CN113524719A - 金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺 - Google Patents
金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺 Download PDFInfo
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Abstract
本发明涉及一种金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺,包括:将浸有树脂的碳纤维束带以低张力缠绕在铝合金内衬上并安装气阀等其余部件,得到未固化的储气瓶;在未固化储气瓶内外部双面施以1.5~2MPa的等大压强,内部施压的介质为导热油,外部施压的介质为气体;对未固化储气瓶进行加热、保温,实现纤维复合材料的固化;在固化阶段的末尾增大储气瓶内部的油压并保压,完成气瓶自紧和内衬的时效处理。本发明实现了复合材料储气瓶的固化、自紧和时效处理的一体化,提高了储气瓶加工成型效率;利用热压罐进行固化,保证了固化成型质量;高温气体和液体可以减少铝合金内衬在自紧时产生的残余拉应力,从而使纤维复合材料层产生更大的自紧力。
Description
技术领域
本发明涉及高压气体容器制造领域,更具体地说,涉及一种金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺。
背景技术
目前氢燃料电池车、天然气汽车所使用的气瓶以二型气瓶(金属内胆+纤维环向缠绕)和三型气瓶(金属内胆+纤维全缠绕)为主。传统的二、三型气瓶的制作过程中包括纤维缠绕及固化、自紧等工序,需要使用到固化炉、水泵等设备,气瓶在不同工艺的设备间的运输还需使用物流器械。设备种类多就意味着占地面积大、需要花费额外的时间进行产品的运输,因此工艺流程复杂,制造成本高。
发明内容
本发明要解决的技术问题在于,提供一种金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺,可以减少储气瓶加工所需设备种类和物流运输时间、提高空间利用率,并改善储气瓶成型质量。
本发明解决其技术问题所采用的技术方案是:构造一种金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺,包括以下步骤:
(1)将浸有树脂的碳纤维束带以低张力缠绕在合金内衬上,得到未经固化和自紧处理的储气瓶;
(2)将所述步骤(1)得到的储气瓶送入热压罐内部后升温至70~100℃,并对热压罐内部充气,施加1.5MPa~2MPa的压强;同时将合金内衬内部注满导热油并施加与热压罐内部大小相同的压强,所述热压罐内部压强与所述铝合金内部压强在步骤(2)~(4)中各时刻保持大小一致;
(3)在1.5~2MPa的气压和油压下,将所述步骤(2)得到的储气瓶的温度提升至110~140℃,保温保压1h~1.5h;
(4)在1.5~2MPa的气压和油压下,提高所述步骤(3)得到的储气瓶温度,使其达到140~170℃,保温保压1h~1.5h;
(5)在140~170℃温度下,加大所述步骤(4)得到的储气瓶内部的油压直至其达到自紧压强,而储气瓶外部气压维持之前的大小不变;在此状态下保持10~15min;
(6)将所述步骤(5)得到的储气瓶内部的油压降低至2MPa;待油压降至2MPa后,保持油压不变,将热压罐内气压降至当地大气压、气温降至安全范围内;
(7)将所述步骤(6)得到的储气瓶内的油压降至当地大气压值,向储气瓶内充入燃料气,排出导热油,打开热压罐,得到储气瓶成品。
上述方案中,所述步骤(1)中复合材料储气瓶的合金内衬的材料为铝合金,选用的复合材料为碳纤维增强树脂基复合材料。
