WO2014139531A1 - An end cap - Google Patents

An end cap Download PDF

Info

Publication number
WO2014139531A1
WO2014139531A1 PCT/DK2014/000007 DK2014000007W WO2014139531A1 WO 2014139531 A1 WO2014139531 A1 WO 2014139531A1 DK 2014000007 W DK2014000007 W DK 2014000007W WO 2014139531 A1 WO2014139531 A1 WO 2014139531A1
Authority
WO
WIPO (PCT)
Prior art keywords
end cap
net
mould
male part
polymer material
Prior art date
Application number
PCT/DK2014/000007
Other languages
French (fr)
Inventor
Jens Egebjerg Nielsen
Original Assignee
Hbn-Teknik A/S
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hbn-Teknik A/S filed Critical Hbn-Teknik A/S
Priority to EP14701897.2A priority Critical patent/EP2969456A1/en
Publication of WO2014139531A1 publication Critical patent/WO2014139531A1/en

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • 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
    • F17C1/04—Protecting sheathings
    • F17C1/06—Protecting sheathings built-up from wound-on bands or filamentary material, e.g. wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14631—Coating reinforcements
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2201/00—Vessel construction, in particular geometry, arrangement or size
    • F17C2201/01—Shape
    • F17C2201/0104—Shape cylindrical
    • F17C2201/0109—Shape cylindrical with exteriorly curved end-piece
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2201/00—Vessel construction, in particular geometry, arrangement or size
    • F17C2201/05—Size
    • F17C2201/056—Small (<1 m3)
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2203/00—Vessel construction, in particular walls or details thereof
    • F17C2203/06—Materials for walls or layers thereof; Properties or structures of walls or their materials
    • F17C2203/0602—Wall structures; Special features thereof
    • F17C2203/0612—Wall structures
    • F17C2203/0614—Single wall
    • F17C2203/0619—Single wall with two layers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2203/00—Vessel construction, in particular walls or details thereof
    • F17C2203/06—Materials for walls or layers thereof; Properties or structures of walls or their materials
    • F17C2203/0634—Materials for walls or layers thereof
    • F17C2203/0658—Synthetics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2203/00—Vessel construction, in particular walls or details thereof
    • F17C2203/06—Materials for walls or layers thereof; Properties or structures of walls or their materials
    • F17C2203/0634—Materials for walls or layers thereof
    • F17C2203/0658—Synthetics
    • F17C2203/0663—Synthetics in form of fibers or filaments
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2203/00—Vessel construction, in particular walls or details thereof
    • F17C2203/06—Materials for walls or layers thereof; Properties or structures of walls or their materials
    • F17C2203/0634—Materials for walls or layers thereof
    • F17C2203/0658—Synthetics
    • F17C2203/0663—Synthetics in form of fibers or filaments
    • F17C2203/0673—Polymers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2205/00—Vessel construction, in particular mounting arrangements, attachments or identifications means
    • F17C2205/03—Fluid connections, filters, valves, closure means or other attachments
    • F17C2205/0388—Arrangement of valves, regulators, filters
    • F17C2205/0394—Arrangement of valves, regulators, filters in direct contact with the pressure vessel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2209/00—Vessel construction, in particular methods of manufacturing
    • F17C2209/21—Shaping processes
    • F17C2209/2109—Moulding
    • F17C2209/2118—Moulding by injection
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2209/00—Vessel construction, in particular methods of manufacturing
    • F17C2209/22—Assembling processes
    • F17C2209/221—Welding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2209/00—Vessel construction, in particular methods of manufacturing
    • F17C2209/23—Manufacturing of particular parts or at special locations
    • F17C2209/234—Manufacturing of particular parts or at special locations of closing end pieces, e.g. caps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2221/00—Handled fluid, in particular type of fluid
    • F17C2221/03—Mixtures
    • F17C2221/031—Air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2223/00—Handled fluid before transfer, i.e. state of fluid when stored in the vessel or before transfer from the vessel
    • F17C2223/01—Handled fluid before transfer, i.e. state of fluid when stored in the vessel or before transfer from the vessel characterised by the phase
    • F17C2223/0107—Single phase
    • F17C2223/0123—Single phase gaseous, e.g. CNG, GNC
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2260/00—Purposes of gas storage and gas handling
    • F17C2260/01—Improving mechanical properties or manufacturing
    • F17C2260/011—Improving strength
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2260/00—Purposes of gas storage and gas handling
    • F17C2260/04—Reducing risks and environmental impact
    • F17C2260/042—Reducing risk of explosion
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2270/00—Applications
    • F17C2270/01—Applications for fluid transport or storage
    • F17C2270/0165—Applications for fluid transport or storage on the road
    • F17C2270/0168—Applications for fluid transport or storage on the road by vehicles
    • F17C2270/0171—Trucks

Definitions

  • the present invention relates to an end cap for a pressure tank manufactured from a fibre reinforced polymer material.
