阅读说明：本技术 一种防爆裂塑料内胆复合材料储罐及其制作方法 (Anti-burst plastic inner container composite material storage tank and manufacturing method thereof ) 是由 刘峰 赵利可 李楠 周晓兵 刘岩 于 2020-12-30 设计创作，主要内容包括：本发明公开了一种防爆裂塑料内胆复合材料储罐及其制作方法,包括塑料内胆、凸台和复合材料缠绕层；塑料内胆表面铺设或缠绕预浸编织纤维层,构成阻隔层；阻隔层的表面采用长丝缠绕构成结构层；阻隔层包括第一组碳纤维和第二组碳纤维；第一组碳纤维与所述第二组碳纤维之间采用交错碳纤维编织；本发明通过在塑料内胆和结构层之间,增加编织碳纤维和高延展性树脂构成的阻隔层,分担塑料内胆的缠绕轴和防渗漏功能以及分担外部结构纤维层载荷；通过阻隔层编织方式的设计可以控制阻隔层载荷的传递和分布,阻隔层碳纤维第一失效模式为由编织模式设计决定的负载超荷引起的碳纤维有序断裂而导致的撕裂,失效发生时内容气体将沿外层结构层孔隙发生泄露。(The invention discloses an anti-burst plastic liner composite material storage tank and a manufacturing method thereof, wherein the anti-burst plastic liner composite material storage tank comprises a plastic liner, a boss and a composite material winding layer; laying or winding a pre-impregnated woven fiber layer on the surface of the plastic inner container to form a barrier layer; the surface of the barrier layer is wound by filaments to form a structural layer; the barrier layer comprises a first group of carbon fibers and a second group of carbon fibers; the first group of carbon fibers and the second group of carbon fibers are woven by adopting staggered carbon fibers; according to the invention, the barrier layer formed by weaving carbon fibers and high-ductility resin is additionally arranged between the plastic inner container and the structural layer, so that the winding shaft and the anti-leakage function of the plastic inner container are shared, and the load of the external structural fiber layer is shared; the transmission and the distribution of barrier layer load can be controlled through the design of barrier layer weaving mode, and the first failure mode of barrier layer carbon fiber is the tearing that leads to for the orderly fracture of carbon fiber that causes of the load overload that is decided by weaving mode design, and content gas will reveal along outer structural layer pore place when the failure takes place.)

1. An anti-burst plastic liner composite material storage tank comprises a plastic liner, a boss and a composite material winding layer; the method is characterized in that: the surface of the plastic inner container is paved or wound with a pre-impregnated woven fiber layer to form a barrier layer; the surface of the barrier layer is wound by filaments to form a structural layer; the barrier layer comprises a first set of carbon fibers and a second set of carbon fibers; the first group of carbon fibers and adopt crisscross carbon fiber to weave between the second group of carbon fibers, through the transmission and the distribution of barrier layer load can be controlled in the design of barrier layer weaving mode, and the first failure mode of barrier layer carbon fiber is the tearing that leads to for the orderly fracture of carbon fiber that causes by the load overload that weaves the mode design decision, and content gas will follow outer structural layer pore and take place to reveal when the failure takes place.

2. The burst-proof plastic liner composite storage tank as claimed in claim 1, wherein: the barrier layer bears a predetermined proportion of the total load generated within the tank in response to internal pressurisation, much higher than the proportion to which the plastics liner is subjected.

3. The burst-proof plastic liner composite storage tank as claimed in claim 1, wherein: each carbon fiber of the second set of carbon fibers is interwoven with one or more carbon fibers of the first set of carbon fibers at one or more angular tension angles.

4. The burst-proof plastic liner composite storage tank as claimed in claim 1, wherein: the structural layer is formed by alternately winding spiral layers and inclined layers by adopting prepreg filaments or cutting unidirectional prepreg tapes or wet winding.

5. The burst-proof plastic liner composite storage tank as claimed in claim 1, wherein: the barrier layer resin is made of high-ductility materials, and the barrier layer carbon fibers are not broken before breaking failure.

