CN102405371B - 气罐的制造方法 - Google Patents

气罐的制造方法 Download PDF

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CN102405371B
CN102405371B CN2009801586972A CN200980158697A CN102405371B CN 102405371 B CN102405371 B CN 102405371B CN 2009801586972 A CN2009801586972 A CN 2009801586972A CN 200980158697 A CN200980158697 A CN 200980158697A CN 102405371 B CN102405371 B CN 102405371B
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outer circumferential
circumferential face
gas tank
joint
lid
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CN102405371A (zh
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稻木秀介
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Toyota Motor Corp
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    • 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
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/56—Winding and joining, e.g. winding spirally
    • B29C53/58—Winding and joining, e.g. winding spirally helically
    • B29C53/60—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels
    • B29C53/602—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels for tubular articles having closed or nearly closed ends, e.g. vessels, tanks, containers
    • 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
    • F17C13/00—Details of vessels or of the filling or discharging of vessels
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/32—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F17C2205/0134—Two or more vessels characterised by the presence of fluid connection between vessels
    • F17C2205/0142—Two or more vessels characterised by the presence of fluid connection between vessels bundled in parallel
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    • F17C2205/00—Vessel construction, in particular mounting arrangements, attachments or identifications means
    • F17C2205/03—Fluid connections, filters, valves, closure means or other attachments
    • F17C2205/0302—Fittings, valves, filters, or components in connection with the gas storage device
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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Abstract

本发明可适当地进行绕线法所进行的外周层的形成，并且使盖轻量化而实现气罐的轻量化。高压气罐具有在气罐主体的轴向的端部安装的盖和在气罐主体的外周面和盖的外周面上通过绕线法形成的外周层。在气罐主体的轴向的端部，盖的外侧端面比外周层的外侧端面向内侧凹陷而形成凹部。