  • Pressure tanks for compressed gas or liquid are widely used.
  • pressure tanks are used for compressed air for the brake systems or liquids for the hydraulic systems.
  • a truck with a trailer may be equipped with several pressure tanks.
  • the braking system alone may comprise several pressure tanks for compressed air.
  • the hydraulic system may comprise several tanks for liquid or oil.
  • Pressure tanks for compressed gas or liquid have traditionally been manufactured from metallic material, such as steel or aluminium.
  • Such pressure tanks are normally made from a tubular member which, at both ends, is provided with end caps to achieve a closed gas- and liquid- tight tank structure.
  • the tubular member is normally produced by extrusion of polymer material, e.g. polyamide.
  • the end caps are manufactured from injection molded polymer material, such as polyamide.
  • the tubular member is normally reinforced with fibres which are wrapped around the tubular structure, preferably with different orientations.
  • the polymer material for the end caps normally incorporates an amount of fibres, e.g. glass fibres.
  • the polymer material may incorporate around 30 % of fibres.
  • the end caps may comprise openings and fittings for pressure tubes and other equipment required to operate the pressure tank.
  • the pressure tanks manufactured from polymer material have many good properties. They are relatively easy to produce, they are not vulnerable to corrosion, and they have a lower weight than traditional pressure tanks made from metallic material.
  • United States Patent Application US 2008/0149636 Al discloses a composite pressure vessel, which includes two end caps comprising a first layer and a second layer. The two layers are joined and heated to adhere the two layers to form a sheet. Subsequently the sheet is cut and pressed into the shape of an end cap.
  • the first layer may be a thermoplastic polypropylene liner
  • the second layer may be thermoplastic reinforced with fibres such as glass fibres.
  • the pressure tanks manufactured from polymer material have a problem.
  • This problem relates to the end caps and cold weather conditions, i.e. weather with temperatures below 0 °C.
  • cold weather the polymer material becomes brittle, and, although, reinforced with fibres in the polymer matrix it has been found that the end caps may burst if they are exposed to an impact e.g. caused by a stone or blow e.g. from a person trying to clean the pressure tank.
  • the object of the present invention is to provide an end cap for a pressure tank which is safer in use.
  • the present invention relates to an end cap for a pressure tank manufactured from a fibre reinforced polymer material, wherein the end cap comprises a pre-shaped net integrated in one surface of the fibre reinforced polymer material constituting the end cap.
  • the end cap according to the invention which is manufactured from a moulded polymer material, comprises a pre-shaped net integrated in the polymer matrix constituting the end cap.
  • the net contributes to making the end cap stronger, and also has the effect that the end cap will not burst. In case the end cap is damaged, the net will ensure that the end cap material is more ductile, and that only minor cracks appear in the material, and an optional elevated pressure in the pressure tank will leak out in a slow and controlled manner.
  • the net is pre-shaped in order to ensure that the net will be properly integrated in one surface of the end cap.
  • the net will become integrated in the surface of the end cap during manufacture.
  • the net is pre-shaped with a curve which substantially corresponds to the curved surfaces of the end cap.
  • the net may be impregnated with a polymer thermoplastic material which will enable the net to remain in the pre-shaped shape.
  • end cap as such is made from fibre reinforced polymer material, which is expected to provide high strength
  • the further application of a pre-shaped net has been found to provide unexpected good properties of the end cap material, in particular when the end cap is subjected to temperatures below 0 °C.
  • the net will, however, improve the properties of the end cap within the whole temperature range for which the end cap is intended for use. i.e. normal summer to winter temperatures.
  • the pressure tank comprises two end caps, i.e. one end cap at each end of the tubular member.
  • the two end caps may be identical or they may be different.
  • One of the two end caps may be equipped with fittings for pressure tubes and optional other means for establishing an external connection.
  • the other end cap may be an end cap without any openings.
