CN102163727A - 具有改善热阻的陶瓷化聚合物的压力容器 - Google Patents

具有改善热阻的陶瓷化聚合物的压力容器 Download PDF

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CN102163727A
CN102163727A CN2011100405146A CN201110040514A CN102163727A CN 102163727 A CN102163727 A CN 102163727A CN 2011100405146 A CN2011100405146 A CN 2011100405146A CN 201110040514 A CN201110040514 A CN 201110040514A CN 102163727 A CN102163727 A CN 102163727A
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CN102163727B (zh
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P.布罗伊尔
M.林德纳
A.弗勒利希
M.布吕格尔曼
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GM Global Technology Operations LLC
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Abstract

本发明涉及具有改善热阻的陶瓷化聚合物的压力容器。本发明公开了一种盛放加压流体的容器，该容器具有由可模制材料形成的中空内壳，其中形成有空腔，在内部容器壳上形成的中间壳，和在所述中间壳上形成的外壳，所述外壳具有形成在其外表面的陶瓷层。

Description

具有改善热阻的陶瓷化聚合物的压力容器
技术领域
本发明涉及一种容器，尤其涉及一种压力容器，其具有由可模制材料形成的中空内壳，在内壳上形成的中间壳，和在中间壳上形成的外壳，外壳浸渍有适用于当接触热能时形成围绕外层的陶瓷层的陶瓷化材料。
背景技术
燃料电池已被提议作为一种电动汽车和其他应用的动力源。在质子交换膜（PEM）型燃料电池中，氢气作为燃料提供给燃料电池的阳极以及氧气作为氧化剂提供给燃料电池的阴极。在燃料电池组中多个燃料电池叠放在一起以形成燃料电池***。燃料和氧化剂通常储存在加压中空容器中，如燃料箱，例如，布置在车辆底盘上。
典型的加压容器10如图1a、1b和2所示。容器10包括三个壳：内壳12、形成在内壳12上的中间壳14、和形成在中间壳14上的外壳16。内壳12通常由聚合物材料形成，如聚乙烯，对苯二甲酸乙二醇聚酯（PET），乙烯-乙烯醇，或乙烯醋酸乙烯酯共聚物。内壳12也可由可模制材料形成，如金属、玻璃等等。中间壳14通常由从碳纤维和碳纤维复合物中的一种通过细丝缠绕工艺形成并为容器10提供结构强度。外壳16通常由绕中间壳14缠绕的玻璃纤维形成。外壳16通常浸渍有环氧树脂或其他合适的粘合剂以促进外壳16与中间壳14的粘合。
容器10的内壳12通常形成在便于与容器10的内部流体连通的终止部的外部或内部上。在图1a中，终止部是金属凸起部18。金属凸起部18与阀门20连通，但是金属凸起部18也与用于与其他容器配件流体连通（未示出）的任何装置连通，如泄压装置、喷嘴、管道等等。
为了减小热能对典型的容器的一个或多个内壳的影响，金属壳形成在容器的外壳周围。这种金属壳的形成是劳动密集型的、增加了重量、并最大化了容器的装配和材料成本。
开发一种适应于减小热能对容器的影响的中空压力容器是可取的，同时也最小化其装配和材料成本。
发明内容
与本发明相一致的，适合于减小热能对容器的影响，同时也最小化其装配和材料成本的中空压力容器已令人惊讶地被发现。
在一个实施例中，容器包括由可模制材料形成的内壳并在其中形成空腔；中间壳形成在所述内壳上；和外壳形成在所述中间壳上，所述外壳浸渍有陶瓷化材料。
在另一个实施例中，容器包括由可模制材料形成的内壳并在其中形成空腔；由碳纤维形成的中间壳形成在所述内壳上；和由浸渍有陶瓷化材料的玻璃纤维形成外壳，其中陶瓷化材料适合于当接触热能时形成围绕外层的陶瓷层。
在另一个实施例中，容器包括由可模制材料形成的中空内壳并在其中形成空腔；第一壳；形成在所述第一壳和所述外壳之间的第二壳；和形成在所述第一壳上并进入所述第一壳中的陶瓷壳，所述陶瓷壳由浸渍在所述第一壳的材料中的陶瓷化材料形成，其中所述陶瓷化材料当接触热能时形成所述陶瓷壳。
本发明还提供了如下方案：
方案1. 一种容器，包括：
由可模制材料形成并在其中形成空腔的内壳；
形成在所述内壳上的中间壳；和
形成在所述中间壳上的外壳，所述外壳浸渍有陶瓷化材料。
方案2. 如方案1的容器，其中陶瓷化材料适合于当与热能接触时形成环绕所述外壳的陶瓷层。
方案3. 如方案2的容器，其中热能的范围从大约300摄氏度到大约1000摄氏度。
方案4. 如方案1的容器，其中陶瓷层渗入所述外壳。
方案5. 如方案4的容器，其中陶瓷层将所述外壳粘合到所述中间壳。
方案6. 如方案1的容器，其中陶瓷化材料包括聚合物、至少一种耐火矿物和熔剂。
方案7. 如方案6的容器，其中陶瓷化材料进一步包括功能性添加剂。
方案8. 如方案7的容器，其中功能性添加剂是阻燃剂、抑烟剂、发泡剂、着色剂以及上述添加剂组合中的其中之一。
方案9. 如方案6的容器，其中聚合物是三元乙丙橡胶、聚酯、丙烯腈酸酯、氯乙烯、聚烯烃、聚酰胺、上述材料的衍生物、上述材料的共混物、及上述材料的共聚物中的至少一种。
方案10. 如方案6的容器，其中耐火矿物是陶瓷形成前体物和陶瓷的其中之一。
方案11. 如方案6的容器，其中耐火矿物是硅酸盐矿物。
方案12. 如方案11的容器，其中硅酸盐矿物是粘土和云母的其中之一。
方案13. 如方案6的容器，其中熔剂包括铅、硼、钠、钾、锂、钙、镁、钡、锌、锶和长石的其中之一。
方案14. 如方案13的容器，其中长石是钾长石和钠长石中的一种。
方案15. 如方案1的容器，其中所述中间壳由碳纤维形成。
方案16. 如方案1的容器，其中所述外壳由玻璃纤维形成。