6. The burst-proof plastic liner composite storage tank as claimed in claim 1, wherein: the barrier layer comprises warp knitted carbon fibers and weft knitted carbon fibers; plain weave or twill weave is adopted between the warp-knitted carbon fibers and the weft-knitted carbon fibers.

7. The manufacturing method of the anti-burst plastic inner container composite material storage tank is characterized by comprising the following steps of:

s1, improving the surface tension of the plastic liner by a plasma surface treatment method and the like;

s2, laying or winding a pre-impregnated woven fiber layer on the surface of the plastic inner container to form a barrier layer, wherein the barrier layer can be produced by resin transfer molding, vacuum-assisted resin transfer molding, carbon fiber winding, carbon fiber laying or centrifugal casting, and is cured or uniformly cured after final winding is finished;

s3, winding filaments on the surface of the barrier layer to form a structural layer, wherein the structural layer is divided into spiral layers and inclined layers which are alternately wound, and the alternate winding can be performed by using prepreg filaments, cutting unidirectional prepreg tapes or wet winding;

and S4, curing the structural layer to form the composite structure storage tank.

8. The method for manufacturing the anti-burst plastic liner composite material storage tank as claimed in claim 7, wherein the method comprises the following steps: in the step S3, the carbon fibers and the resin of the structural layer have good compatibility with the barrier layer.

Technical Field

The invention relates to the technical field of storage tanks, in particular to an anti-burst plastic inner container composite material storage tank and a manufacturing method thereof.

Background

The existing hydrogen storage bottles in China are mainly 35Mpa three-type bottles. The metal hydrogen embrittlement effect is more obvious along with the increase of hydrogen storage pressure, and the upgrading space is limited by directly using the prior three-type bottle technical route. The 70Mpa four-type bottle wound by the plastic inner container has the characteristics of corrosion resistance, light weight and high strength, and has a good development prospect.

Conventional composite wrapped pressure vessels have an inner bladder with an outer layer of composite generally designed to prevent structural failure due to bottle rupture, while the inner bladder is designed to contain the enclosed fluid. This in turn leads to a significant decoupling of the structural design of the pressure vessel from its fluid containment requirements. This can lead to one or three practical results. First, liners in pressure vessels are inefficient at bearing the internal pressure load of the pressure vessel, which makes the liner a burden that is prone to weight gain. Second, the failure mode of conventional pressure vessels having an internal bladder, when overpressure occurs, is essentially a catastrophic rupture of the unitary structural shell rather than a leak through the internal bladder. However, for many application scenarios, both single pressurization and cyclic pressurization are required to achieve fail-safe performance in terms of "leak-before-burst" because it greatly reduces the likelihood of human injury or death from destructive destruction of the pressure vessel.

In order to solve the first problem mentioned above, and to minimize the weight of the composite pressure vessel, it is desirable to reduce the mass of the inner container while preventing leakage. To address the second problem above, and to design a composite pressure vessel for a benign "leak-before-burst" failure mode, it is desirable to reduce the structural function undertaken by the inner vessel and to identify the cause of structural failure; therefore, the invention provides an anti-burst plastic inner container composite material storage tank structure and a manufacturing method thereof.

Disclosure of Invention

The invention aims to provide an anti-burst plastic inner container composite material storage tank structure and a manufacturing method thereof, wherein a barrier layer can provide excellent barrier property and load capacity, so that the quality of an inner container is greatly reduced; in another aspect, the barrier layer may be designed to have predictable stiffness and strain-to-failure properties, thereby allowing for effective structural load sharing between the barrier fiber layer and the outer structural fiber layer, and a highly predictable leak-failure response from strain to leak.