  • the fittings may be produced during the manufacture or moulding of the end caps, and the pre-shaped net may be adapted to the fittings.
  • the end cap according to the invention comprises a first surface and a second surface.
  • the first surface may be the surface of the end cap that has been facing the female part of the mould
  • the second surface may be the surface of the end cap that has been facing the male part of the mould.
  • the second surface will constitute the inner surface when the end cap is mounted on a pressure tank.
  • the net is integrated in the first surface or the second surface of the end cap. This embodiment facilitates the manner in which the net may be placed in the mould before the polymer is injected.
  • the pre-shaped net Before the mould is assembled, the pre-shaped net may simply be placed on the surface of the male part or the female part of the mould and when the mould is assembled and the polymer injected for the formation of the end cap, the net will be integrated in the first surface or the second surface of the end cap.
  • the net covers substantially the entire first surface or substantially the entire second surface.
  • the pre-shaped net will be adapted to allow openings for fittings and similar devices in the end cap.
  • the net may be any kind of net which will provide sufficient strength to the end cap, such as a polymer net from e.g. polyethylene, polyamide or polyaramide, however, the net is preferably selected from a metal net, a glass fibre net, or a pre- satured glass fibre mesh.
  • the net may also be a pre-formed dry- fibre or wet fibre web.
  • the size of the meshes in the net may be in the range from approximately 1 to 15 mm, conveniently in the range of 5 to 10 mm.
  • the thread or wire thickness of the net may be in the range of 0,1 to 5 mm.
  • the end cap may be made from several polymer materials, it is preferred to manufacture the end cap from polyamide.
  • the polyamide may be reinforced with glass fibres, which may be present in an amount of 25-35 %.
  • the present invention also provides a method of producing an end cap for a pressure tank by moulding a polymer material in a mould with a male part and a female part. The method comprises the following steps:
  • the invention provides a method of incorporating a pre-shaped net into the polymer matrix of the end cap, thereby increasing the strength of the end cap.
  • the pre-shaping of the net may facilitate the mounting of the net in or on a mould part, e.g. the male part of the mould.
  • a mould part e.g. the male part of the mould.
  • the net may be treated by heating.
  • the net may be impregnated with a thermoplastic polymer material, which will soften during heat treatment and harden after cooling, thereby allowing the net to remain in the pre-shaped shape.
  • the net may be prepared for mounting in a mould adapted for providing end caps with e.g. openings or fittings for pipes.
  • the net may be prepared by cutting the net to fit in the mould and optionally by cutting holes in the net adapted to the openings or fittings in the end cap, before the net is mounted in the mould.
  • the net is mounted on the male part of the mould before the two mould parts are pressed together. In this manner the net may be incorporated into the end cap in an uncomplicated operation, which only requires that the net is mounted on the male part of the mould.
  • the net is attached to a frame in such a way that the net is placed on the male part or on the female part of the mould before the male part and female part of the mould are pressed together.
  • the net will then be placed in the mould on one of the two mould parts, and after the moulding process be integrated in one surface of the end cap formed by the injected polymer.
  • the pre-shaped net may be heated before the male part and the female part of the mould are pressed together.
  • the heating of the pre-shaped net will soften the material of the net and make it easier to integrate in the polymer material of the end cap.
  • the net is easier to place in the mould if the net substantially follows the surface of the male mould part or the surface of the female mould part.
  • the method therefore provides the embodiments in which the net is integrated in the outer surface or in the inner surface of the moulded end cap.
  • the polymer material is reinforced with fibres, preferably glass fibres.
  • the fibres increase the strength of the polymer material and may be present in an amount of 25 to 35 %.
  • the polymer melt is normally injected into the mould by means of several nozzles.
  • the polymer melt is injected into the mould by means of a single nozzle.
  • the nozzle is located in the male part of the mould, and the nozzle is located in a central portion of the male part of the mould. Alternatively it would be possible to locate the nozzle in a central portion of the female part of the mould.
  • the invention provide a method for producing end caps with a high strength and by which the moulded end caps require very little post treatment.
  • Fig . 1 shows a pressure tank
  • Fig. 2 shows the end caps for the pressure tank
  • Fig. 3 shows an end cap according to the invention
  • Fig. 4 shows a section of an end cap according to the invention
  • Fig. 5 shows an arrangement for moulding an end cap according to the invention
  • Fig. 6 shows a frame for use in the arrangement
  • Fig. 7 shows a section of the moulding principle according to the invention.
