CN115401927A - 一种内嵌金属密封件的气瓶塑料内胆及其制备方法 - Google Patents

一种内嵌金属密封件的气瓶塑料内胆及其制备方法 Download PDF

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CN115401927A
CN115401927A CN202210968383.6A CN202210968383A CN115401927A CN 115401927 A CN115401927 A CN 115401927A CN 202210968383 A CN202210968383 A CN 202210968383A CN 115401927 A CN115401927 A CN 115401927A
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plastic
sealing element
metal sealing
gas cylinder
inner container
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胡海晓
陈宏达
李书欣
曹东风
李瑞琦
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Foshan Xianhu Laboratory
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Abstract

本发明涉及一种内嵌金属密封件的气瓶塑料内胆及其制备方法。首先在金属密封件的外表面包覆上至少一层塑料，然后再将其固定至滚塑模具中，接着成型出内嵌金属密封件的气瓶塑料内胆。通过上述方法将金属与塑料的一次成型及直接复合，转化为二次成型及塑料与塑料之间的复合，整个制备工艺不受内嵌件尺寸限制，显著提高了金属密封件内嵌部位的塑料填充率并杜绝了孔洞的出现，有效避免了滚塑成型的局限性，保证了气瓶的可靠性和安全性。

Description

一种内嵌金属密封件的气瓶塑料内胆及其制备方法
技术领域
本发明涉及压力容器及氢能源技术领域，具体涉及一种内嵌金属密封件的气瓶塑料内胆及其制备方法。
背景技术
氢气作为一种公认的清洁能源，近年来发展势头十分迅猛。相对于石油、天然气、煤炭等传统化石能源，氢气燃烧后的产物为水，不存在氮氧化物及二氧化碳等气体排放问题，在改善空气质量和节能减排方面优势明显，这也促使世界各国大力发展氢能源产业。
氢气的密度比空气小，常温常压下为气态，低温高压下可转变为液态，进而能够方便的储存和运输。发展氢能源产业首先要解决的一个核心问题，就是如何安全、高效的储存、运输氢气，这对气瓶的设计、制造提出了极高的要求。传统的储气瓶通常为金属材质，不仅较为笨重增加了运输难度，而且金属瓶体易腐蚀破损，氢气一旦泄露很容易爆炸，存在极大的安全风险。
随着技术的发展，越来越多的氢气瓶采用了复合材料，这种气瓶通常由塑料内胆和碳纤维缠绕外层构成，由此实现了轻量化、高强度、高密封性的设计要求。虽然绝大部分瓶身可以采用塑料内胆加碳纤维复合材料缠绕制造，但是瓶口部分依然为金属材料。传统制备方法通常是将金属瓶口(即内嵌件)直接放入模具中，然后滚塑或注塑成型得到塑料内胆，接着在其表面缠绕碳纤维，最终得到气瓶成品。研究发现，在利用上述方法制备气瓶内胆的过程中，树脂往往难以流入并完全填充金属嵌件与模具之间的空隙，容易导致封头部分出现较大的缺料或孔隙缺陷。另外，采用嵌件加注塑的工艺制备气瓶内胆时，后续还需通过热熔的方式将两个半注塑件焊接起来，然而在焊缝位置易出现氢渗等问题。以上这些缺点严重影响了气瓶产品质量。
发明内容
本发明的目的在于解决现有储氢气瓶制造过程中存在的上述问题，提供一种内嵌金属密封件的气瓶塑料内胆的制备方法，该方法包括以下步骤：(a)制备金属密封件备用；(b)在金属密封件表面预制至少一层塑料包覆层，得到复合内嵌件；(c)将复合内嵌件置于模具中成型，得到含金属嵌件的气瓶塑料内胆。
进一步的，步骤(a)所述金属密封件包括一体成型的底座1和外凸部2，在外凸部2中设置有贯通孔3，在外凸部2远离底座1一侧设置有台阶4。
进一步的，步骤(b)所述复合内嵌件呈半包埋状态，即塑料包覆层5并未完全(即部分)将金属密封件包裹住。
更进一步的，步骤(b)所述塑料包覆层5仅包覆金属密封件台阶4以下的外表面。
进一步的，步骤(b)所述塑料包覆层的材质(即包材)与塑料内胆主体的材质相同或相近(优选相同)，并且塑料包覆层材料的熔点不低于塑料内胆主体材料的熔点。
更进一步的，所述塑料包覆层的材质选自聚丙烯(PP)、聚乙烯(PE)、尼龙(PA)及其他通用塑料或工程塑料中的至少一种，优选高密度PE或PA；塑料内胆主体的材质选自PP、PE、PA及其他通用塑料或工程塑料中的至少一种，优选高密度PE或PA。
进一步的，步骤(b)中塑料包覆层的厚度相当于气瓶塑料内胆厚度的0.5-3倍，优选为1-2倍。