The invention is realized by the following technical scheme:

an anti-burst plastic liner composite material storage tank comprises a plastic liner, a boss and a composite material winding layer; the bosses are positioned at the two ends of the bottle body, are coaxial with the plastic liner and are used for fixing the bottle valve port and the rotating shaft in the winding process of the composite material; wherein: the surface of the plastic inner container is paved or wound with a pre-impregnated woven fiber layer to form a barrier layer; the surface of the barrier layer is wound by filaments to form a structural layer; the barrier layer comprises a first set of carbon fibers and a second set of carbon fibers; the first group of carbon fibers and adopt crisscross carbon fiber to weave between the second group of carbon fibers, through the transmission and the distribution of barrier layer load can be controlled in the design of barrier layer weaving mode, and the first failure mode of barrier layer carbon fiber is the tearing that leads to for the orderly fracture of carbon fiber that causes by the load overload that weaves the mode design decision, and content gas will follow outer structural layer pore and take place to reveal when the failure takes place.

Further, the barrier layer bears a predetermined proportion of the total load generated within the tank in response to internal pressurization, much higher than the proportion that the plastic liner bears.

Further, each carbon fiber of the second set of carbon fibers is interwoven with one or more carbon fibers of the first set of carbon fibers at a tension angle of a particular angle.

Further, each carbon fiber of the second set of carbon fibers is interwoven with one or more carbon fibers of the first set of carbon fibers at one or more angular tension angles.

Further, the structural layer is wound alternately into spiral and inclined layers by adopting prepreg filaments or cutting unidirectional prepreg tapes or wet winding.

Further, the barrier layer resin is made of a high-ductility material, and the barrier layer carbon fiber should not be broken before the breaking failure occurs.

Further, the barrier layer comprises more than two different sets of carbon fibers, the angle and tensile load of the different carbon fibers being relatively adjustable to achieve multiple effects on stiffness and strength properties.

Further, the barrier layer comprises warp-knit carbon fibers and weft-knit carbon fibers; plain weave or twill weave is adopted between the warp-knitted carbon fibers and the weft-knitted carbon fibers.

Further, the manufacturing method of the anti-burst plastic inner container composite material storage tank comprises the following steps:

s1, improving the surface tension of the plastic liner by a plasma surface treatment method and the like;

s2, laying or winding a pre-impregnated woven fiber layer on the surface of the plastic inner container to form a barrier layer, wherein the barrier layer can be produced by resin transfer molding, vacuum-assisted resin transfer molding, carbon fiber winding, carbon fiber laying or centrifugal casting, and is cured or uniformly cured after final winding is finished;

s3, winding filaments on the surface of the barrier layer to form a structural layer, wherein the structural layer is divided into spiral layers and inclined layers which are alternately wound, and the alternate winding can be performed by using prepreg filaments, cutting unidirectional prepreg tapes or wet winding;

and S4, curing the structural layer to form the composite structure storage tank.

Further, in the step S3, the carbon fiber and the resin of the structural layer have good compatibility with the barrier layer.

The invention has the beneficial effects that:

1) the invention adds the barrier layer formed by the woven carbon fiber and the high-ductility resin between the plastic inner container and the structural layer to share the structure and the anti-seepage function of the plastic inner container. Because the structural load contribution of the liner in the composite hydrogen storage bottle is far less than that of the barrier layer and the structural layer, and the load of the barrier layer is designed to be lower than that of the structural load, the failure mode of the barrier layer is mainly tearing caused by the fracture of carbon fibers, so that internal pressor leaks from microgaps of the structural layer. The failure mode of the barrier layer mainly comprising carbon fiber fracture can be predicted, so that the anti-burst plastic liner composite material storage bottle structure with high repeatability and predictability leakage failure response can be designed.

2) The barrier layer is formed outside the plastic liner by combining the woven or knitted carbon fiber reinforced material and/or the high-ductility resin material, provides an excellent anti-leakage barrier function, and shares the hydrogen storage load borne by the liner. The incorporation of a high tenacity resin material into the woven or knitted fiber layers may provide resistance to microcracking. The woven or braided fiber layers provide a hard protective barrier against the propagation of voids and resin microcracks due to manufacturing defects when the composite pressure vessel is pressurized alone or subjected to pressure cycling during use.