  • Fig. 8 shows a front view of the moulding principle.
  • Figure 1 shows a pressure tank 1 provided with two end caps 2, 3.
  • the end caps are mounted on the tubular member 4, which constitutes the major part of the tank volume of the pressure tank 1.
  • the end caps 2, 3 are welded to the tubular member 4 at the connection points 5a and 5b. The weldings provide a strong and air-tight pressure tank 1.
  • the end caps 2 and 3 are made from fibre reinforced polyamide (PA6-GF30). However, the end caps 2 and 3 are not identical as the end cap 2 is provided with fittings 6 to connect the pressure tank 1 with pressure pipes (not shown).
  • the tubular member 4 is made from several layers of polyamide wound with fibres.
  • Figure 2 shows a front view of the end caps 2 and 3.
  • Figure 2A shows the end cap 2 with the fittings 6, and figure 2B shows the end cap 3 which have no fittings.
  • Figure 3 shows and end cap 2 with fittings 6.
  • the end cap 2 is reinforced with a pre-shaped net 7 integrated in the surface 8 (the outer surface) of the end cap 2. In this embodiment, the net 7 has been integrated in the surface 8 during the moulding process by placing the pre-shaped net 7 in the female part of the mould. The net 7 has been subjected to a pre-forming procedure to fit in the mould.
  • Figure 4 shows a section of an alternative embodiment of the end cap 3.
  • the pre-shaped net 7 is integrated in the inner surface 9 of the end cap 3.
  • the polymer shell 10 of the end cap 3 is visible in the section.
  • the polymer in this embodiment is fibre reinforced polyamide PA6- GF30, which is a polyamide with 30 % glass fibres.
  • the pre- shaped net 7 may be an organo sheet (0.5 mm GF-PA) which is manufactured from e.g. glass or mineral fibres satured with a polymer, such as polyamide.
  • connection point 5 is also seen in a sectional view, and the connection point 5 comprises a recess 11 adapted to receive the tubular member.
  • This design will ensure a very strong and tight connection between the end cap and the tubular member when the parts are welded together.
  • Figures 5 and 6 illustrate the moulding process of the end cap 3 shown in figure 4.
  • Figure 5 shows the mould which comprises two parts, the male part 20 and the female part 21.
  • a frame 22 holding the pre-shaped net 7 is placed between the two parts 20 and 21.
  • the pre-shaped net 7 in the frame 22 will be pressed into the mould in such a way that the pre-shaped net 7 will substantially follow the surface 23 of the male part 20 of the mould.
  • the net 7 will substantially be integrated in the inner surface of the moulded end cap, as shown in figure 4.
  • Figure 6 shows the frame 22 with the attached net 7.
  • the dotted line 24 encircles the part of the net which will be integrated in the end cap. The remaining part of the net has to be removed after the moulding process.
  • Figure 7 schematically shows the situation when the male part 20 of the mould and the female part 21 of the mould are pressed together and hot polymer melt is injected into the mould via the nozzle 25 in the male part 20 of the mould.
  • the mould system comprising the male part 20 and the female part 21 has only one single nozzle 25 for the injection of hot polymer melt.
  • the female part 21 of the mould is shaped to form openings 26 for fittings in the moulded end cap.
  • the pre-shaped net 7 is placed on the male part 20 of the net, and when the polymer melt is injected into the mould via the nozzle outlet 27 placed in the central portion of the male part 20, the polymer melt will fill the cavity 28 with a circular pattern.
  • the pattern by which the polymer melt spreads in the mould is indicated by the dotted lines 29.
  • the polymer melt fills the cavity 28 it will press the pre-shaped net 7 towards the surface of the male part 20, which will cause the net to be integrated in inner surface of the resulting end cap.
  • Figure 8 schematically shows how the polymer melt spreads in the cavity 28 from the nozzle inlet 27 in the male part 20.
  • the polymer melt spreads in a circular pattern indicated by dotted lines 30 in the cavity 28 between the male part 20 and the female part 21.
  • the first end cap was manufactured from fibre reinforced polyamide PA6-GF30.
  • the second end cap was also manufactured from polyamide PA6-GF30 and, moreover, with a net (organo sheet 1 mm GF-PA) integrated in the inner surface, as described above. Consequently, the first end cap was the known type, and the second end cap was according to the present invention.