进一步的，步骤(b)采用注塑成型或者3D打印成型的方式在金属密封件表面预制塑料包覆层，包覆成型前将金属密封件加热至包材熔点温度。注塑成型的工艺参数为：注射机压力150-250t，注塑机锁模力1500-2000N；3D打印成型的工艺参数为：喷嘴温度高于包材熔点40-60℃，打印速度为30-80mm/s。
进一步的，步骤(c)采用滚塑成型或者注塑成型的方式制备含金属嵌件的气瓶塑料内胆，其中滚塑成型的工艺参数为：加热温度高于树脂基体熔点50-100℃，加热时间5-30min。
本发明的另一重目的在于提供一种按照上述方法制备得到的气瓶塑料内胆，在该塑料内胆外表面缠绕碳纤维就能得到气瓶成品。
传统工艺通常直接将金属密封件与塑料内胆一次成型直接复合在一起，这对于注塑成型气瓶问题不大，但是由于抽芯、顶出等原因需先分别注塑两个半气瓶内胆然后进行焊接，后期使用过程中焊缝处易产生氢渗等问题。滚塑成型可实现气瓶内胆整体成型，但由于热塑性树脂粘度较高，导致金属密封件的外表面难以被融化的塑料彻底填满，使得局部出现孔洞，这些孔洞严重影响了该部位的强度和密封性，气瓶的可靠性和安全性因此大幅降低。究其原因，主要是滚塑过程中高粘度树脂难以流入金属密封件与模具之间的空隙。考虑到滚塑成型的局限性，因此只能从嵌件制备工艺方面入手进行改进。为此发明人创造性的提出在金属密封件表面先预制一层塑料包覆层，利用塑料包覆层作为桥梁和纽带，将其与气瓶塑料内胆主体有效的复合在一起，极大的提高了内嵌部位的成型质量。
与现有技术相比，本发明的有益效果主要体现在以下几个方面：
(1)预先在金属密封件特定部位形成与内胆材质相同或相近的塑料包覆层，有助于提前掌握金属与塑料界面间的结合情况，早发现早剔除存在孔洞和瑕疵的半成品，既降低了生产、检测成本又有助于提高产品质量和稳定性；
(2)将金属与塑料的直接复合转化为塑料与塑料之间的复合，大幅度降低了后续气瓶塑料内胆的制造难度，显著提升了金属密封件嵌入部位的成型质量，基本杜绝了低填充以及孔洞现象的发生；
(3)不受金属密封件和气瓶的结构、外形限制，能够用于制造各种规格、造型的气瓶；
(4)整个工艺较为简单，改造成本低但是效果好。
附图说明
图1为金属密封件的结构示意图；
图2为金属密封件包覆塑料前后的对照图；
图3为气瓶结构示意图；
图4为气瓶生产工艺流程图。
其中1-底座，2-外凸部，3-贯通孔，4-台阶，5-塑料包覆层。
具体实施方式
为使本领域普通技术人员充分理解本发明的技术方案和有益效果，以下结合具体实施例及附图进行进一步说明。
实施例1
一种气瓶塑料内胆，主要包括塑料内胆主体和内嵌在其端部的金属密封件，其中塑料内胆为高密度PE材质，金属密封件为铝材。塑料内胆的容量为9L，壁厚5mm。金属密封件的底座半径为30mm，壁厚3mm，中间通孔半径15mm。
该气瓶塑料内胆的制造过程如下：
第一步：首先按照设计图纸铸造出金属密封件，结合塑料内胆结构对金属密封件的封头内嵌部位进行适当的分割。生产好的金属密封件如图1所示，主要包括圆形底座1和中空柱状外凸部2，在中空柱状外凸部2顶部设置有台阶4，贯通孔3从圆形底座1的中间向上延伸至中空柱状外凸部2末端，由此形成预留的气体通道。
第二步：将金属密封件的表面清理干净并固定在模具中并预热，采用注塑成型的方式在其外表面制备一层PE包覆层，由此得到复合内嵌件。注塑成型的工艺如下：温度200℃，注射压力200t，锁模力2000N。注塑所使用的塑料配方为：高密度PE占比95％，抗氧化剂和抗老化剂5％。制备好的复合内嵌件如图2所示，其中左图为包覆前的金属密封件，右图为包覆后的金属密封件。从图2中可以很明显的看出，整个金属密封件处于半包覆状态，仅在外表面的部分区域包覆有5mm厚的塑料。
第三步：将制备好的复合内嵌件固定在模具中，采用滚塑成型的方法制得完整的气瓶塑料内胆，由此实现金属密封件与塑料内胆的完美结合。滚塑成型工艺如下：温度230℃，滚塑时间25min，滚塑所使用的塑料配方为：高密度PE占比95％，抗氧化剂和抗老化剂5％。制得的气瓶塑料内胆局部结构如图3所示，复合嵌件的金属部分与树脂部分连接良好，无明显二次熔接线(图中示意性画出)。
制得气瓶塑料内胆后，还可以进一步在其表面缠绕碳纤维复合材料并固化，由此得到气瓶成品，整个制备工艺如图4所述。
实施例2
一种气瓶塑料内胆，主要包括塑料内胆主体和内嵌在其端部的金属密封件，其中塑料内胆为PA6材质，金属密封件为铝材。塑料内胆的容量为9L，壁厚5mm。金属密封件的底座半径30mm，壁厚3mm，中间通孔半径15mm。
该气瓶塑料内胆的制造过程如下：
第一步：首先按照设计图纸铸造出金属密封件，结合塑料内胆结构对金属密封件的封头内嵌部位进行适当的分割，生产好的金属密封件清理干净备用。
第二步：采用3D打印的方式在预热好的金属密封件外表面制备一层PA6包覆层，由此得到复合内嵌件。3D打印工艺参数如下：喷嘴温度高于包材熔点240℃，打印速度为70mm/s，填充密度100％，塑料包覆层的厚度为5mm。
第三步：将制备好的复合内嵌件固定在模具中，采用滚塑成型的方法得到完整的气瓶塑料内胆，由此实现金属密封件与塑料内胆的完美结合。滚塑成型的工艺如下：温度280℃，滚塑时间25min，滚塑所使用的塑料为高密度PA6。
制得塑料内胆后，还可以参照图4所示方法进一步缠绕碳纤维复合材料并固化，最终得到气瓶成品。

