Patent Description:
A high-pressure tank storing high pressure gas such as hydrogen is installed in a vehicle using a gaseous fuel such as a natural gas vehicle or a hydrogen fuel cell vehicle. In particular, as a high-pressure tank storing high pressure hydrogen gas, a high-pressure tank corresponding to type <NUM> is used.

In general, the high-pressure tank of type <NUM> is manufactured by forming a composite material layer on a surface of a liner made of a plastic material by a filament winding technique. The liner is manufactured by combining a metal boss and a knob to a plastic material such as polyolefin-based resin or polyamide-based resin. The composite material layer is formed by winding a composite fiber in which a carbon fiber or a glass fiber is mixed with a polymer resin such as an epoxy resin on the surface of the liner.

In the case of a high-pressure tank of a one port type, a port that is a head boss to which a valve for an entry of gas such as hydrogen is coupled is formed on one side, and a knob that is a tail boss for the purpose of fixing the tank is formed on the other side. A method in which a metallic knob cap is externally coupled to the knob has been conventionally used.

The knob cap serves to be coupled to a fixing shaft and fix the tank in order to prevent the tank from shaking during a filament winding process. Since the entire knob cap is made of metal, the knob cap became a factor hindering a weight reduction of the high-pressure tank.

The present invention has been made in an effort to provide a knob cap for a high-pressure tank formed by combining a first knob cap portion and a second knob cap portion.

An exemplary embodiment of the present invention provides a knob cap for a high-pressure tank having advantages of installing a reinforcing cap having impact resistance so as to improve a protective effect against an external impact.

Another embodiment of the present invention provides a knob cap for a high-pressure tank including a first knob cap portion having a coupling groove coupled to a knob of a liner of the high-pressure tank in a lower surface, including a peripheral wing portion extending outward to be in contact with a surface of the liner to outside of a lower portion, and having a column portion in the shape of a column extending upward in a center; and a second knob cap portion integrally coupled with the first knob cap portion, having the column portion of the first knob cap portion inserted into a hollow, and including a plurality of inner grooves in the shape of a column having an upper end opened outside of the hollow and extending downward.

According to an embodiment of the present invention, the first knob cap portion may be formed of a metal material, advantageously aluminum, and the second knob cap portion may be formed of a plastic material, advantageously a polyolefin-based resin, a composite material based on the polyolefin-based resin, or a fiber composite material containing a glass fiber or a carbon fiber in a combination of the resin.

According to an embodiment of the present invention, a reinforcing cap in the shape of a disk in which a coupling protrusion coupled to the inner groove is formed downward and a fixing hole communicatively connected with the hollow of the second knob cap portion is formed may be coupled to an upper portion of the second knob cap portion.

According to an embodiment of the present invention, a reinforcing material in the shape of a column may be inserted into the inner groove.

According to an embodiment of the present invention, the first knob cap portion may include an upper step surface formed outward in a lower end of the column portion because an outer circumferential surface is formed in step manner, a side surface formed on the upper step surface in a height direction, and a lower step surface extending outward from a lower end of the side surface, and the upper step surface, the side surface, and the lower step surface may be formed to be in contact with the second knob cap portion.

According to an embodiment of the present invention, the first knob cap portion may include a horizontal step surface extending outward from the lower end of the column portion, and the horizontal step surface and the lower surface of the second knob cap may be coupled to be in contact with each other.

According to an embodiment of the present invention, an undercut groove may be formed in at least a part of a surface of the first knob cap portion in contact with the second knob cap portion, and a protrusion portion figuratively coupled to the undercut groove may be formed in the second knob cap portion, and the first knob cap portion and the second knob cap portion may be physically coupled to each other through the undercut groove and the protrusion portion.

According to an embodiment of the present invention, an outer circumferential step may be formed in an outer circumferential surface of the second knob cap portion and may be formed on an upper end of the outer circumferential surface, and a composite material layer may be molded on the outer circumferential step when the high-pressure tank is manufactured.

According to the knob cap for the high-pressure tank according to the present invention having the configuration as described above, it is possible to apply a plastic material to a part of the knob cap that is conventionally formed of a metal material, thereby achieving a weight reduction.