  • the pressure in the tanks was 9 bars (air pressure) and the temperature was approximately -5 °C.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • General Engineering & Computer Science (AREA)
  • Filling Or Discharging Of Gas Storage Vessels (AREA)
  • Pressure Vessels And Lids Thereof (AREA)

Abstract

The present invention relates to an end cap for a pressure tank manufactured from a fibre reinforced polymer material, where the end cap, moreover, comprises a net integrated with the fibre reinforced polymer material constituting the end cap. The invention also provides a method of manufacturing the end cap.

Description

AN END CAP
The present invention relates to an end cap for a pressure tank manufactured from a fibre reinforced polymer material.
Pressure tanks for compressed gas or liquid are widely used. In particular within transport i.e. for trucks, pressure tanks are used for compressed air for the brake systems or liquids for the hydraulic systems. Thus, a truck with a trailer may be equipped with several pressure tanks. The braking system alone may comprise several pressure tanks for compressed air. Also the hydraulic system may comprise several tanks for liquid or oil.
Pressure tanks for compressed gas or liquid have traditionally been manufactured from metallic material, such as steel or aluminium. However, in recent years use of other materials has been investigated, and pressure tanks based on polymer material have been developed. Such pressure tanks are normally made from a tubular member which, at both ends, is provided with end caps to achieve a closed gas- and liquid- tight tank structure. The tubular member is normally produced by extrusion of polymer material, e.g. polyamide. The end caps are manufactured from injection molded polymer material, such as polyamide. In order to achieve sufficient strength, the tubular member is normally reinforced with fibres which are wrapped around the tubular structure, preferably with different orientations. The polymer material for the end caps normally incorporates an amount of fibres, e.g. glass fibres. The polymer material may incorporate around 30 % of fibres. The end caps may comprise openings and fittings for pressure tubes and other equipment required to operate the pressure tank. The pressure tanks manufactured from polymer material have many good properties. They are relatively easy to produce, they are not vulnerable to corrosion, and they have a lower weight than traditional pressure tanks made from metallic material. United States Patent Application US 2008/0149636 Al discloses a composite pressure vessel, which includes two end caps comprising a first layer and a second layer. The two layers are joined and heated to adhere the two layers to form a sheet. Subsequently the sheet is cut and pressed into the shape of an end cap. The first layer may be a thermoplastic polypropylene liner, and the second layer may be thermoplastic reinforced with fibres such as glass fibres.
However, it has been realised that the pressure tanks manufactured from polymer material have a problem. This problem relates to the end caps and cold weather conditions, i.e. weather with temperatures below 0 °C. In cold weather, the polymer material becomes brittle, and, although, reinforced with fibres in the polymer matrix it has been found that the end caps may burst if they are exposed to an impact e.g. caused by a stone or blow e.g. from a person trying to clean the pressure tank.
Due to the pressure of about 10 bars in the pressure tank the bursting of an end cap appears like an explosion where fractures of polymer material are hurled away from the pressure tank. This may cause dangerous situations, which is undesired. Also the blast arising from an explosion of the pressure tank may cause damage.
The object of the present invention is to provide an end cap for a pressure tank which is safer in use.
Thus, in a first aspect, the present invention relates to an end cap for a pressure tank manufactured from a fibre reinforced polymer material, wherein the end cap comprises a pre-shaped net integrated in one surface of the fibre reinforced polymer material constituting the end cap. The end cap according to the invention, which is manufactured from a moulded polymer material, comprises a pre-shaped net integrated in the polymer matrix constituting the end cap. The net contributes to making the end cap stronger, and also has the effect that the end cap will not burst. In case the end cap is damaged, the net will ensure that the end cap material is more ductile, and that only minor cracks appear in the material, and an optional elevated pressure in the pressure tank will leak out in a slow and controlled manner. The net is pre-shaped in order to ensure that the net will be properly integrated in one surface of the end cap. The net will become integrated in the surface of the end cap during manufacture. The net is pre-shaped with a curve which substantially corresponds to the curved surfaces of the end cap. The net may be impregnated with a polymer thermoplastic material which will enable the net to remain in the pre-shaped shape.
Although the end cap as such is made from fibre reinforced polymer material, which is expected to provide high strength, the further application of a pre-shaped net has been found to provide unexpected good properties of the end cap material, in particular when the end cap is subjected to temperatures below 0 °C. The net will, however, improve the properties of the end cap within the whole temperature range for which the end cap is intended for use. i.e. normal summer to winter temperatures.