Drawings

FIG. 1 is a schematic structural view of an anti-burst plastic liner composite storage tank according to an embodiment of the present invention;

FIG. 2 is an enlarged schematic view of section III of FIG. 1;

FIG. 3 shows a carbon fiber weave pattern of a carbon fiber composite material according to an embodiment of the present invention;

FIG. 4 is another carbon fiber weave pattern for a carbon fiber composite of an embodiment of the present invention;

fig. 5 shows another carbon fiber weaving pattern of the carbon fiber composite material according to the embodiment of the invention.

Description of reference numerals: 1-boss; 2-structural layer; 3-plastic inner container; 4-barrier layer.

Detailed Description

The invention will be described in detail with reference to the drawings and specific embodiments, which are illustrative of the invention and are not to be construed as limiting the invention.

It should be noted that all the directional indications (such as up, down, left, right, front, back, upper end, lower end, top, bottom … …) in the embodiments of the present invention are only used to explain the relative position relationship between the components, the movement situation, etc. in a specific posture (as shown in the drawings), and if the specific posture is changed, the directional indication is changed accordingly.

In the present invention, unless expressly stated or limited otherwise, the term "coupled" is to be interpreted broadly, e.g., "coupled" may be fixedly coupled, detachably coupled, or integrally formed; can be mechanically or electrically connected; they may be directly connected or indirectly connected through intervening media, or they may be connected internally or in any other suitable relationship, unless expressly stated otherwise. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.

In addition, the descriptions related to "first", "second", etc. in the present invention are only for descriptive purposes and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature; in addition, technical solutions between various embodiments may be combined with each other, but must be realized by a person skilled in the art, and when the technical solutions are contradictory or cannot be realized, such a combination should not be considered to exist, and is not within the protection scope of the present invention.

As shown in fig. 1 and 2, the anti-burst plastic liner composite material storage tank comprises a plastic liner 3 and a boss 1; wherein: a pre-impregnated woven fiber layer is laid or wound on the surface of the plastic inner container 3 to form a barrier layer 4; the surface of the barrier layer 4 is wound by filaments to form a structural layer 2; the barrier layer 4 comprises a first set of carbon fibres and a second set of carbon fibres; first group carbon fiber with adopt crisscross carbon fiber to weave between the second group carbon fiber, through the transmission and the distribution of barrier layer load can be controlled in the design of barrier layer 4 weaving mode, and the first failure mode of barrier layer 4 carbon fiber is the tearing that leads to for the orderly fracture of carbon fiber that causes by the load overload that weaves the mode design decision, and content gas will follow outer structural layer 2 holes and take place to reveal when the failure takes place.

A barrier layer 4 made of woven fibers and high-ductility resin is added between the plastic liner 3 and the structural layer 2 to share the structure and the leakage prevention function of the plastic liner 3. Since the structural load contribution of the liner in the composite hydrogen storage cylinder is much less than that of the barrier layer 4 and the structural layer 2, and the barrier layer 4 load is designed to be lower than the structural load, the failure mode of the barrier layer 4 is mainly tearing caused by the fracture of carbon fibers, thereby causing the internal pressurization object to leak from the micro-gap of the structural layer 2. The failure mode of the barrier layer 4 mainly comprising carbon fiber fracture can be predicted, so that the anti-burst plastic liner 3 composite material storage bottle structure with high repeatability and predictability leakage failure response can be designed.

The structure of the anti-burst plastic inner container 3 composite material storage tank combines the weaving or weaving of the carbon fiber reinforced material and/or the high-ductility resin material to form the barrier layer 4 outside the plastic inner container 3, and the barrier layer 4 provides an excellent anti-leakage barrier function and shares the hydrogen storage load born by the inner container. The incorporation of a high tenacity resin material into the woven or knitted fiber layers may provide resistance to microcracking. The woven or braided fiber layers provide a hard protective barrier against the propagation of voids and resin microcracks due to manufacturing defects when the composite pressure vessel is pressurized alone or subjected to pressure cycling during use.

