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WRAPPED GAS CYLINDERS
Product
IntroductionWRAPPED GAS CYLINDER
Brand: KAIGEN and LEO
I. Type
Type - 2 (Type - II, metal liner radially wrapped gas cylinder), Type - 3 (Type - III, metal liner fully wrapped gas cylinder), Type - 4 (Type - IV, non-metal liner fully wrapped gas cylinder)
II. TYPE - III Metal Liner Fully Wrapped Gas Cylinder
Metal liner fully wrapped gas cylinder combines the excellent sealing and damage resistance of metal with the high strength and lightweight characteristics of composite materials, making it the leading technology in the field of high-pressure, lightweight and high-safety gas cylinders.
(I) Advantages of metal liner fully wrapped gas cylinders
1. High pressure: can be designed and withstand very high pressure (commonly 20MPa, 30MPa, 35MPa, 70MPa or even higher).
2. Lightweight: Compared with all-metal gas cylinders of the same volume and pressure, the weight is significantly reduced (usually 40%-70% less), which greatly improves portability and application efficiency (such as vehicle endurance, firefighter carrying).
3. High safety
• The metal liner provides reliable sealing.
• There are obvious signs before the break (such as resin cracking and fiber breaking sound).
• If the material layer is accidentally damaged (such as scratches and impacts), the metal liner can usually still maintain structural integrity for a period of time ("leak before explosion" mode), providing a time window for safe disposal and avoiding catastrophic instantaneous explosion ("explosion" mode).
• Excellent fatigue life: Under reasonable design and use conditions, it has a good charge and discharge cycle life.
• Corrosion resistance, insulation, shock absorption, environmental adaptability, and heat resistance.
(II) Application of metal liner fully wrapped gas cylinders
• Hydrogen energy and fuel cells: fuel cell vehicles (FCEV), hydrogen fuel cell drones, hydrogen storage at hydrogen refueling stations, hydrogen storage for fixed fuel cell systems, and fuel cell backup power supplies.
• Natural gas fuel cylinders: CNG (compressed natural gas) vehicles, buses, passenger cars, taxis, power supply vehicles, forklifts, special vehicles, trucks, etc.
• Breathing air: firefighter self-contained breathing apparatus (SCBA), mine rescue, coal mine rescue, medical oxygen cylinders, diving cylinders.
• Aerospace: spacecraft propellant storage, aircraft emergency oxygen system.
• Industrial gas: storage and transportation of high-purity or specialty gases.
• Energy storage (compressed air): compressed air energy storage system for microgrid peak load regulation or energy recovery; paintball guns.
(III) Parameters of metal liner fully wrapped gas cylinders
Water capacity: 0.19 L, 0.22 L, 0.25 L, 0.3 L, 0.35 L, 0.36 L, 0.37 L, 0.42 L, 0.45 L, 0.5 L, 0.6 L, 0.62 L, 0.7 L, 0.75 L, 0.8 L, 1.1 L, 1.2 L, 1.3 L, 1.4 L, 1.5 L, 1.6 L, 2 L, 2.1 L, 2.17 L, 2.2 L, 2.4 L, 2.5 L, 2.6 L, 2.7 L, 3 L, 3.1 L, 4 L, 4.7 L, 5 L, 6.8 L, 6.9 L, 8 L, 8.5 L, 9 L, 10 L, 12 L, 18 L, 20 L, 23.5 L, 25 L, 28 L, 29 L, 35 L, 45 L, 50 L, 53 L, 56 L, 60 L, 61 L, 62 L, 65 L, 76 L, 78 L, 85 L, 100 L, 110 L, 120 L, 130 L, 140 L, 165 L, 166 L, 175 L, 187 L, 180 L, 200 L, 203 L, 210 L, 220 L, 230 L, 240 L, 255 L, 260 L, 270 L, 278 L, 385 L, 410 L, 450 L, 500 L, etc.