方案17. 一种容器，包括：
由可模制材料形成并在其中形成空腔的内壳；
由碳纤维形成在所述内壳上的中间壳；和
由浸渍有陶瓷化材料的玻璃纤维形成的外壳，其中陶瓷化材料适合于当与热能接触时形成环绕所述外壳的陶瓷层。
方案18. 如方案17的容器，其中陶瓷化材料包括聚合物、至少一种耐火矿物和熔剂。
方案19. 一种容器，包括：
由可模制材料形成并在其中形成空腔的中空内壳；
第一壳；
形成在所述第一壳和所述外壳之间的第二壳；和
形成在所述第一壳上并渗入形成所述第一壳的材料内的陶瓷壳，所述陶瓷壳由浸渍在所述第一壳的材料内的陶瓷化材料形成，其中当与热能接触时所述陶瓷化材料形成所述陶瓷壳。
方案20. 如方案19的容器，其中陶瓷化材料包括聚合物、至少一种耐火矿物和熔剂。
附图说明
当结合参考附图，对于本领域技术人员而言，本发明的上述和其它优点将从以下优选实施例的详细描述中变得显而易见。
图1a为现有技术中已知的容器的部分截面立体图；
图1b为图1a中由圆b强调的容器的不完整的横截面放大视图；
图2为图1a的容器的横截面端部正视图；
图3为根据本发明的实施例的容器的横截面端部正视图；
图4为图3中容器在接触热能之后的横截面端部正视图。
具体实施方式
下面详细的说明书和附图描述和阐述了本发明的各种具体实施例。说明书和附图作用为使得本领域技术人员制造并使用本发明，且不以任何方式限制本发明的范围。在所披露的方法方面，提出的步骤在本质上是具体的，因此，这些步骤的顺序不是必要或关键的。
图3和图4说明了中空压力容器310，其具有内壳312、中间壳314和外壳316。如图1a、1b和2中说明的容器10一样，容器310具有大致圆柱的形状且适合于容纳加压流体（未示出）。可以理解，容器310可以具有所需的任何形状，且容器310可包括额外的层，如所需的屏障层、箔层、多孔渗透层等等，和共同拥有的申请号为11/847,007的美国专利申请以及申请号为11/956,863的美国专利申请中公开的类似，其因此在这里以整体合并作为参考。加压流体可以是任意流体， 例如，氢气和氧气、液体、以及同时为液体和气体。
容器310的内壳312是适合于储存加压流体的中空容器，如图所示，内壳312由一层聚合物材料形成，但是内壳312也可按要求由多层形成。内壳312可通过吹塑、挤出吹塑、旋转成型或任意其他合适的加工过程形成。在所示实施例中，内壳312大致为圆柱形状。然而，内壳312可具有所需要的任意形状。如同容器10一样，内壳312的第一端（未示出）可容纳至少一部分凸起部（未示出）。内壳312可由塑料形成，如聚乙烯，对苯二甲酸乙二醇聚酯（PET），乙烯-乙烯醇，或乙烯醋酸乙烯酯共聚物。内壳312也可由其他模制材料如金属、玻璃等等形成。
容器310的中间壳314在内壳312和外壳316之间布置内壳312上。中间壳314具有大致圆柱的形状。如图所示，中间壳314基本邻接内壳312。中间壳314可由任意可模制的材料形成，如金属和塑料，例如，或中间壳314可由细丝缠绕工艺形成。如果中间壳314通过细丝缠绕工艺形成，那么中间壳314可例如由碳纤维、玻璃纤维、复合纤维和具有树脂涂料的纤维等等形成。可以理解，使用来形成中间壳314的材料可基于用来将中间壳314粘贴到内壳312的工艺、容器310的使用以及待储存在容器310内的流体的性质来选择。
容器310的外壳316布置在至少一部分中间壳314上。外壳316具有大致圆柱的形状。如图3和4所示，外壳316基本邻接中间壳314。外壳316由浸渍有或以其他方式涂覆有陶瓷化材料322的玻璃纤维通过细丝缠绕工艺形成。由于陶瓷化材料322，外壳316具有比典型容器的玻璃纤维外壳更大的厚度，如容器10的外壳16。外壳316也可浸渍有环氧树脂以促进外壳316与中间壳314的粘合。可以理解，外壳316可由碳纤维、复合纤维、具有树脂涂层的纤维和其他任何适合于以细丝缠绕的材料形成。额外的陶瓷化材料322可通过喷涂工艺、涂覆在工艺、浸蘸工艺以及其他适合于将陶瓷化材料322填充到外壳316的纤维之间的空隙空间的工艺布置在外壳316的表面上。
陶瓷化材料322是一种复合材料，其包括基体、至少一种耐火矿物和熔剂。陶瓷化材料322也可选择性地包括功能添加剂。在图3所示的实施例中，基体是一种聚合物材料，如聚酯，丙烯腈酸酯，氯乙烯，聚烯烃，聚酰胺，上述材料的衍生物，上述材料的共混物，及上述材料的共聚物。基体也可以是橡胶，如三元乙丙橡胶（EPDM）。耐火矿物可以是陶瓷形成前体物或陶瓷的其中之一，如硅酸盐矿物。硅酸盐矿物可以是粘土或云母。熔剂可以是任意用来降低耐火材料的熔点的材料。熔剂可以是铅、硼、钠（soda）、钾、锂、钙、镁、钡、锌、锶和包括上述任意材料的化合物，如二硅酸铅。熔剂还可以是长石，如钾长石和钠长石。功能性添加剂可以是阻燃剂、抑烟剂、发泡剂、着色剂以及上述添加剂组合中的其中之一。
在使用中，容器310连接到燃料电池动力车辆。可以理解，容器310可连接到以任何方式驱动的车辆。当容器310在正常操作条件下并处于环境温度时，容器310如上所述。然而，当容器310与具有从大约150摄氏度到大约300摄氏度的温度的热能接触时，聚合物基体降解。当聚合物基体降解时和容器310与温度从大约300摄氏度到大约1000摄氏度的热能接触时，耐火矿物进入液态相并形成多孔陶瓷壳324，称为陶瓷化过程，如图4所示。陶瓷化涉及处于液态相的耐火矿物颗粒的粘结或熔合，以及耐火矿物颗粒的反应烧结。耐火矿物这样选择以至于形成的陶瓷当与具有温度从大约750摄氏度到大约1000摄氏度的热能接触时不会发生收缩。耐火矿物的熔点通过熔剂材料降低以促进陶瓷壳324的形成。熔剂和耐火矿物，以及它们每种使用的量是基于它们每种的性质选择的，以确保液态相的耐火材料具有所需的粘度且在与温度从大约300摄氏度到大约1000摄氏度的热能接触时不从外壳316中的空隙空间流走。由于容器310与热能接触的结果，陶瓷壳324围绕外壳316形成且陶瓷壳324渗入外壳316中。陶瓷壳324适合于最小化容器310的中间壳314和内壳312与热能接触。
从前面的描述中，本领域技术人员可以很容易地确定本发明的本质特征，在不脱离本发明的精神和范围下，可以改变和改进本发明以使其适用于不同的用途和条件。

