CN117329433A - 复合圆柱形罐的制造方法和通过该方法制造的复合罐 - Google Patents

复合圆柱形罐的制造方法和通过该方法制造的复合罐 Download PDF

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Publication number
CN117329433A
CN117329433A CN202310737949.9A CN202310737949A CN117329433A CN 117329433 A CN117329433 A CN 117329433A CN 202310737949 A CN202310737949 A CN 202310737949A CN 117329433 A CN117329433 A CN 117329433A
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CN
China
Prior art keywords
composite
permeable member
shell layer
tank
end fitting
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Pending
Application number
CN202310737949.9A
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English (en)
Inventor
菲利普·帕宾
托尼·范斯维根霍文
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Corvis Co NV
Liquid Air Georg Claude Method Research And Development Co ltd
Original Assignee
Corvis Co NV
Liquid Air Georg Claude Method Research And Development Co ltd
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Filing date
Publication date
Application filed by Corvis Co NV, Liquid Air Georg Claude Method Research And Development Co ltd filed Critical Corvis Co NV
Publication of CN117329433A publication Critical patent/CN117329433A/zh
Pending legal-status Critical Current

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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
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Abstract

本发明公开了用于容纳流体的纤维复合圆柱形罐(1)的制造方法，包括：‑组装可移除的工具套件(5)的步骤(S0)；‑将端部配件(91、92)应用于工具套件(5)的步骤(S1)，所述端部配件具有开口，所述开口足够大，以用于在拆卸之后，穿过开口，移除工具套件(5)；‑通过用透气件(11)包裹组装的工具套件(5)，形成屏障层(2)的步骤(S2)；‑通过将由混合纤维和树脂的第一复合材料制成的第一复合带(12)缠绕在屏障层(2)上，形成第一壳层(3)的步骤(S3)；‑通过开口(911、921)，拆卸和移除工具套件(5)的步骤(S4)。因此，本发明可以比现有技术的纤维复合罐，更快速地制造纤维复合圆柱形罐，同时能够承受过压。

Description

复合圆柱形罐的制造方法和通过该方法制造的复合罐
技术领域
本发明涉及加压流体的储罐。
更具体地说，本发明涉及一种用于容纳加压流体的纤维复合圆柱形罐的制造方法，以及通过这种方法所获得的纤维复合圆柱形罐。