Working pressure: 15 MPa, 15.3 MPa, 20 MPa, 25 MPa, 30 MPa, 31 MPa, 35 MPa, 40 MPa, 70 MPa, 200 Bar, 300 Bar, etc.
Diameter: 60 mm, 61.4 mm, 65 mm, 75 mm, 78 mm, 83 mm, 87.9 mm, 96 mm, 97 mm, 100 mm, 101 mm, 105 mm, 108 mm, 109 mm, 110 mm, 111 mm, 112 mm, 113 mm, 114 mm, 115 mm, 116 mm, 118 mm, 120 mm, 125 mm, 128 mm, 130 mm, 132 mm, 135 mm, 136 mm, 137 mm, 139 mm, 140 mm, 140.4 mm, 156 mm, 157 mm, 158 mm, 159 mm, 160 mm, 162 mm, 165 mm, 166.8 mm, 170 mm, 171 mm, 172.5 mm, 173 mm, 174 mm, 174.3 mm, 178 mm, 179 mm, 180 mm, 195.9 mm, 196 mm, 200 mm, 205 mm, 220 mm, 222 mm, 280 mm, 300 mm, 325 mm, 352 mm, 356 mm, 370 mm, 376 mm, 380 mm, 400 mm, 402 mm, 406 mm, 408 mm, 410 mm, 424 mm, 448 mm, 500 mm, 580 mm, 610 mm, etc.
Material: Aluminum Alloy (6061) + Carbon Fiber + Glass Fiber + Epoxy Resin, Seamless Steel (37Mn, 34CrMo4, 30CrMo, 4130X, 35CrMo) + Carbon Fiber + Glass Fiber + Epoxy Resin
Wall Thickness: 3.5 mm, 3.6 mm, 4.6 mm, 5.9 mm, 7.3 mm, etc.
Standard and Certification: ASME, DOT, DOT/UN ISO, TPED, CE, PED, ECE R, UN ISO, EN ISO, UL, TC, AS/NZS, ISO, Rho, EN, CU-TR, EAC, GOST, KGS, KR, KSB, JIS B, KHK, CDG & TPE, IS, PESO, AS, AD, ADR/RID, GB, CLASSIFICATION SOCIETY STANDARDS (ABS, BV, KR, LR, DNV, GL, NK, RINA, RS, CCS, CFR)
(IV) Advantages of KAIGEN
1. The inner wall thickness is uniform and the wall thickness difference is small. The shoulder and bottom shape are highly accurate and consistent. The inner surface is anodized for better corrosion resistance.
2. The three-dimensional finite element theory is used to optimize the winding layer structure and the fiber layer stacking problem of the head part.
3. Production and testing are strictly in accordance with standard requirements.
4. The use of high-strength and high-modulus carbon fiber materials has excellent durability and longer service life.
5. The failure mode of leaking before bursting greatly reduces the risk of failure, and the safety and reliability of the gas cylinder are higher.
6. Products have withstood long-term market testing and are widely praised.
III. TYPE - IV Non-metallic Liner Fully Wrapped Gas Cylinder (Plastic Liner Fully Wrapped Gas Cylinder)
Plastic liner fully wrapped gas cylinder is an advanced high-pressure gas storage container that uses the plastic liner to provide lightweight base and sealing, and relies on the high-strength fiber composite material wrapping layer to provide pressure-bearing strength.
(I) Advantages of plastic liner fully wrapped gas cylinder
1. Extremely lightweight: This is the biggest advantage over metal liner fully wrapped gas cylinders (such as aluminum alloy liner wrapped carbon fiber), and the weight can be reduced by 30% or more. It is crucial for weight-sensitive applications such as on-board hydrogen storage and portable devices.
2. Good corrosion resistance: Plastic liner has excellent corrosion resistance to a variety of gases and chemical environments.
3. Fatigue resistance: Composite materials have good fatigue resistance, and plastic liner also has a certain toughness.
4. Potentially low cost: The plastic liner itself and its molding process (such as injection molding, blow molding) may be lower than the metal liner processing cost in large-scale production.