上述方案中,所述步骤(2)中的储气瓶内部充入的导热油为烷基联苯型导热油。
上述方案中,所述步骤(5)~(6)中储气瓶的自紧、内衬时效处理在热压罐内完成。
上述方案中,所述步骤(7)中的储气瓶内部充入的用于排油的燃料气为储气瓶被设计所存储的气体。
实施本发明的金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺,具有以下有益效果:
本发明实现了复合材料储气瓶的固化、自紧和时效处理的一体化,提高了储气瓶加工成型效率;利用热压罐进行固化,使得纤维复合材料在固化过程中紧密贴合于铝合金内衬外表面,有利于排出多余树脂,保证了固化成型质量;高温气体和液体可以减少铝合金内衬在自紧时产生的残余拉应力,增大了内衬的塑性应变,从而使纤维复合材料层产生更大的自紧力。
附图说明
下面将结合附图及实施例对本发明作进一步说明,附图中:
图1是本发明金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺采用设结构示意图;
图2是本发明金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺流程示意图。
具体实施方式
为了对本发明的技术特征、目的和效果有更加清楚的理解,现对照附图详细说明本发明的具体实施方式。
如图1所示,在本发明的金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺采用的设备如下,其包括输气管1、高温气阀2、气管贯通孔3、热压罐4、气瓶5、输油管6、油管贯通孔7、油压传感器8和热压罐气压传感器9。
图2为本发明所述的工艺参数,其中T为热压罐温度;Pi为储气瓶内部压强(油压),Po为储气瓶外部压强(气压);T1、T2和T3分别为预固化温度、固化第一阶段温度、固化第二阶段温度;P1为固化阶段储气瓶内外部气压,P2为预设自紧压强;t1为储气瓶内外部压强达到固化需求的时刻,t2为固化开始时刻,t3为第一次升温开始时刻,t4为第一次升温结束时刻,t5为第二次升温开始时刻,t6为第二次升温结束时刻,t7为自紧增压开始时刻,t8为自紧起始时刻,t9为卸载开始时刻,t10为卸载结束、冷却开始时刻。
金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺包括以下步骤:
(1)将浸有树脂的碳纤维束带以低张力缠绕在铝合金内衬上,并安装其余的零部件,得到未经固化和自紧处理的复合材料储气瓶。
(2)将所述步骤(1)得到的储气瓶放入热压罐内,向热压罐内充入高压气体并将气温升至70~100℃;与此同时向储气瓶内部充入导热油,储气瓶内油压与热压罐内气压大小相同,为1.5~2Mpa。
(3)在1.5~2MPa的双面压强下,将所述步骤(2)得到的储气瓶的温度提升至110~140℃,保温保压1h~1.5h。
(4)在1.5~2MPa的双面压强下,提高所述步骤(3)得到的储气瓶温度提升至140~170℃,保温保压1h~1.5h。
(5)在140~170℃温度下,对所述步骤(4)得到的储气瓶内部进行增压,使内部油压达到预设值,而储气瓶外部气压维持在1.5~2MPa;在此状态下维持10~15min。
(6)将所属步骤(5)得到的储气瓶内部的油压降低至2MPa;待油压降至2MPa后,保持油压不变,将热压罐内气压降至当地大气压、气温降至安全范围内。
(7)通过向储气瓶内充入以燃料气体排出所述步骤(6)得到的储气瓶内的液体,打开热压罐,得到储气瓶成品。
实施例1
本发明在一种35MPa三型储氢瓶制备中的应用
该储氢瓶瓶身由铝合金内衬、碳纤维承压层、玻璃纤维保护层构成。
取一铝合金内衬,其参数如下:公称外径370mm,总体长度830mm,其中直筒段540mm,两端封头处椭圆曲面矢高为120mm,瓶口长度40mm、外径为50mm,直筒部分壁厚3mm,封头处壁厚为5mm,材料为6061铝合金。