Claims (10)

1. 一种容器，包括：
由可模制材料形成并在其中形成空腔的内壳；
形成在所述内壳上的中间壳；和
形成在所述中间壳上的外壳，所述外壳浸渍有陶瓷化材料。
2. 如权利要求1的容器，其中陶瓷化材料适合于当与热能接触时形成环绕所述外壳的陶瓷层。
3. 如权利要求2的容器，其中热能的范围从大约300摄氏度到大约1000摄氏度。
4. 如权利要求1的容器，其中陶瓷层渗入所述外壳。
5. 如权利要求4的容器，其中陶瓷层将所述外壳粘合到所述中间壳。
6. 如权利要求1的容器，其中陶瓷化材料包括聚合物、至少一种耐火矿物和熔剂。
7. 如权利要求6的容器，其中陶瓷化材料进一步包括功能性添加剂。
8. 如权利要求7的容器，其中功能性添加剂是阻燃剂、抑烟剂、发泡剂、着色剂以及上述添加剂组合中的其中之一。
9. 一种容器，包括：
由可模制材料形成并在其中形成空腔的内壳；
由碳纤维形成在所述内壳上的中间壳；和
由浸渍有陶瓷化材料的玻璃纤维形成的外壳，其中陶瓷化材料适合于当与热能接触时形成环绕所述外壳的陶瓷层。
10. 一种容器，包括：
由可模制材料形成并在其中形成空腔的中空内壳；
第一壳；
形成在所述第一壳和所述外壳之间的第二壳；和
形成在所述第一壳上并渗入形成所述第一壳的材料内的陶瓷壳，所述陶瓷壳由浸渍在所述第一壳的材料内的陶瓷化材料形成，其中当与热能接触时所述陶瓷化材料形成所述陶瓷壳。
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