According to the present invention, it is possible to form the knob cap for the high-pressure tank in a hybrid structure of the first knob cap portion made of a metal material and the second knob cap portion made of a lightweight material, thereby reducing the weight of the knob cap by applying a weight reduction available material.

According to the present invention, it is possible to install the reinforcing cap having an impact resistance on the upper surface of the knob cap, thereby increasing the ability to respond to a drop test and an external impact.

Since the present invention may have various changes and may have various forms, embodiments will be described in detail in the detailed description. However, this is not intended to limit the present invention to the specific form of disclosure, it should be understood to include all modifications, equivalents and substitutes included in the spirit and scope of the present invention. In describing each of the drawings, like reference numerals have been used for like elements.

The above terms are used only for the purpose of distinguishing one element from another element. The terms used in the present application are only used to describe specific embodiments, and are not intended to limit the present invention. The singular expression includes the plural expression unless the context clearly dictates otherwise.

<FIG> is a diagram of a configuration of a liner of a high-pressure tank according to the present invention. The high-pressure tank storing high-pressure gas such as hydrogen includes a liner <NUM> and a composite material layer <NUM> (see <FIG>) formed by winding a fiber-reinforced composite material on an outer surface of the liner by a filament winding technique. The liner <NUM> stores high-pressure gas in an internal space and maintains tightness of the gas, and the composite material layer <NUM> serves to support a stress acting in a circumferential direction of the liner due to an internal pressure of the gas.

The liner <NUM> uses a plastic material such as polyolefin-based resin or polyamide-based resin for a weight reduction, and is manufactured through blow molding, rotational molding, or injection molding.

The composite material layer <NUM> is formed by wrapping a fiber-reinforced composite material in which a carbon fiber or a glass fiber is mixed with a polymer resin such as an epoxy resin on the surface of the liner <NUM>, to maintain strength.

The high-pressure tank manufactured as described above is used for compressing and storing various fluids including liquefied petroleum gas (LPG), compressed natural gas (CNG), light hydrocarbons (methane, propane, and butane) and hydrogen gas.

A valve is coupled to one side of the liner <NUM> and a port <NUM> through which a gaseous fuel may enter and exit is formed therein, and a knob <NUM> for fixing purpose is provided on the other side. A knob cap <NUM> according to an embodiment of the present invention is coupled to the knob <NUM>.

<FIG> are diagrams illustrating a knob cap for a high-pressure tank according to a first embodiment of the present invention.

In the first embodiment of the present invention shown in <FIG> and <FIG>, when compared with a modification example of the first embodiment of the present invention shown in <FIG>, an outer circumferential step is additionally formed along a periphery of an outer circumferential surface of a second knob cap portion and the remaining configuration is the same.

Referring to <FIG>, the knob cap <NUM> according to the first embodiment of the present invention includes a first knob cap portion <NUM> and a second knob cap portion <NUM>. The first knob cap portion <NUM> and the second knob cap portion <NUM> are integrally molded to form the knob cap <NUM>. The knob cap <NUM> is coupled to the knob <NUM> formed on the other end of the liner <NUM> located inside the composite material layer <NUM> in the high-pressure tank <NUM>.

The first knob cap portion <NUM> is formed of a metal material. It is advantageous that aluminum (Al) is used as the metal material.

A coupling groove <NUM> to which the knob <NUM> of the high-pressure tank liner <NUM> is coupled is formed in the center of a lower surface of the first knob cap portion <NUM>, and a column portion <NUM> formed on the same axis as the coupling groove <NUM> on an upper side and moving upward is included.

According to an embodiment of the present invention, the coupling groove <NUM> may be formed as a nut-type groove having a screw thread on an inner circumferential surface. Accordingly, the coupling groove <NUM> may be screw-coupled to the knob <NUM> having a screw thread formed on the outer circumferential surface.

According to the first embodiment of the present invention, the outer circumferential surface of the first knob cap portion <NUM> is formed in a step manner.

In the first knob cap portion <NUM>, an upper step surface <NUM> enlarged in an outward direction from a lower end of the column portion <NUM> is formed, a lower step surface <NUM> is formed to a lower side, and a side surface <NUM> forming a height part between the upper step surface <NUM> and the lower step surface <NUM> is formed. According to the first embodiment of the present invention, the first knob cap portion <NUM> is integrally formed while the side surface <NUM> and the upper and lower step surfaces <NUM> and <NUM> are in contact with the second knob cap portion <NUM>.