在铝合金内衬外表面涂覆丙烯酸清漆层,用以消除缠绕时可能产生的静电并提供一定的黏性,使碳纤维复合材料能较好地附着在内衬外表面上。
将碳纤维浸渍环氧树脂后调节张力为25N,对铝合金内衬进行纤维缠绕,具体的缠绕铺设为:直筒部分交替缠绕环向缠绕层与螺旋缠绕层,铺层次序为4层环向缠绕-4层螺旋缠绕-4层环向缠绕-4层螺旋缠绕-4层环向缠绕-4层螺旋缠绕-4层环向缠绕-4层螺旋缠绕-4层环向缠绕;铝合金内衬椭圆曲面尾部、肩部均螺旋缠绕,方向一致且连续,铺层次序为36层同向螺旋缠绕。
将玻璃纤维浸渍环氧树脂后调节张力为25N,在碳纤维承压层外表面进行缠绕。铺设形式为:一层螺旋缠绕后叠加一层环向缠绕。
将气阀等其余部件安装在铝合金内衬上,并检查其气密性,气密性良好方可进入下一步骤。
将充气接头一端与储氢瓶阀门对接,另一端与输油管和输气管对接。
利用两层矩形真空密封袋从上方和下方将储氢瓶包裹,四角对齐。密封袋尺寸为:1200mm×800mm,从内到外铺层顺序为:脱模布、吸胶布、隔离膜和密封袋。真空密封袋的边缘由密封条连接并封闭。正对着储氢瓶瓶口的一侧密封条经上下两侧绕过充气接头,使得充气接头一部分在真空密封袋外、一部分在真空密封袋内。
将储氢瓶置于热压罐内的固定架上,关闭罐门,将热压罐内气温以2℃/min的速率升至80℃。热压罐开始升温的同时开始增大罐内气压,并向储氢瓶内充入导热油直至充满。以尽可能快的速率增大罐体内的气压直至达到1.8MPa。增压的过程中需保证储氢瓶内外部压强时刻相等。
热压罐内温度达到80℃且储氢瓶内外部压强达到1.8Mpa后停止升温、增压,此时储氢瓶的固化处理开始。在开始固化处理的0~45min内保持初始状态(T=80℃、Pi=Po=1.8MPa)不变。在此期间环氧树脂开始软化,纤维复合材料在热压罐压力的作用下开始排出内部气泡和多余树脂,并向铝合金内衬贴合。
时间为45min时,开始提高热压罐内温度,在时间为70min时温度提高到130摄氏度,而储氢瓶内外部压强不变。此时环氧树脂开始固化。
时间为130min时再次提高热压罐内温度,在时间为140min时温度达到160℃,而储氢瓶内外部压强不变。此时环氧树脂逐渐固化成型。
时间为200min时,开始增大储氢瓶内部的油压,热压罐内温度保持不变。时间为210min时储氢瓶内油压达到42MPa,此时铝合金内衬开始产生不可恢复的塑性形变。
在时间为220min时,开始降低储氢瓶内部的油压。待油压降至2MPa后,保持油压不变,将热压罐内气压降至当地大气压、气温降至安全范围内。随后向储氢瓶内充入氢气,将导热油排尽。油排尽后取出储氢瓶。
实施例2
本发明在一种20MPaCNG3型气瓶制备中的应用
该储气瓶瓶身由铝合金内衬、碳纤维承压层、玻璃纤维保护层构成。
取一铝合金内衬,其参数如下:公称外径300mm,总体长度690mm,其中直筒段450mm,两端封头处椭圆曲面矢高为100mm,瓶口长度40mm、外径为50mm,直筒部分壁厚2mm,封头处壁厚为4mm,材料为6061铝合金。
在铝合金内衬外表面涂覆丙烯酸清漆层,用以消除缠绕时可能产生的静电并提供一定的黏性,使碳纤维复合材料能较好地附着在内衬外表面上。
将碳纤维浸渍环氧树脂后调节张力为25N,对铝合金内衬进行纤维缠绕,具体的缠绕铺设为:直筒部分交替缠绕环向缠绕层与螺旋缠绕层,铺层次序为3层环向缠绕-3层螺旋缠绕-3层环向缠绕-3层螺旋缠绕-3层环向缠绕-3层螺旋缠绕-3层环向缠绕-3层螺旋缠绕-3层环向缠绕;铝合金内衬椭圆曲面尾部、肩部均螺旋缠绕,方向一致且连续,铺层次序为27层同向螺旋缠绕。
将玻璃纤维浸渍环氧树脂后调节张力为25N,在碳纤维承压层外表面进行缠绕。铺设形式为:一层螺旋缠绕后叠加一层环向缠绕。
将气阀等其余部件安装在铝合金内衬上,并检查其气密性,气密性良好方可进入下一步骤。