As mentioned, the pressure tank comprises two end caps, i.e. one end cap at each end of the tubular member. The two end caps may be identical or they may be different. One of the two end caps may be equipped with fittings for pressure tubes and optional other means for establishing an external connection. The other end cap may be an end cap without any openings. The fittings may be produced during the manufacture or moulding of the end caps, and the pre-shaped net may be adapted to the fittings.
The end cap according to the invention comprises a first surface and a second surface. The first surface may be the surface of the end cap that has been facing the female part of the mould, and the second surface may be the surface of the end cap that has been facing the male part of the mould. Thus, the second surface will constitute the inner surface when the end cap is mounted on a pressure tank. Moreover, the net is integrated in the first surface or the second surface of the end cap. This embodiment facilitates the manner in which the net may be placed in the mould before the polymer is injected. Before the mould is assembled, the pre-shaped net may simply be placed on the surface of the male part or the female part of the mould and when the mould is assembled and the polymer injected for the formation of the end cap, the net will be integrated in the first surface or the second surface of the end cap.
For the purpose of obtaining the best possible properties of the end cap, it is preferred that the net covers substantially the entire first surface or substantially the entire second surface. However, as previously mentioned, the pre-shaped net will be adapted to allow openings for fittings and similar devices in the end cap. The net may be any kind of net which will provide sufficient strength to the end cap, such as a polymer net from e.g. polyethylene, polyamide or polyaramide, however, the net is preferably selected from a metal net, a glass fibre net, or a pre- satured glass fibre mesh. The net may also be a pre-formed dry- fibre or wet fibre web. The size of the meshes in the net may be in the range from approximately 1 to 15 mm, conveniently in the range of 5 to 10 mm. The thread or wire thickness of the net may be in the range of 0,1 to 5 mm. Although the end cap may be made from several polymer materials, it is preferred to manufacture the end cap from polyamide. The polyamide may be reinforced with glass fibres, which may be present in an amount of 25-35 %. The present invention also provides a method of producing an end cap for a pressure tank by moulding a polymer material in a mould with a male part and a female part. The method comprises the following steps:
- pre-shaping a net
- placing the pre-shaped net between the male part and the female part of a mould;
- pressing the male part and the female part of the mould together;
- injecting a polymer melt into the mould;
- allowing the polymer to harden in the mould; and
- removing the moulded end cap from the mould:
Consequently, the invention provides a method of incorporating a pre-shaped net into the polymer matrix of the end cap, thereby increasing the strength of the end cap.
The pre-shaping of the net may facilitate the mounting of the net in or on a mould part, e.g. the male part of the mould. During the pre-shaping process the net may be treated by heating. The net may be impregnated with a thermoplastic polymer material, which will soften during heat treatment and harden after cooling, thereby allowing the net to remain in the pre-shaped shape.
Moreover, the net may be prepared for mounting in a mould adapted for providing end caps with e.g. openings or fittings for pipes. The net may be prepared by cutting the net to fit in the mould and optionally by cutting holes in the net adapted to the openings or fittings in the end cap, before the net is mounted in the mould. In an embodiment of the method, the net is mounted on the male part of the mould before the two mould parts are pressed together. In this manner the net may be incorporated into the end cap in an uncomplicated operation, which only requires that the net is mounted on the male part of the mould.
In an alternative embodiment of the method the net is attached to a frame in such a way that the net is placed on the male part or on the female part of the mould before the male part and female part of the mould are pressed together. When the mould parts are pressed together, the net will then be placed in the mould on one of the two mould parts, and after the moulding process be integrated in one surface of the end cap formed by the injected polymer..
In order to facilitate the moulding process the pre-shaped net may be heated before the male part and the female part of the mould are pressed together. The heating of the pre-shaped net will soften the material of the net and make it easier to integrate in the polymer material of the end cap.
Thus, it has been found that the net is easier to place in the mould if the net substantially follows the surface of the male mould part or the surface of the female mould part. The method therefore provides the embodiments in which the net is integrated in the outer surface or in the inner surface of the moulded end cap.
According to the method, the polymer material is reinforced with fibres, preferably glass fibres. The fibres increase the strength of the polymer material and may be present in an amount of 25 to 35 %.