A peripheral wing portion <NUM> extending in an outward direction and in contact with the surface of the liner <NUM> is formed in an annular shape on the lower portion of the first knob cap portion <NUM>. The entire bottom surface of the peripheral wing portion <NUM> is in close contact with the surface of the liner <NUM>.

Since the peripheral wing portion <NUM> extending outward in the lower portion of the knob cap <NUM> is a part extending from the first knob cap portion <NUM>, the peripheral wing portion <NUM> is formed of an aluminum material in the same way as the first knob cap portion <NUM>. Thus, the peripheral wing portion <NUM> may resist pressure or impact.

The column portion <NUM> is formed on an upper side of the first knob cap portion <NUM>. The column portion <NUM> extends upward in the center of the first knob cap portion <NUM>. The column portion <NUM> is formed to have a smaller diameter or a smaller width than that of the upper surface of a body of the first knob cap portion <NUM>. The column portion <NUM> may have a cylindrical or polygonal column shape.

The second knob cap portion <NUM> has a cylindrical shape having a hollow <NUM> in which the column portion <NUM> is inserted in the center, and is coupled to the upper portion of the first knob cap portion <NUM>.

According to the first embodiment of the present invention, the outer circumferential surface of the first knob cap portion <NUM> is formed in a step manner, and the lower surface of the second knob cap portion <NUM> is formed in the form of a stepped groove having a contact surface corresponding to the upper step surface <NUM>, the side surface <NUM>, and the lower step surface <NUM>.

When viewed as a whole, the knob cap <NUM> in which the first knob cap portion <NUM> and the second knob cap portion <NUM> are integrated includes an approximately cylindrical portion, and the peripheral wing portion <NUM> extending outward while continuing in a curve in a lower side of the cylindrical portion.

A reinforcing cap <NUM> to be described below may be coupled to the upper portion of the second knob cap portion <NUM>.

A plurality of inner grooves <NUM> are formed in the second knob cap portion <NUM> and arranged to surround the hollow <NUM>. The inner groove <NUM> is a groove in the shape of a column that extends downward from the upper surface of the second knob cap portion <NUM>, that is, has the upper end opened and extending downward. The inner groove <NUM> may be formed in the form of a circular column, a polygonal column, etc. The inner grooves <NUM> are arranged in plurality spaced apart from each other at equal intervals in a circumferential direction, and spaced in a radial direction.

The inner groove <NUM> functions to prevent shrinkage from occurring during demolding from a mold after injection molding. That is, when the knob cap <NUM> is demolded from the mold after molding, shape deformation may occur as an amount of cooling shrinkage in the central portion is relatively increased, and the inner groove <NUM> functions to prevent the shape deformation due to the shrinkage.

According to the present invention, the inner groove <NUM> may be used as a reinforcing material mounting hole. That is, when physical properties deteriorate due to the inner groove <NUM>, the physical properties may be reinforced by inserting a reinforcing material in a shape corresponding to the inner groove <NUM>, that is, a column shape.

According to an embodiment of the present invention, the second knob cap portion <NUM> is formed of a fiber composite material. The second knob cap portion <NUM> is formed of polyolefin resin (HDPE series) or polyamide series (PA6, PA66, etc.) and a compound material based thereon or a fiber composite material (SFT, LFT, etc.) containing a fiber (a carbon fiber and a glass fiber) in a combination of the above resin, it is advantageous to first manufacture the first knob cap portion <NUM> of an aluminum material and then integrally form the second knob cap portion <NUM> through insert injection. When the knob cap <NUM> having the second knob cap portion <NUM> made of such a plastic material is applied to the knob <NUM> of the high-pressure tank <NUM>, a weight of the high-pressure tank is reduced, which enables a weight reduction of the high-pressure tank.

According to the embodiment of the present invention, a physical shape coupling is formed by an undercut groove <NUM> and a protrusion portion <NUM> along the contact surface of the first knob cap portion <NUM> and the second knob cap portion <NUM>. Referring to <FIG>, the undercut groove <NUM> in a ring shape is formed in at least one of an outer circumferential surface of the column portion <NUM> of the first knob cap portion <NUM>, the upper step surface <NUM>, and the lower step surface <NUM>.