将充气接头一端与储氢瓶阀门对接,另一端与输油管和输气管对接。
利用两层矩形真空密封袋从上方和下方将储气瓶包裹,四角对齐。密封袋尺寸为:1000mm×700mm,从内到外铺层顺序为:脱模布、吸胶布、隔离膜和密封袋。真空密封袋的边缘由密封条连接并封闭,脱模布、吸胶布、隔离膜和密封袋。正对着储气瓶瓶口的一侧密封条经上下两侧绕过充气接头,使充气接头一部分在真空密封袋外、一部分在真空密封袋内。
将储气瓶置于热压罐内的固定架上,关闭罐门,将热压罐和储气瓶内气温以2℃/min的速率升至80℃。热压罐开始升温的同时开始增大罐内气压,并向储气瓶内充满导热油,以尽可能快的速率增大罐体与储气瓶内的压强直至二者均达到1.8MPa。增压的过程中需保证储气瓶内外部压强相等。
热压罐内温度达到80℃且储气瓶内外部气压达到1.8Mpa后停止升温、增压,此时储气瓶的固化处理开始。在开始固化处理的0~45min内保持初始状态(T=80℃、Pi=Po=1.8MPa)不变。在此期间环氧树脂开始软化,纤维复合材料在热压罐压力的作用下开始排出内部气泡和多余树脂,并向铝合金内衬贴合。
时间为45min时,开始提高热压罐内温度,在时间为70min时温度提高到130摄氏度,而储气瓶内外部压强不变。此时环氧树脂开始固化。
时间为130min时再次提高热压罐内温度,在时间为140min时温度达到160℃,而储气瓶内外部压强不变。此时环氧树脂逐渐固化成型。
时间为200min时,开始增大储气瓶内部的油压,热压罐内温度保持不变。时间为210min时储气瓶内气压达到45MPa,此时铝合金内衬开始产生不可恢复的塑性形变。
在时间为220min时,开始降低储气瓶内部的油压。待油压降至2MPa后,保持油压不变,将热压罐内气压降至当地大气压、气温降至热压罐外部环境温度。随后向储气瓶内充入天然气,将导热油排尽。油排尽后取出储气瓶。
实施例3
本发明在一种10MPa医用车载氧气瓶制备中的应用
该储气瓶瓶身由铝合金内衬、碳纤维承压层构成。
取一铝合金内衬,其参数如下:公称外径150mm,总体长度1200mm,其中直筒段900mm,两端封头处椭圆曲面矢高为120mm,瓶口长度40mm、外径为50mm,直筒部分壁厚2mm,封头处壁厚为3mm,材料为6061铝合金。
在铝合金内衬外表面涂覆丙烯酸清漆层,用以消除缠绕时可能产生的静电并提供一定的黏性,使碳纤维复合材料能较好地附着在内衬外表面上。
将碳纤维浸渍环氧树脂后调节张力为25N,对铝合金内衬进行纤维缠绕,具体的缠绕铺设为交替缠绕环向缠绕层与纵向缠绕层,铺层次序为3层环向缠绕-3层纵向缠绕-3层环向缠绕-3层纵向缠绕-3层环向缠绕-3层纵向缠绕-3层环向缠绕-3层纵向缠绕-3层环向缠绕。
将玻璃纤维浸渍环氧树脂后调节张力为25N,在碳纤维承压层外表面进行缠绕。铺设形式为:一层螺旋缠绕后叠加一层环向缠绕。
将气阀等其余部件安装在铝合金内衬上,并检查其气密性,气密性良好方可进入下一步骤。
将充气接头一端与储氢瓶阀门对接,另一端与输油管和输气管对接。
利用两层矩形真空密封袋从上方和下方将储气瓶包裹,四角对齐。密封袋尺寸为:1500mm×500mm,从内到外铺层顺序为:脱模布、吸胶布、隔离膜和密封袋。真空密封袋的边缘由密封条连接并封闭,脱模布、吸胶布、隔离膜和密封袋。正对着储气瓶瓶口的一侧密封条经上下两侧绕过充气接头,使充气接头一部分在真空密封袋外、一部分在真空密封袋内。
将储气瓶置于热压罐内的固定架上,关闭罐门,将热压罐和储气瓶内气温以2℃/min的速率升至80℃。热压罐开始升温的同时开始增大罐内气压,并向储气瓶内充满导热油,以尽可能快的速率增大罐体与储气瓶内的气压直至二者均达到1.8MPa。增压的过程中需保证储气瓶内外部压强相等。