背景技术
对于氢气运输，高压纤维复合罐的使用正在显著增加。热塑性V型罐构成符合氢气使用的令人感兴趣的复合罐设计。
通常，所谓的热塑性V型罐具有由与罐相同的树脂所制成的均匀衬里。术语“衬里”在此用于描述罐内表面上的保证罐密封性的部分。可替代地，V型罐可以不具有衬里。
如本申请的共同申请人之一的国际专利申请WO2011/143723中所描述的，通过围绕可移除的工具套件，缠绕纤维复合膜，可以制造无衬里的V型罐，该纤维复合膜起屏障层作用，并且具有与用于罐的树脂相同的树脂，使得罐更均匀。
围绕与罐表面相匹配的可移除的工具套件的整个表面缠绕膜可能是耗时的，并且需要使用缠绕机器。此外，在缠绕时，膜可能撕裂，这增加了重复缠绕过程的需要。此外，通常难以找到由与用于罐的树脂化学地相容的材料所制成的膜。
本申请具有对国际专利申请WO2011/143723中所描述的方法的改进，以便制造无衬里的V型复合罐。
发明内容
对于用于加压流体的具有保证罐密封性的均匀壁的储罐存在需要，并且对于用于制造这种储罐的方便的方法存在需要。
为此，本发明涉及一种用于容纳流体的纤维复合圆柱形罐的制造方法，该方法包括以下步骤：
-组装可再使用和可移除的工具套件的步骤；
-将端部配件应用于工具套件的步骤，所述端部配件具有开口，该开口足够大，以用于在拆卸之后，穿过所述开口，移除工具套件；
-通过用透气件包裹组装的工具套件，形成屏障层的步骤；
-通过将由混合纤维和树脂的第一复合材料制成的第一复合带缠绕在屏障层上，形成第一壳层的步骤；
-通过开口，拆卸和移除工具套件的步骤。
包裹为无缠绕的包封。透气件是由纤维制成的非编织的材料。
本发明去除了制造纤维复合罐的方法中的膜缠绕步骤，由此缩短了制造时间。而且，透气材料的使用拓宽了与第一复合带化学地相容的材料的选择，并且因此有利于制造方法。
在实施方式中，方法进一步包括通过将由混合纤维和树脂的第二复合材料制成的第二复合带缠绕在第一壳层上和端部配件的外周缘部分上，形成第二壳层的步骤，所述外周缘部分围绕开口。第二壳层允许纤维复合罐承受更高的压力值，通常为700巴的工作压力。
有利地，透气件由聚酯或聚酰胺或与第一复合材料和第二复合材料的树脂化学地相容的任何其他聚合物制成。透气件还可以是不同聚合物(例如，像聚酯和聚酰胺)的组合。
有利地，透气件包括在110g/m2与600g/m2之间的单位面积质量。透气件的单位面积质量的选择允许调节纤维复合罐的期望的密封性。
有利地，透气件包括在2mm与3mm之间的厚度。
有利地，透气件包括高于50℃的玻璃化转变温度。透气件的玻璃化转变温度的选择允许在现有制造方法的条件下实施本发明。
有利地，透气件和第一复合材料是化学地相容的。透气件和第一复合材料一起形成整体结构。这允许改进纤维复合罐的壁的均匀性，并且因此改进纤维复合罐的密封性。
有利地，第一复合材料是热塑性材料。
有利地，第一复合材料包括碳纤维、玻璃纤维或玄武岩纤维。
本发明的另一方面涉及一种通过根据本发明的方法制造的用于容纳流体的纤维复合材料圆柱形罐，该罐包括由透气件、树脂和纤维的混合物构成的壳层，并且包括端部配件，壳层和端部配件形成能够承受至少2巴的过压的整体刚性结构。因此可以比现有技术的纤维复合罐，更快速地制造通过这种方法所获得的纤维复合圆柱形罐，同时能够承受过压。
附图说明
在解释本发明的优选实施方式的附图和附图描述中进一步阐明本发明。注意，这些附图不是按比例绘制的。附图旨在描述本发明的原理。
图1示出了根据本发明的纤维复合罐的示意性截面视图。
图2示例了用于制造根据本发明的纤维复合罐的方法的主要步骤。
图3示意性地示出了适于实施用于制造根据本发明的纤维复合罐的方法的组装的工具套件。
图4示意性地示出了图2的工具套件的部件的子组件。
图5示意性地示出了具有两个端部配件的图2的组装的工具套件。
图6示意性地示出了具有开口的端部配件的实施方式。
图7示意性地示出了在根据本发明的方法的第一缠绕步骤的早期阶段的根据本发明的纤维复合罐。
图8示意性地示出了在根据本发明的方法的第一缠绕步骤的后期阶段的根据本发明的纤维复合罐。
图9示意性地示出了在根据本发明的方法的第一缠绕步骤已经完成之后的根据本发明的纤维复合罐。
图10示出了根据本发明的一个实施方式的纤维复合罐的示意性截面视图。