Claims (10)

1.一种内嵌金属密封件的气瓶塑料内胆的制备方法，其特征在于该方法包括以下步骤：(a)制备金属密封件备用；(b)在金属密封件表面预制至少一层塑料包覆层，得到复合内嵌件；(c)将复合内嵌件置于模具中成型，得到含金属嵌件的气瓶塑料内胆。
2.如权利要求1所述的制备方法，其特征在于：步骤(a)所述金属密封件包括一体成型的底座和外凸部，在外凸部上设置有贯通孔，在外凸部远离底座一侧设置有台阶。
3.如权利要求2所述的制备方法，其特征在于：步骤(b)所述复合内嵌件呈半包埋状态，塑料包覆层仅包覆金属密封件台阶以下的外表面。
4.如权利要求1所述的制备方法，其特征在于：步骤(b)所述塑料包覆层的材质与塑料内胆主体的材质相同或不同，并且塑料包覆层材料的熔点不低于塑料内胆主体材料的熔点。
5.如权利要求1所述的制备方法，其特征在于：所述塑料包覆层的材质选自PP、PE、PA及其他通用塑料或工程塑料中的至少一种；塑料内胆主体的材质选自PP、PE、PA及其他通用塑料或工程塑料中的至少一种。
6.如权利要求1所述的制备方法，其特征在于：步骤(b)中塑料包覆层的厚度相当于气瓶塑料内胆厚度的0.5-3倍。
7.如权利要求1所述的制备方法，其特征在于：步骤(b)采用注塑成型或者3D打印成型的方式在金属密封件表面预制塑料包覆层，包覆成型前将金属密封件加热至包材熔点温度。
8.如权利要求7所述的制备方法，其特征在于：注塑成型的工艺参数为：注射机压力150-250t，注塑机锁模力1500-2000N；3D打印成型的工艺参数为：喷嘴温度高于包材熔点40-60℃，打印速度为30-80mm/s。
9.如权利要求1所述的制备方法，其特征在于：步骤(c)采用滚塑成型或者注塑成型的方式制备含金属嵌件的气瓶塑料内胆，其中滚塑成型的工艺参数为：加热温度高于树脂基体熔点50-100℃，加热时间5-30min。
10.一种气瓶塑料内胆，其特征在于：该气瓶塑料内胆按照权利要求1-9中任意一种方法制备得到。
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