在本发明的基础上所作的任何显而易见的改进、替换或变型均属于本发明的保护范围。
Claims (6)
1.一种具有多层结构的复合材料低温压力容器，其特征在于：包括铝合金内胆(1)，所述铝合金内胆(1)上依次包覆有复合材料承力层(2)和保温层(3)和复合材料缓冲层(4)，所述复合材料承力层(2)和保温层(3)和复合材料缓冲层(4)依次包覆在铝合金内胆(1)上。
2.根据权利要求1所述的具有多层结构的复合材料低温压力容器，其特征在于：还包括基座(5)，所述基座(5)与铝合金内胆(1)连通并依次穿过复合材料承力层(2)和保温层(3)和复合材料缓冲层(4)。
3.根据权利要求1所述的具有多层结构的复合材料低温压力容器，其特征在于：所述基座(5)包括内胆固定层(5-1)、真空抽气口(5-2)、压力真空表(5-3)、真空阀门(5-4)和尾部顶针固定槽(5-5)，所述内胆固定层(5-1)与铝合金内胆(1)连接，所述真空抽气口(5-2)与内胆固定层(5-1)连接且与铝合金内胆(1)连通，所述真空抽气口(5-2)还分别与压力真空表(5-3)和真空阀门(5-4)连通，所述压力真空表(5-3)和真空阀门(5-4)位于复合材料缓冲层(4)外部，所述尾部顶针固定槽(5-5)设在内胆固定层(5-1)的底部。
4.根据权利要求1所述的具有多层结构的复合材料低温压力容器的制造方法，其特征在于：包括如下步骤：
步骤一：根据复合材料低温压力容器的容积、尺寸、重量、工作温度和工作内压，设计铝合金内胆(1)、复合材料承力层(2)的厚度及纤维铺层方式、保温层厚度、复合材料缓冲层(4)的厚度及纤维铺层方式、基座(5)的尺寸参数，并利用有限元软件进行数值模拟和强度、刚度的校核；
步骤二：按照步骤一的设计要求制作铝合金内胆(1)和底部的基座(5)，并用环氧胶黏剂将基座(5)粘接在铝合金内胆(1)底部；
步骤三：按照步骤一设计的复合材料承力层(2)在螺旋向和环向缠绕，并根据要求进行角度和层数的调整，然后放入烘箱中加热固化成型；
步骤四：按照步骤一设计的保温层(3)结构，将保温材料包覆在固化成型后的复合材料承力层(2)外部；
步骤五：按照步骤一设计的复合材料缓冲层(4)在螺旋向和环向缠绕，并根据要求进行角度和层数的调整，然后放入烘箱中加热固化成型，从而完成具有多层结构的复合材料压力容器的制造；
步骤六：通过步骤一所述基座(5)的真空抽气口(5-2)将保温层(3)内真空度抽至-1个标准大气压，之后关闭真空阀门(5-4)，通过基座(5)上连接的压力真空表(5-3)实时监测保温层中的真空度。
5.根据权利要求4所述的具有多层结构的复合材料低温压力容器的制造方法，其特征在于：所述步骤三和步骤五中的固化成型条件均依次为：80～100℃保温1～2h，110～130℃保温1～2h，150～160℃保温4～6h。
6.根据权利要求4所述的具有多层结构的复合材料低温压力容器的制造方法，其特征在于：所述步骤四中的保温材料为具有连通孔道的聚氨酯保温材料，通过环氧胶黏剂将保温材料固定在复合材料承力层(2)外部。
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