Description

气罐的制造方法
技术领域
本发明涉及具有在气罐主体的轴向的端部安装的盖和在气罐主体的外周面和盖的外周面上通过绕线法形成的外周层的气罐及气罐的制造方法。 
背景技术
在例如汽车等装载的燃料电池系统中，使用高压气罐来作为燃料气体的供给源。通常，高压气罐具有在气罐主体的轴向的两端部安装的盖(金属盖，接口件，口金)和在气罐主体的外周面和盖的外周面上通过绕线(フイラメントワインデイング)法卷绕强化纤维形成的强化纤维层。 
现有技术文献 
专利文献1：特开2000-266289号公报； 
专利文献2：特开2003-287193号公报。 
发明内容
发明所要解决的问题 
但是，在通过绕线法在气罐主体的外周面卷绕纤维的工序中，例如，在螺旋卷绕时，在图9所示的气罐主体100的轴向端部的盖101上使纤维折回地进行卷绕纤维。因此，在大体圆筒状的盖101的外周面，形成具有厚度的强化纤维层102。这样，盖具有承担强化纤维层的心轴的一部分的作用，因此轴向上需要足够的长度。其结果，盖变大，变重。在盖变重时，高压气罐变重，从例如气罐的搬运性和装载气罐的汽车的燃料经济性等观点来看不理想。 
本发明鉴于上述问题而研制，其目的是可适当地进行绕线法所进行的 强化纤维层等的外周层的形成，并且使盖轻量化而实现气罐的轻量化。 
用于解决问题的手段 
本发明是一种气罐的制造方法，其特征在于，具有：在形成于气罐主体的轴向的端部的盖上，连接具有与所述盖的外周面平滑地连续的外周面的转轴的连接部的工序；在由上述转轴来使气罐主体旋转的同时在上述气罐主体的外周面、上述盖的外周面和上述连接部的外周面的一部分上卷绕纤维，从而通过绕线法在上述气罐主体的外周面和上述盖的外周面及上述连接部的外周面的一部分形成外周层的工序；将上述转轴的连接部从上述盖取下，在上述气罐主体的轴向的端部形成上述盖的上述轴向的外侧端面比上述外周层的上述轴向的外侧端面向内侧凹陷的凹部的工序。 
上述转轴的连接部的前端侧可随着接近前端而使外径逐渐变小。 
在上述转轴的连接部的外周面，可粘贴脱模膜。 
发明的效果 
根据本发明，可适当地进行绕线法所进行的外周层的形成，且可使金轻量化而实现气罐的轻量化。 
附图说明
图1是装载高压气罐的燃料电池汽车的示意图。 
图2是表示高压气罐的构成的概况的纵剖视图。 
图3是高压气罐的盖侧的端部的放大纵剖视图。 
图4是高压气罐的端包套(エンドボス)侧的端部的放大纵剖视图。 
图5是表示高压气罐的制造方法的主要工序的流程图。 
图6是表示在纤维卷绕装置中在树脂内衬上卷绕强化纤维的状况的说明图。 
图7是连接部连接的高压气罐的盖侧的端部的放大纵剖视图。 
图8是连接部连接的高压气罐的端包套侧的端部的放大纵剖视图。 
图9是表示改良前的盖的放大剖视图。 
具体实施方式
下面参照附图来对本发明的优选实施方式进行说明。图1是装载本实施方式涉及的气罐的燃料电池汽车1的示意图。 
在燃料电池汽车1上，在车体的后部装载有例如三个高压气罐2。高压气罐2构成燃料电池系统3的一部分，可通过供气线路4从各高压气罐2向燃料电池5供给燃料气。在高压气罐2中储存的燃料气是可燃性的高压气体，是例如氢气。再有，高压气罐2不仅可适用于燃料电池汽车1，除了电动车、混合动力汽车等车辆外，还可适用于各种移动体(例如，船舶和飞机、机器人等)和固定设置设备(住宅、大厦)。 
图2是表示高压气罐2的构成的概况的纵剖视图。高压气罐2具有例如大体椭圆形的气罐主体10和在该气罐主体10的轴向(图2的左右方向)的两端部设置的盖11、12。一个盖12是在气罐主体10和其外部之间不进行气体的流入流出的端包套(以下，盖12为“端包套12”)。 
气罐主体10具有例如双层结构，具有内侧的树脂内衬20和将该树脂内衬20的外周面覆盖的作为外周层的FRP(纤维强化塑料，Fiber Reinforced Plastics)层21。 
树脂内衬20具有与气罐主体10大致相同的大体椭圆体形状。树脂内衬20由例如尼龙6、尼龙6.6等聚酰胺系树脂成形。 
FRP层21通过绕线法用含有树脂的纤维成形而形成。FRP层21遍及气罐主体10的外周面、盖11的外周面11a和端包套12的外周面12a形成。作为FRP层21的树脂，使用例如环氧树脂、变性环氧树脂或不饱和聚酯树脂等。此外，作为纤维，使用例如碳纤维、金属纤维等。 