热压罐内温度达到80℃且储气瓶内外部气压达到1.8Mpa后停止升温、增压,此时储气瓶的固化处理开始。在开始固化处理的0~45min内保持初始状态(T=80℃、Pi=Po=1.8MPa)不变。在此期间环氧树脂开始软化,纤维复合材料在热压罐压力的作用下开始排出内部气泡和多余树脂,并向铝合金内衬贴合。
时间为45min时,开始提高热压罐内温度,在时间为70min时温度提高到130摄氏度,而储气瓶内外部压强不变。此时环氧树脂开始固化。
时间为130min时再次提高热压罐内温度,在时间为140min时温度达到160℃,而储气瓶内外部压强不变。此时环氧树脂逐渐固化成型。
时间为200min时,开始增大储气瓶内部的油压,热压罐内温度保持不变。时间为210min时储气瓶内气压达到20MPa,此时铝合金内衬开始产生不可恢复的塑性形变。
在时间为220min时,开始降低储气瓶内部的油压。待油压降至2MPa后,保持油压不变,将热压罐内气压降至当地大气压、气温降至热压罐外部环境温度。随后向储气瓶内充入氧气,将导热油排尽。油排尽后取出储气瓶。
上面结合附图对本发明的实施例进行了描述,但是本发明并不局限于上述的具体实施方式,上述的具体实施方式仅仅是示意性的,而不是限制性的,本领域的普通技术人员在本发明的启示下,在不脱离本发明宗旨和权利要求所保护的范围情况下,还可做出很多形式,这些均属于本发明的保护之内。
Claims (5)
1.一种金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺,其特征在于,包括以下步骤:
(1)将浸有树脂的碳纤维束带以低张力缠绕在合金内衬上,得到未经固化和自紧处理的储气瓶;
(2)将所述步骤(1)得到的储气瓶送入热压罐内部后升温至70~100℃,并对热压罐内部充气,施加1.5MPa~2MPa的压强;同时将合金内衬内部注满导热油并施加与热压罐内部大小相同的压强,所述热压罐内部压强与所述铝合金内部压强在步骤(2)~(4)中各时刻保持大小一致;
(3)在1.5~2MPa的气压和油压下,将所述步骤(2)得到的储气瓶的温度提升至110~140℃,保温保压1h~1.5h;
(4)在1.5~2MPa的气压和油压下,提高所述步骤(3)得到的储气瓶温度,使其达到140~170℃,保温保压1h~1.5h;
(5)在140~170℃温度下,加大所述步骤(4)得到的储气瓶内部的油压直至其达到自紧压强,而储气瓶外部气压维持之前的大小不变;在此状态下保持10~15min;
(6)将所述步骤(5)得到的储气瓶内部的油压降低至2MPa;待油压降至2MPa后,保持油压不变,将热压罐内气压降至当地大气压、气温降至安全范围内;
(7)将所述步骤(6)得到的储气瓶内的油压降至当地大气压值,向储气瓶内充入燃料气,排出导热油,打开热压罐,得到储气瓶成品。
2.根据权利要求1所述的金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺,其特征在于,所述步骤(1)中复合材料储气瓶的合金内衬的材料为铝合金,选用的复合材料为碳纤维增强树脂基复合材料。
3.根据权利要求1所述的金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺,其特征在于,所述步骤(2)中的储气瓶内部充入的导热油为烷基联苯型导热油。
4.根据权利要求1所述的金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺,其特征在于,所述步骤(5)~(6)中储气瓶的自紧、内衬时效处理在热压罐内完成。
5.根据权利要求1所述的金属内衬纤维缠绕储气瓶固化自紧热处理一体化工艺,其特征在于,所述步骤(7)中的储气瓶内部充入的用于排油的燃料气为储气瓶被设计所存储的气体。
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