The reason why the braided material prevents microcracks is as follows:

the woven material is effectively utilized in embodiments of the present invention due to its high efficiency in distributing loads, mitigating microcracks, void generation and propagation of manufacturing induced defects, and providing a ductile, damage-resistant barrier layer 4. The carbon fibers in the woven structure are continuous and mechanically locked, thereby providing a natural mechanism by which loads can be distributed throughout the structure. This effective load distribution also makes the braided structure very impact resistant. Since all the carbon fibers in the woven structure are loaded, the woven material will absorb a large amount of energy when broken. This braided structure is thus also effective in preventing fatigue failure. Like filament wound structures, braided carbon fibers are helically wound, but they also have the additional function of mechanical interlocking. When the overall structure is subjected to high fatigue cycles, cracks will propagate through the matrix of filament wound or unidirectional woven material laminations. However, when cracks occur in the woven structure, the propagation of the cracks may be prevented at the intersections of the reinforcing carbon fibers. Furthermore, when the woven material is nested with other woven materials to produce a woven composite, there is virtually no delamination when subjected to fatigue loads. Because the composite woven layers move relative to each other, cracks are less likely to form and propagate between the woven reinforcement layers. The construction of the woven material provides a natural compliance so that the carbon fibers do not have to be cut, stitched or otherwise manipulated when placed.

It is noted that in a first set of embodiments, a fully composite pressure vessel or tank structure includes a body defining an enclosed interior volume. A cross-sectional structure of a pressure vessel has a plurality of carbon fiber resin reinforced polymer layers. At least one set of reinforced polymer layers is designed as a barrier layer 4 that provides a protective barrier against leakage and/or damage due to impact, while also providing a portion of the desired stiffness and strength of the pressure vessel structure. The other structural layers 2 are designed to provide the remaining required stiffness and strength to the pressure vessel structure.

In various embodiments, one or more barrier layers 4 may comprise carbon fiber windings or a combination of carbon fiber windings. The woven fiber layers provide protection against propagation due to manufacturing defects, voids, and resin microcracks when the composite pressure vessel is pressurized alone or subjected to pressure cycling during use, and thus, in various embodiments of such woven fiber layers, desirable barrier properties may be produced.

In particular, in the solution of the present embodiment, the barrier layer 4 bears a predetermined proportion of the total load generated in the tank in response to the internal pressurisation, much higher than the proportion to which the plastic liner 3 bears.

Specifically, in this embodiment, each carbon fiber of the second group of carbon fibers is interwoven with one or more carbon fibers of the first group of carbon fibers at the same tension angle. It is noted that both the first set of carbon fibers and the second set of carbon fibers participate in the internal pressurization reaction of the pressure vessel. As the internal pressure increases, the tension in the carbon fibers increases almost uniformly until the rupture strength of all the carbon fibers is exceeded. This "uniformly stretched" (uniformly tensioned) barrier design is intended to produce effective load sharing between the barrier and non-barrier layers and to provide uniform rupture strength of the barrier layer 4 in either direction of load bearing.

Specifically, in this embodiment, each carbon fiber of the second group of carbon fibers is interwoven with one or more carbon fibers of the first group of carbon fibers at a tension angle of one or more angles; resulting in uneven tensioning of the two sets of carbon fibers. The carbon fibers react to the internal pressure of the pressure vessel, and as the internal pressure increases, the tension in one set of carbon fibers increases more rapidly than the tension in the other set of carbon fibers. In this case, the design of the barrier layer 4 is intended to achieve preferential failure in one particular direction (i.e., the direction of the higher loaded carbon fibers).

Specifically, in the embodiment, the structural layer 2 is wound alternately in spiral and inclined layers by using prepreg filaments or cut unidirectional prepreg tapes or wet winding.