Therefore, during injection molding by inserting the first knob cap portion <NUM>, the protrusion portion <NUM> corresponding to the undercut groove <NUM> is formed in the second knob cap portion <NUM>, while the first knob cap portion <NUM> and the second knob cap portion <NUM> are physically integrally coupled to each other through the undercut groove <NUM> and the protrusion portion <NUM>. Through this, in the first knob cap portion <NUM> and the second knob cap portion <NUM>, a deterioration in a coupling force that may occur during insert injection molding of different materials is prevented.

Referring to <FIG> and <FIG>, an outer circumferential step <NUM> may be formed along the upper end of the outer circumferential surface of the second knob cap portion <NUM>. As shown in <FIG>, the composite material layer <NUM> is formed on the outer circumferential step <NUM> when the high-pressure tank <NUM> is formed. That is, the knob cap <NUM> and the composite material layer <NUM> are figuratively coupled through the outer circumferential step <NUM>. Therefore, compared to the modification example of the first embodiment of the present invention shown in <FIG>, it is more advantageous to inject an impact through the composite material layer <NUM> when the impact is applied from the outside.

The second knob cap portion <NUM> includes the reinforcing cap <NUM> that is coupled to the inner groove <NUM> and protects the high-pressure tank <NUM> from external pressure or impact to cover the upper portion of the second knob cap portion <NUM>.

According to an embodiment of the present invention, the reinforcing cap <NUM> covering the upper surface of the knob cap <NUM> may be coupled to the knob cap <NUM> to the upper side of the second knob cap portion <NUM>. A fixing groove may be formed in the center of the upper surface of the column portion <NUM>.

The reinforcing cap <NUM> is in the shape of a thin disk with a fixing hole <NUM> formed in the center, and a plurality of coupling protrusions <NUM> correspondingly coupled to the inner groove <NUM> are formed downward on a lower surface. Although not shown in <FIG>, a fixing member having a lower end fastened to the fixing groove of the column portion <NUM> is inserted through the fixing hole <NUM> to fix the reinforcing cap <NUM> and the knob cap <NUM>.

The reinforcing cap <NUM> may be formed of an expanded polypropylene (EPP) foam. As a result, the reinforcing cap <NUM> has an excellent recovery against repeated impact and deformation, maintains a high dimensional stability when exposed to an extreme temperature, and has an excellent impact resistance, a repeated buffering property, a flexibility and a chemical resistance.

<FIG> are diagrams for explaining a knob cap for a high-pressure tank according to a second embodiment of the present invention.

Hereinafter, when describing the second embodiment of the knob cap for a high-pressure tank according to the present invention with reference to <FIG>, the same reference numerals are used for the components having the same configuration and the same functions as those of the first embodiment of the present invention. In order to avoid repeated descriptions, detailed descriptions of the same or similar configurations will be omitted. The second embodiment of the present invention shown in <FIG> and <FIG> additionally includes an outer circumferential step formed on the outer circumferential surface of the second knob cap portion, compared to a modification example of the second embodiment of the present invention shown in <FIG>, and the remaining configuration is the same.

As shown in <FIG>, the knob cap according to the second embodiment of the present invention includes the first knob cap portion <NUM> and the second knob cap portion <NUM> in the same manner as in the first embodiment. However, there are some differences in a shape.

The first knob cap portion <NUM> according to the second embodiment of the present invention includes the column portion <NUM> extending upward in the center, and a horizontal step surface <NUM> enlarged in an outward direction in a lower end of the column portion <NUM>. Unlike the upper step surface <NUM> of the first embodiment of the present invention, the horizontal step surface <NUM> extends to the outer circumferential surface of the knob cap <NUM>, and thus the side surface <NUM> of the first knob cap portion <NUM> does not come into contact with the lower surface of the second knob cap portion <NUM> and forms an outer circumferential surface continuously connected to the outer circumferential surface of the second knob cap portion <NUM>.

The second knob cap portion <NUM> is integrally formed in contact with the first knob cap portion <NUM> on the horizontal step surface <NUM>.