5. No metal fatigue: Avoids the metal fatigue problem that may occur in the metal liner.
(II) Application of fully wrapped gas cylinders with plastic liner
• Hydrogen energy and fuel cells: Hydrogen fuel cell vehicles (FCEV) are currently the main application market, and lightweighting directly improves the vehicle's range and energy efficiency. In addition, there is hydrogen storage at hydrogen refueling stations, hydrogen storage in fixed fuel cell systems, and fuel cell backup power.
• Natural gas fuel cylinders: CNG (compressed natural gas) vehicles, buses, passenger cars, taxis, power supply vehicles, forklifts, special vehicles, trucks, etc.
• Drones and aerospace: spacecraft propellant storage, aircraft emergency oxygen systems, scenarios that require lightweight high-pressure gas storage systems.
• Respirators/medical oxygen supply: portable high-pressure oxygen cylinders for firefighters' self-contained air breathing apparatus (SCBA), mine self-rescuers, coal mine rescue, and medical oxygen cylinders.
• Industrial gas storage and transportation: occasions with special requirements for weight or corrosion resistance.
• Energy storage (compressed air): Compressed air energy storage systems for microgrid peak load regulation or energy recovery.
• Small fuel gas cylinders, such as LPG cylinders.
(III) Parameters of fully wrapped plastic liner gas cylinders
Water Capacity: 1.2 L, 1.5 L, 2 L, 3 L, 4.7 L, 6.8 L, 6.9 L, 7 L, 9 L, 12.5 L, 18.2 L, 24.5 L, 25 L, 26.2 L, 27.4 L, 34.5 L, 62 L, 66 L, 115 L, 130 L, 140 L, 160 L, 230 L, 250 L, etc.
Working Pressure: 20 Bar, 200 Bar, 70 MPa, etc.
Diameter: 305 mm, 335 mm, 365 mm, 402 mm, 416 mm, 452 mm, etc.
Material: High-density Polyethylene (HDPE, (C₂H₄)ₙ, [ - CH₂ - CH₂ - ]ₙ ) + Carbon Fiber + Glass Fiber + Epoxy Resin
Wall Thickness: 1.5 mm, 9.8 mm, etc.
Standard and Certification: ASME, DOT, DOT/UN ISO, TPED, CE, PED, ECE R, UN ISO, EN ISO, UL, TC, AS/NZS, ISO, Rho, EN, CU-TR, EAC, GOST, KGS, KSB, JIS B, KHK, CDG & TPE, IS, PESO, AS, AD, ADR/RID, GB, CLASSIFICATION SOCIETY STANDARDS (ABS, BV, KR, LR, DNV, GL, NK, RINA, RS, CCS, CFR)
(IV) KAIGEN's advantages
1. Plastic liner design: Establish a plastic liner buckling eigenvalue analysis model, determine the relationship between the liner size parameters and the critical pressure, and form plastic liner design criteria.
2. Cylinder mouth structure design: Create a composite material failure analysis model based on failure criteria, study the influence mechanism of the metal valve seat structure on the stress and failure of the composite material layer, and form a cylinder mouth structure design method.
3. Liner rotational molding process: Develop a vacuum rotational molding method, establish the matching rules of heating, cooling and other process parameters with liner molding, and form a high-precision rotational molding process for plastic liner.
4. Carbon fiber winding layer design: Use three-dimensional finite element theory to establish the laying and hole expansion method, optimize the winding layer structure and the fiber layer stacking problem of its head part, and form a carbon fiber winding layer design process.
IV. TYPE-II Metal Liner Hoop-wound Cylinder (Steel Liner Hoop-wound Cylinder)
Metal liner hoop-wound cylinder is a high-pressure gas cylinder that uses the metal liner as the core pressure-bearing structure and enhances the circumferential strength of the cylinder body through the hoop fiber winding layer.
(I) Advantages of Metal Liner Hoop-wound Cylinder
1. Excellent temperature resistance: The metal liner can withstand higher operating and ambient temperatures.
2. Extremely low gas permeability: The barrier property of metal to small molecule gases such as hydrogen is much better than that of plastic, and the storage loss is extremely small.