Specifically, in this embodiment, the barrier layer 4 and the structural layer 2 are made of high-ductility resin materials. It should be noted that the key to the design of the barrier layer 4 is that its first mode of failure under pressure is to limit the rupture of the carbon fibre reinforcement on the barrier layer 4, resulting in leakage of the internal pressurisation. Such carbon fiber-based failure modes are accurately predictable, allowing the design of fully composite pressure vessel structures with highly repeatable and predictable leakage failure responses. To ensure that carbon fiber breakage is the first failure mode, the barrier layer 4 (or layers) must be of a highly ductile resin material to provide resistance to initiation and propagation of microcracks until the strain exceeds the strain-to-failure capability of the carbon fiber reinforcement.

Specifically, in this embodiment, the barrier layer 4 includes more than two groups of different carbon fibers, and the angles and tensile loads of the different carbon fibers can be relatively adjusted to achieve various influences on the stiffness and strength performance.

Specifically, in this embodiment, the barrier layer 4 includes warp-knitted carbon fibers and weft-knitted carbon fibers; plain weave or twill weave is adopted between the warp-knitted carbon fibers and the weft-knitted carbon fibers. It is noted that the carbon fibers in the barrier layer 4 may be applied by a filament winding or filament laying process, wherein the carbon fibers are placed at two or more intersecting angles; referring to fig. 3, the warp-knitted carbon fibers and the weft-knitted carbon fibers are interlaced one on top of the other to form barrier layer 4 carbon fibers; referring to 4, the warp-knitted carbon fibers and the weft-knitted carbon fibers are interwoven in two upper parts and two lower parts to form barrier layer 4 carbon fibers; referring to fig. 5, the warp-knitted carbon fibers and the weft-knitted carbon fibers are interwoven in three-over-three-under to form barrier layer 4 carbon fibers.

It is noted that in some instances, the barrier layer is the first composite layer within the pressure vessel. In one example, one or more non-barrier layers may be disposed between two barrier layers. In another example, one or more barrier layers may be disposed between two non-barrier layers. In other cases, multiple barrier layers may be interleaved with multiple non-barrier layers.

In some cases, the barrier layer may be disposed across all portions of the pressure vessel. In other cases, the barrier layer traverses only a portion of the pressure vessel.

Specifically, in the embodiment, a method for manufacturing a composite storage tank with an anti-burst plastic inner container includes the following steps:

s1, improving the surface tension of the plastic inner container 3 by a method such as plasma surface treatment;

s2, laying or winding a pre-impregnated woven fiber layer on the surface of the plastic inner container to form a barrier layer, wherein the barrier layer 4 can be produced by resin transfer molding, vacuum-assisted resin transfer molding, carbon fiber winding, carbon fiber laying or centrifugal casting, and the barrier layer 4 is cured or uniformly cured after final winding is finished;

s3, winding filaments on the surface of the barrier layer 4 to form a structural layer 2, wherein the structural layer 2 is divided into spiral layers and inclined layers which are alternately wound, and the alternate winding can be performed by using prepreg filaments, cutting unidirectional prepreg tapes or wet winding;

and S4, curing the structural layer 2 to form the composite structure storage tank.

The method for manufacturing the composite material tank with the burst-proof plastic liner 3 is characterized in that the carbon fiber reinforced material for the barrier layer 4 is placed on the inflated liner subjected to the plasma surface treatment, and the liner provides a three-dimensional shape for the interior of the tank body. And then impregnating the carbon fiber resin reinforcing material into the carbon fiber of the barrier layer 4, curing the reinforcing layer to serve as a winding shaft of the structural layer 2, and winding the carbon fiber and resin of the structural layer 2 on the barrier layer 4 by using a standard carbon fiber winding technology. Finally, the resin in the structural layer 2 is cured.

Specifically, in this embodiment, in step S3, the carbon fibers and the resin of the structural layer 2 have good compatibility with the barrier layer 4.

The technical solutions provided by the embodiments of the present invention are described in detail above, and the principles and embodiments of the present invention are explained herein by using specific examples, and the descriptions of the embodiments are only used to help understanding the principles of the embodiments of the present invention; meanwhile, for a person skilled in the art, according to the embodiments of the present invention, there may be variations in the specific implementation manners and application ranges, and in summary, the content of the present description should not be construed as a limitation to the present invention.