图11示出了根据本发明的第二实施方式的纤维复合罐的示意性截面视图。
具体实施方式
除非另外说明，否则出现在不同附图上的相同元件具有单一附图标记。
此外，说明书和权利要求书中的术语“第一”、“第二”等用于区分类似元件，并且不一定用于描述先后顺序或时间顺序。
图1示出了根据本发明的实施方式的纤维复合罐1。在图1中，罐1是圆柱形的。罐1具有在60升到2000升或甚至更大的范围内的内部体积。纤维复合罐1包括内屏障层2和第一壳层3。可以在图1中观察到可选的第二壳层4。第二壳层4的存在取决于纤维复合罐1必须承受的压力的值。通常，当纤维复合罐1必须承受50巴或更高的量级的压力时，需要第二壳层4。
根据实施方式，罐1包括一个或两个开口。在图1的实施方式中，罐仅包括一个开口911。在罐1包括两个开口(例如，图10和图11的实施方式)的实施方式中，开口布置在罐1的两个相对端部处，优选地面向彼此。
纤维复合罐1可以包含多种类型的流体。“流体”是指气体或液体。可包含在纤维复合罐1中的气体的实例是氢、氧、或氮。
在下文中，将描述用于制造在图1中示出的纤维复合罐1的方法。该方法是在国际专利申请WO2011/143723中描述的方法的改进，并且包含将在下面描述的共同步骤。那些共同步骤的更详细的描述可以在上述国际专利申请中找到。
图2示意性地示例了用于制造根据本发明的纤维复合罐1的方法的主要步骤。
在步骤S0中，组装可再使用和可移除的工具套件。
图3示出了可以用在本说明书的方法中的可移除的工具套件5的实例。可移除的工具套件5包括并排地放置以形成圆形外表面的多个长形区段6。工具套件5具有旋转对称形状，该形状具有围绕对称轴线XX的变化的外径，并且适用于膜缠绕。该几何形状在选择待制造的纤维复合罐1的形状时提供灵活性。纤维复合罐1可以是圆柱形、球形、椭圆形或者任何其他形状。
工具套件5的长形区段6由金属，例如铝、铝合金、钢或不锈钢制成。
当组装的工具套件5时，使用区段保持器7以及两个主轴部件81和82将长形区段6保持在一起。长形区段6通过拉动主轴部件81和82远离彼此而保持在位。区段保持器7安装到主轴部件81和82上，用于接合长形区段6的相对端部。为了示例目的，图4示出了由布置在两个主轴部件81和82上的两个区段保持器7所保持的长形区段6的子组件。
在步骤S1中，将两个端部配件应用于组装的工具套件5上。为了将端部配件91、92应用于组装的工具套件5，端部配件91和92对第一和第二主轴部件81和82移位。图5示出了具有应用于其上的两个端部配件91和92的组装的工具套件。可替代地，仅一个端部配件91可以应用于组装的可移除的工具套件。两个端部配件91和92中的每个均包括开口911、921，该开口足够大，以能够通过开口911、921，拆卸和移除可移除的工具套件5。开口911、912的尺寸设计成，一旦拆卸，使得可移除的工具套件5的部件能够通过开口911、921。
端部配件91和92将在纤维复合罐1的制造之后保持在位。
在一些实施方式中，端部配件91和92由塑料制成。在这种情况下，它们很好地适于制造能够承受适度的过压(例如，低于50巴)的小的、轻质的罐。
在一些实施方式中，端部配件91和92是与内层2和第一壳层3的材料相容的聚合物。在这种情况下，它们很好地适于制造能够承受高压(例如，高于50巴)的罐。
可以选择端部配件91和92的材料，以便增加纤维复合罐1的密封性。
图6示出了端部配件91、92的实施方式。在图6中，可以观察到围绕开口911、921的外周缘部分10。开口911、921可以具有与工具套件5的部件的形状相匹配的形状，以便允许它们的移除。在图6的实施例中，开口911、921是圆形的。
在步骤S0和S1之后，在步骤S2中，将组装的工具套件5与端部配件91和92一起用透气件11包裹。“透气件”是指由纤维制成的非编织的材料。例如，透气件可以是聚酯或聚酰胺。透气件可以由与制造第一壳层3的聚合物相同的聚合物制造。通常地，透气件是毛毡。毛毡是一种非编织的织物材料，其通过将纤维铺垫、冷凝和压制在一起而制成。
透气件11具有适于覆盖组装的工具套件5的整个表面的尺寸。通常，透气件11被切割成组装的工具套件5的尺寸，并且放置在组装的工具套件5上。透气件包括在110g/m2与600g/m2之间的单位面积质量。选择透气件的每个表面的质量，以便适配罐的密封性。通常，透气件11包括2mm或3mm的厚度。一旦被包裹，透气件11就形成内屏障层2。