In mould injection procedures the polymer melt is normally injected into the mould by means of several nozzles. However, according to the method of the present invention, the polymer melt is injected into the mould by means of a single nozzle.
Moreover, the nozzle is located in the male part of the mould, and the nozzle is located in a central portion of the male part of the mould. Alternatively it would be possible to locate the nozzle in a central portion of the female part of the mould.
The use of only one nozzle placed in the central portion of the mould makes it possible to obtain a good control of the injected polymer melt and, moreover, a good integration of the pre- shaped net in the surface of the moulded end cap.
The invention provide a method for producing end caps with a high strength and by which the moulded end caps require very little post treatment.
The invention will now be described in further detail with reference to an example and drawings in which :
Fig . 1 shows a pressure tank; Fig. 2 shows the end caps for the pressure tank; Fig. 3 shows an end cap according to the invention; Fig. 4 shows a section of an end cap according to the invention;
Fig. 5 shows an arrangement for moulding an end cap according to the invention;
Fig. 6 shows a frame for use in the arrangement;
Fig. 7 shows a section of the moulding principle according to the invention; and
Fig. 8 shows a front view of the moulding principle.
The figures only show a few illustrative embodiments of the present invention. In the figures, the same reference numerals have been used for the same parts.
Figure 1 shows a pressure tank 1 provided with two end caps 2, 3. The end caps are mounted on the tubular member 4, which constitutes the major part of the tank volume of the pressure tank 1. The end caps 2, 3 are welded to the tubular member 4 at the connection points 5a and 5b. The weldings provide a strong and air-tight pressure tank 1.
The end caps 2 and 3 are made from fibre reinforced polyamide (PA6-GF30). However, the end caps 2 and 3 are not identical as the end cap 2 is provided with fittings 6 to connect the pressure tank 1 with pressure pipes (not shown). The tubular member 4 is made from several layers of polyamide wound with fibres. Figure 2 shows a front view of the end caps 2 and 3. Figure 2A shows the end cap 2 with the fittings 6, and figure 2B shows the end cap 3 which have no fittings. Figure 3 shows and end cap 2 with fittings 6. The end cap 2 is reinforced with a pre-shaped net 7 integrated in the surface 8 (the outer surface) of the end cap 2. In this embodiment, the net 7 has been integrated in the surface 8 during the moulding process by placing the pre-shaped net 7 in the female part of the mould. The net 7 has been subjected to a pre-forming procedure to fit in the mould.
Figure 4 shows a section of an alternative embodiment of the end cap 3. In this embodiment, the pre-shaped net 7 is integrated in the inner surface 9 of the end cap 3.
The polymer shell 10 of the end cap 3 is visible in the section. The polymer in this embodiment is fibre reinforced polyamide PA6- GF30, which is a polyamide with 30 % glass fibres. The pre- shaped net 7 may be an organo sheet (0.5 mm GF-PA) which is manufactured from e.g. glass or mineral fibres satured with a polymer, such as polyamide.
In figure 4, the connection point 5 is also seen in a sectional view, and the connection point 5 comprises a recess 11 adapted to receive the tubular member. This design will ensure a very strong and tight connection between the end cap and the tubular member when the parts are welded together. Figures 5 and 6 illustrate the moulding process of the end cap 3 shown in figure 4.
Figure 5 shows the mould which comprises two parts, the male part 20 and the female part 21.
A frame 22 holding the pre-shaped net 7 is placed between the two parts 20 and 21. When the two parts 20 and 21 are pressed together, the pre-shaped net 7 in the frame 22 will be pressed into the mould in such a way that the pre-shaped net 7 will substantially follow the surface 23 of the male part 20 of the mould. As a result, the net 7 will substantially be integrated in the inner surface of the moulded end cap, as shown in figure 4.
Optional devices for heating the net, dies and other means for injecting the polymer into the mould and moulding the end cap have been excluded from figure 5 for clarity.
Figure 6 shows the frame 22 with the attached net 7. The dotted line 24 encircles the part of the net which will be integrated in the end cap. The remaining part of the net has to be removed after the moulding process.