3. High impact resistance and damage tolerance: The metal liner is more resistant to mechanical damage such as scratches and collisions.
4. Mature long-term performance and reliability: The aging behavior of metal materials has been studied more deeply, and the verification of design life (such as 15-30 years) is more mature.
5. Relatively simple manufacturing and inspection: The metal liner process is mature, and the non-destructive testing (such as ultrasonic) standards are perfect. The hoop winding process itself is also simpler than full winding (spiral + hoop winding).
6. Cost (specific range): For applications that require high reliability, high temperature resistance, low permeability and are not very sensitive to weight, its comprehensive cost may be competitive (especially when using glass fiber winding).
(II) Advantages of metal liner hoop-wound gas cylinders
• Lower cost: Compared with metal liner fully wound gas cylinders (Type III) or plastic liner fully wound gas cylinders (Type IV), the main advantage of Type II gas cylinders is cost.
• The amount of composite materials used is significantly reduced (only the cylinder is wound, the length accounts for about 60% - 80% of the total length; and cheaper glass fiber is usually used instead of carbon fiber).
• The winding process is simpler and faster (only hoop winding is required).
• Lower weight than all-metal cylinders: lighter than all-metal gas cylinders (Type I) of the same volume and pressure, achieving partial lightweight.
• Reliable sealing: The metal liner ensures good sealing.
• Head has good impact resistance: Metal heads are directly exposed or have only a thin protective layer, which is more resistant to external impact damage than composite heads.
(III) Parameters of metal liner hoop-wound gas cylinders
Water capacity: 45 L, 50 L, 55 L, 60 L, 65 L, 70 L, 75 L, 77 L, 78 L, 80 L, 82 L, 85 L, 87 L, 90 L, 93 L, 95 L, 100 L, 103 L, 105 L, 107 L, 110 L, 115 L, 120 L, 125 L, 130 L, 140 L, 145 L, 150 L, 160 L, 170 L, 180 L, 190 L, 200 L, etc.
Working pressure: 20 MPa, 200 Bar, etc.
Diameter: 310 mm, 325 mm, 335 mm, 356 mm, 370 mm, 406 mm, 420 mm, etc.
Material: Seamless Steel (37Mn, 34CrMo4, 30CrMo, 4130X, 35CrMo) + Glass Fiber + Epoxy Resin
Wall Thickness: 4 mm, 4.6 mm, 4.7 mm, 5 mm, 5.5 mm, 6 mm, 7 mm, 8 mm, etc.
Standard and Certification: ASME, DOT, DOT/UN ISO, TPED, CE, PED, ECE R, UN ISO, EN ISO, UL, TC, AS/NZS, ISO, Rho, EN, CU-TR, EAC, GOST, KGS, KR, KSB, JIS B, KHK, CDG & TPE, IS, PESO, AS, AD, ADR/RID, GB, CLASSIFICATION SOCIETY STANDARDS (ABS, BV, KR, LR, DNV, GL, NK, RINA, RS, CCS, CFR)
(IV) Advantages of KAIGEN
1. Spinning technology is used to ensure uniform wall thickness and small wall thickness difference of the inner liner, and the shoulder and bottom shapes are of high precision and consistency.
2. Three-dimensional finite element theory is used to optimize the fiber layer stacking problem of the winding layer structure.
3. Production and testing are strictly in accordance with standard requirements.
4. High-strength and high-modulus fiber materials are used, which have excellent durability and longer service life.
5. Products have withstood long-term market testing and are widely praised.
If you are interested in Ground, Electroplated, Electrochemical Polished, and Coated Wrapped Gas Cylinders, please go to WRAPPED AND SEAMLESS CYLINDERS FOR ULTRA-HIGH PURITY MATERIALS.
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• Whatis special about KAIGEN and LEO's ALUMINUM ALLOY LINERS CARBON FIBER FULLY WRAPPEDGAS CYLINDERS?