在一些实施方式中，透气件包括玻璃化转变温度，该玻璃化转变温度高于用于制造纤维复合罐1的方法的后续步骤的工作温度，这将进一步描述。例如，透气件包括高于60℃的玻璃化转变温度。透气件的玻璃化转变温度特别适于每次红外辐射的加热。
例如，当端部配件91、92包括围绕开口911、921的外周缘部分10时，如图6所示，透气件11覆盖开口911、921外部的端部配件91、92，直到外周缘部分10。
因此，不同于国际专利申请WO2011/143723中公开的方法，内屏障层2不是通过缠绕膜形成，而是通过用透气件11简单地包裹组装的工具套件5形成。因此，不需要适合于膜缠绕的整套设备，并且不需要缠绕步骤。因此，透气件材料的多样选择是可能的，有助于纤维复合罐的制造。例如，透气材料可以是聚酯或聚酰胺。透气件可以由与制造第一壳层3的聚合物相同的聚合物制造。与发现与这些树脂相容的膜相比，发现与将进一步描述的壳层的树脂化学地相容的透气材料，尤其更容易。
在步骤S2之后，进行步骤S3，在该步骤中，在加热和压力下，用膜缠绕机器，将第一复合带12围绕透气件11缠绕。压力条件来自在缠绕过程中施加在第一复合带12上的张力。例如，通过红外辐射或通过任何其他加热装置，实现加热条件。在通过红外辐射加热的情况下，根据第一复合带12的材料的性质，选择辐射波长。第一复合带12由混合纤维和树脂的第一复合材料制成。例如，第一复合材料可以是由热塑性树脂所浸渍的高强度纤维，诸如玻璃纤维或碳纤维。在另一个实施例中，第一复合材料的纤维可以是金属纤维、矿物纤维、或那些纤维的组合。用于第一复合材料的树脂的实例是聚酰胺11(PA11)、聚酰胺12(PA12)、聚酰胺66(PA66)、聚邻苯二甲酰胺(PPA)。
图7示出了在缠绕步骤的早期阶段用透气件11包裹的组装的工具套件5。为了清楚起见，主轴部件81、82未在图7中示出。在图7中，组装的工具套件5具有单调地减小的直径，该直径范围在从其赤道处的Dmax一直到其相反端处的Dmin。优选地，第一复合带12作为单个连续条带施加。可替代地，第一复合带12作为连续的若干分段被施加。缠绕过程和参数的详细描述可以见于国际专利申请WO2011/143723中。
透气件材料被选择为与第一复合材料的树脂化学地相容。“化学地相容”意指在步骤S6过程中，在透气件材料与第一复合材料的树脂之间产生化学键。例如，在缠绕第一复合带12的同时，透气件11填充有来自第一复合材料的树脂的颗粒。第一复合材料建立了容器1的密封性。
图8示出了在缠绕步骤的后期，用透气件11包裹的组装的工具套件5。只有第一复合带12是可见的，包裹的工具套件5和端部配件91、92被第一复合带隐藏。为了清楚起见，在图8中未示出主轴部件81、82。
图9示出了在完全地缠绕第一复合带12之后，用透气件11包裹的组装的工具套件5。再次，为了清楚起见，在图9中未示出主轴部件81、82。开口911、921未被第一复合带12覆盖，用于移除工具套件5。第一复合带12所覆盖的面积可以大于或小于透气件11所覆盖的面积，但优选地相同。例如，如图6所示，当端部配件91、92包括围绕开口911、921的外周缘部分10时，第一复合带12覆盖开口911、921外部的端部配件，直到外周缘部分10。缠绕的第一复合带12形成纤维复合罐1的第一壳层3。
图10示出了纤维复合罐1的实施方式，其中端部配件91、92位于由透气件11所形成的内屏障层2内部。可以观察到，两个开口911、921都未被覆盖。
在另一个实施方式中，步骤S2发生在步骤S1之前。换言之，在将两个端部配件91、92应用于组装的工具套件5之前，用透气件11包裹组装的工具套件5。在已经应用两个端部配件91、92之后，缠绕第一复合带12。图11示出了相应的纤维复合罐1，其中端部配件91、92位于由透气件11形成的内屏障层2与由缠绕的第一复合带12形成的第一壳层3之间。
一旦第一复合带12已经被缠绕，在随后的步骤S4中，工具套件被拆卸，并且其不同部件通过开口911、921中的至少一个从纤维复合罐1移除。可以如下进行拆卸：在罐体1内推动主轴部件81、82，从主轴部件81、82移除区段保持器7(例如，通过在中空主轴部件81、82内插入手)，从罐1中取出主轴部件81、82，通过开口911、921，将区段保持器7和长形区段6移出容器1，同时将端部配件91和92留在适当位置。