Figure 7 schematically shows the situation when the male part 20 of the mould and the female part 21 of the mould are pressed together and hot polymer melt is injected into the mould via the nozzle 25 in the male part 20 of the mould. The mould system comprising the male part 20 and the female part 21 has only one single nozzle 25 for the injection of hot polymer melt. The female part 21 of the mould is shaped to form openings 26 for fittings in the moulded end cap. The pre-shaped net 7 is placed on the male part 20 of the net, and when the polymer melt is injected into the mould via the nozzle outlet 27 placed in the central portion of the male part 20, the polymer melt will fill the cavity 28 with a circular pattern. The pattern by which the polymer melt spreads in the mould is indicated by the dotted lines 29. Moreover, when the polymer melt fills the cavity 28 it will press the pre-shaped net 7 towards the surface of the male part 20, which will cause the net to be integrated in inner surface of the resulting end cap.
Figure 8 schematically shows how the polymer melt spreads in the cavity 28 from the nozzle inlet 27 in the male part 20. The polymer melt spreads in a circular pattern indicated by dotted lines 30 in the cavity 28 between the male part 20 and the female part 21.
Example: Gunfire test
Two end caps mounted on pressure tanks were tested in a standard gunfire test according to ANSI NGV 2-2007 with a calibre 0.22" projectile at a distance of about 20 m.
The first end cap was manufactured from fibre reinforced polyamide PA6-GF30. The second end cap was also manufactured from polyamide PA6-GF30 and, moreover, with a net (organo sheet 1 mm GF-PA) integrated in the inner surface, as described above. Consequently, the first end cap was the known type, and the second end cap was according to the present invention. During the test the pressure in the tanks was 9 bars (air pressure) and the temperature was approximately -5 °C.
When the first tank was hit by the projectile, a brittle failure appeared in the end cap, and several big fragments were thrown away from the tank in what appeared as a tremendous explosion.
When the second tank was hit by the projectile, only a small crack appeared in the end cap, and the compressed air in the tank leaked out in a controlled manner.
The test clearly showed that a pressure tank with end caps according to the invention is much safer in use, than a pressure tank with the known end caps.

Claims

1. An end cap for a pressure tank manufactured from a fibre reinforced polymer material, wherein the end cap comprises a pre-shaped net integrated in one surface of the fibre reinforced polymer material constituting the end cap.
2. An end cap according to claim 1, wherein the pre-shaped net is integrated in the surface of the end cap which constitutes the inner surface when the end cap is mounted on a pressure tank.
3. An end cap according to claim 1 or 2, wherein the net covers substantially the entire surface.
4. An end cap according to any one of the preceding claims, wherein the net is selected from a metal net, a glass fibre net, a minral fibre net, an aramide net, a ceramic net or net comprising fibres and polymer material.
5. An end cap according to any one of the preceding claims, wherein the end cap is made from polyamide reinforced with glass fibres.
6. A method of producing an end cap for a pressure tank by moulding a polymer material in a mould with a male part and a female part, said method comprising the steps of:
-pre-shaping a net
-placing the pre-shaped net between the male part and the female part of a mould;
-pressing the male part and the female part of the mould together;
-injecting a polymer melt into the mould;
-allowing the polymer to harden in the mould;
-removing the moulded end cap from the mould :
7 A method according to claim 6, wherein the pre-shaped net is mounted on the male part of the mould.
8. A method according to claim 6 or 7, wherein the pre-shaped net is mounted in the female part of the mould.
9. A method according to claim 6, wherein the pre-shaped net is attached to a frame in such a way that the net is placed between the male part and the female part of the mould before the male part and female part of the mould are pressed together.
10. A method according to any one of the preceding claims 6-9, wherein the pre-shaped net is heated before the male part and the female part of the mould are pressed together
11. A method according to any one of the preceding claims 6-10, wherein the pre-shaped net is integrated in a surface of the moulded end cap.
12. A method according to any one of the preceding claims 6-11, wherein the polymer melt is polymer material is reinforced with fibres, preferably glass fibres.
13. A method according to any one of the preceding claims 6-12, wherein the polymer melt is injected into the mould by means of a single nozzle.
14. A method according to claim 13, wherein the nozzle is located in the male part of the mould.
15. A method according to claim 14, wherein the nozzle is located in a central portion of the male part of the mould.
PCT/DK2014/000007 2013-03-13 2014-01-24 An end cap WO2014139531A1 (en)

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LU102845B1 (en) * 2021-07-16 2023-01-16 Plastic Omnium New Energies France Boss assembly for a pressure vessel
WO2023285660A1 (en) * 2021-07-16 2023-01-19 Plastic Omnium New Energies France Boss assembly for a pressure vessel

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