The peripheral wing portion <NUM> extends from the lower side of the side surface <NUM> of the first knob cap portion <NUM> outward to contact the surface of the liner <NUM>.

The second knob cap portion <NUM> has a lower surface in contact with the horizontal step surface <NUM> and has a cylindrical shape having the hollow <NUM> into which the column portion <NUM> is inserted.

According to the second embodiment of the present invention, as in the first embodiment of the present invention, when viewed as a whole, the knob cap <NUM> has an approximately cylindrical portion, and the peripheral wing portion <NUM> extending outward while continuing in a curve in a lower side of the cylindrical portion.

According to the second embodiment of the present invention, the annular undercut groove <NUM> may be formed in at least one of the horizontal step surface <NUM> of the first knob cap portion <NUM> and the outer circumferential surface of the column portion <NUM>, and during injection molding, the protrusion portion <NUM> is formed and is figuratively coupled to the undercut groove <NUM>.

[Table <NUM>] below is to explain a weight reduction rate in the knob cap (Embodiment <NUM>) manufactured according to the first embodiment of the present invention, the knob cap (Embodiment <NUM>) manufactured according to the second embodiment of the present invention and a known knob cap formed of aluminum as a comparative example. The overall shape and size of the knob cap are the same.

In Embodiment <NUM> and Embodiment <NUM>, the knob cap is a form in which the first knob cap portion made of an aluminum material and the second knob cap portion made of a long fiber thermoplastic (LFT) material are integrated through insert injection molding, and the knob cap of the comparative example is formed of an aluminum material.

In Embodiments <NUM> and <NUM> of the present invention, the resin and fiber contents in the LFT were formed to be the same.

In Embodiment <NUM> of the present invention, the volume of the aluminum material is <NUM>% and the volume of the LFT material is <NUM>%, and in Embodiment <NUM>, the volume of the aluminum material is <NUM>% and the volume of the LFT material is <NUM>%. Upon comparing Embodiment <NUM> and Embodiment <NUM> of the present invention, a relatively higher weight reduction ratio may be achieved while the volume occupied by the LFT material is increased in Embodiment <NUM>.

<FIG> and <FIG> are diagrams showing stress distribution analysis results with respect to the knob caps for a high-pressure tank according to the first and second embodiments of the present invention, in order to compare the effect of a structural stability between the first and second embodiments of the present invention.

As an experimental method, after molding a liner, the knob caps according to each embodiment of the present invention are applied to a knob of the liner, a composite material layer is formed by winding and molding a composite material by a filament winding technique, then is completely hardened, and whether the knob cap is deformed is analyzed at a minimum design bursting pressure (<NUM>,<NUM> bar).

As shown in <FIG> and <FIG>, the knob cap according to the first embodiment of the present invention may secure a safety margin of +<NUM>% in the case of a LFT material and +<NUM>% in case of an aluminum material, so that the knob cap of the first embodiment has a more excellent structural stability than that of the second embodiment.

As in the embodiment of the present invention, when the heterogeneous injection molding knob cap <NUM> made of an aluminum metal material and an LFT plastic material is applied, a weight reduction effect of <NUM> to <NUM>% may be obtained, which may act as a factor capable of increasing a weight efficiency of the high-pressure tank.

According to the present invention, it may be confirmed that the weight reduction and the reinforcement of physical properties of the high-pressure tank may be simultaneously obtained.

Claim 1:
A knob cap (<NUM>) for a high-pressure tank (<NUM>), the knob cap (<NUM>) comprising:
a first knob cap portion (<NUM>) having a coupling groove (<NUM>) coupled to a knob of a liner (<NUM>) of the high-pressure tank in a lower surface, including a peripheral wing portion (<NUM>) extending outward to be in contact with a surface of the liner (<NUM>) to outside of a lower portion, and having a column portion (<NUM>) formed in a shape of a column extending upward in a center;
characterized in that the knob cap (<NUM>) further comprises a second knob cap portion (<NUM>) integrally coupled with the first knob cap portion (<NUM>), having the column portion (<NUM>) of the first knob cap portion (<NUM>) inserted into a hollow (<NUM>), and comprising a plurality of inner grooves (<NUM>) in the shape of a column having an upper end opened outside of the hollow (<NUM>) and extending downward.