在可移除的工具套件5已经被完全地拆卸，并且从罐1中移除之后，用端盖封闭开口911和921。端盖是焊接在开口911、921上的包覆模制的凸台。优选地，端盖是包覆模制的金属部件，但是对于小于50巴的工作压力，它们可以仅由聚合物或增强的聚合物制成。
内屏障层2、第一壳层3和端部配件91和92形成能够承受至少2巴的过压的整体刚性结构。整体刚性结构的体积可以在60升到2000升或甚至更大的范围。
在一些实施方式中，执行拆卸和移除工具套件5之后的附加步骤S5。在移除工具套件5之后，通过在端部配件91、92上焊接包覆模制的金属凸台来封闭开口。接着，在步骤S5中，围绕着缠绕的第一复合带12缠绕第二复合带13。第二复合带13由混合纤维和树脂的第二复合材料制成。例如，第二复合材料可以是高强度纤维，诸如玻璃纤维、玄武岩纤维、碳纤维或由热塑性树脂浸渍的任何其他纤维。在另一个实施例中，第二复合材料的纤维可以是金属纤维、矿物纤维或者那些纤维的组合。第二复合材料的树脂优选地与它被缠绕在其上的部件的材料(即，第一复合材料)化学地相容。优选地，第二复合带13作为单个连续条带被应用。可替代地，第二复合带13作为连续的若干分段被应用。在附加步骤S5结束时，缠绕的第二复合带13形成第二壳层4。
内屏障层2、第一壳层3、端部配件91和92以及第二壳层4形成能够承受至少50巴、或甚至更大的过压的整体刚性结构。过压极限值取决于由内屏障层2、第一壳层3、端部配件91和92以及第二壳层4所形成的组合物(即，材料的组合)，由于第二壳层4，可实现更高的压力值。
本发明可以用于制造用于不同应用的多种多样的纤维复合罐，诸如，用于储存例如氢气、氦气、氮气、水、碱、液态酸等的容器。纤维复合罐1的尺寸可以在60L至2000L或甚至更大的范围。

Claims (10)

1.一种用于容纳流体的纤维复合圆柱形罐(1)的制造方法，包括以下步骤：
-组装可再使用和可移除的工具套件(5)的步骤(S0)；
-将端部配件(91、92)应用于工具套件(5)的步骤(S1)，所述端部配件(91、92)具有开口(911、921)，所述开口足够大，以用于在拆卸之后，穿过所述开口，移除工具套件(5)；
-通过用透气件(11)包裹组装的工具套件(5)，形成屏障层(2)的步骤(S2)，所述包裹为无缠绕的包封，并且所述透气件(11)是由纤维制成的非编织的材料；
-通过将由混合纤维和树脂的第一复合材料制成的第一复合带(12)缠绕在屏障层(2)上，形成第一壳层(3)的步骤(S3)；
-通过开口(911、921)，拆卸和移除工具套件(5)的步骤(S4)。
2.根据权利要求1所述的方法，进一步包括通过将由混合纤维和树脂的第二复合材料制成的第二复合带(13)缠绕在第一壳层(3)上和端部配件(91、92)的外周缘部分(10)上，形成第二壳层(4)的步骤(S10)，所述外周缘部分(10)围绕开口(91、92)。
3.根据权利要求2所述的方法，其特征在于，透气件(11)由与第一复合材料和第二复合材料的树脂相容的聚酯和/或聚酰胺制成。
4.根据权利要求1至3中任一项所述的方法，其特征在于，透气件(11)包括在110g/m2与600g/m2之间的单位面积质量。
5.根据前述权利要求中任一项所述的方法，其特征在于，透气件(11)包括在2mm与3mm之间的厚度。
6.根据前述权利要求中任一项所述的方法，其中，透气件包括高于50℃的玻璃化转变温度。
7.根据前述权利要求中任一项所述的方法，其中，透气件(11)和第一复合材料是化学地相容的。
8.根据前述权利要求中任一项所述的方法，其中，第一复合材料包括热塑性材料。
9.根据前述权利要求中任一项所述的方法，其中，第一复合材料包括碳纤维、玻璃纤维或者玄武岩纤维。
10.一种用于容纳流体的纤维复合圆柱形罐(1)，通过根据权利要求1至9中任一项所述的方法制造所述纤维复合圆柱形罐，所述罐包括壳层和端部配件，所述壳层包括透气件、树脂和纤维的混合物，其特征在于，壳层和端部配件形成能够承受至少2巴的过压的整体刚性结构。
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