树脂内衬20的一个端部开口，在该开口部安装有盖11(接口管，接口件)。盖11如图2和图3所示那样形成为在中央具有通孔11b的大体圆盘状，在轴向的中央具有大径部11c，其轴向两侧逐渐缩径。大径部11c外侧的倾斜面为盖11的外周面11a。盖11通过例如铝、铁等成形。盖11例如外侧端面11d比FRP层21的外侧端面21a向内侧凹入，从而在气罐主体10的端部形成凹部A。 
此外，树脂内衬20的另一端部开口，在该开口部安装有端包套12。端包套12如图2和图4所示那样形成为大体圆盘状，在轴向的中央具有大径部12b，其轴向的两侧逐渐缩径。大径部12b外侧的倾斜面为端包套12的外周面12a。端包套12与盖11不同，没有通孔，在外侧端面12d形成有凹部12c。端包套12通过例如铝、铁等成形。端包套12例如外侧端面12d比FRP层21的外侧端面21b向内侧凹入，而在气罐主体10的端部形成有凹部B。 
其次，对如上述那样构成的高压气罐2的制造方法进行说明。图5是不是该制造方法的主要工序的一个实例的流程图。 
首先，在注射模塑成形的树脂内衬20的两端部安装盖11和端包套12。然后，如图6所示，纤维卷绕装置50的转轴51的连接部52与盖11和端包套12连接(图5的工序S1)。连接部52如例如图7和图8所示那样在前端具有与盖11的通孔11b、端包套12的凹部12c嵌合的凸部52a以及在该凸部52a嵌合时与盖11的外周面11a、端包套12的外周面12a平滑地连续的外周面52b。连接部52的前端侧的外周面52b成为随着接近前端侧而外径逐渐变小的倾斜面。此外，在外周面52b，粘贴脱模膜52c。而且，连接部52和盖11及端包套12 的连接通过例如在盖11的通孔11b、端包套12的凹部12c中嵌合连接部52的凸部52a来进行。此时，盖11的外侧端面11d和端包套12的外侧端面12d与连接部52之间存在O形环52d。 
其次，使转轴51旋转，使树脂内衬20旋转，而将强化纤维F在树脂内衬20(气罐主体10)的外周面、盖11的外周面11a、端包套12的外周面12a、连接部52的外周面52b的一部分上卷绕。强化纤维F如图6所示那样在上游部浸渍热塑性树脂，然后用纤维导引部53调整角度，而在树脂内衬20上卷绕。此时的卷绕通过螺旋卷绕、环状卷绕来进行，在螺旋卷绕时，在盖11的外周面11a、端包套12的外周面12a、连接部52的外周面52b的一部分(靠近盖11侧、靠近端包套12侧的一部分)绕挂、弯折强化纤维F来进行。这样，如图7和图8所示，在树脂内衬20(气罐主体10)的外周面、盖11的外周面11a、端包套12的外周面12a以及连接部52的外周面52b的一部分卷绕强化纤维F，形成预定厚度的FRP层21(图5的工序S2)。 
然后，在FRP层21某种程度固化之后，将连接部52从盖11和端包套12取下。这样，如图3和图4所示，在气罐主体10的轴向的两端部，形成盖11的外侧端面11d比FRP层21的外侧端面21a向内侧凹陷的凹部A和端包套12的外侧端面12d比FRP层21的外侧端面21b向内侧凹陷的凹部B(图5的工序S3)。 
根据以上的实施方式，盖11的外侧端面11d和端包套12的外侧端面12d比FRP层21的外侧端面21a、21b向内侧凹陷，在气罐主体10的端部形成凹部A、B，因此可使盖11、端包套12的轴向的长度缩小该量。这样，可使盖11、端包套12轻量化而使高压气罐2轻量化。此外，在形成的凹部A、B嵌入转轴51的连接部52，而可在该连接部52的外周面52b和盖11的外周面11a及端包套12的外周面12a绕挂强化纤维F，因此也可适当地进行绕线法所进行的FRP层21的形成。 
凹部A、B在FRP层21的形成时形成为与盖11、端包套12连接的转轴51的连接部52的形状，因此可如上述那样适当地进行绕线法所进行的FRP层21的形成。 
在上述实施方式中记载的高压气罐2的制造方法具有：在盖11、端包套12上连接转轴51的连接部52的工序；在通过转轴51使气罐主体10旋转的同时在遍及树脂内衬20的外周面、盖11的外周面11a、端包套12的外周面12a和连接部52的外周面52b的一部分的范围内卷绕强化纤维F，而通过绕线法在树脂内衬20的外周面、盖11的外周面11a、端包套12的外周面12a和连接部52的外周面52b的一部分形成FRP层21的工序；和将转轴51的连接部52从盖11和端包套12取下，在气罐主体10的轴向的端部形成盖11的外侧端面11d和端包套12的外侧端面12d比FRP层21的外侧端面21a、21b向内侧凹陷的凹部A、B的工序。这样，可形成轴向的长度短的盖11、端包套12，使盖11、端包套12轻量化，且可使高压气罐2轻量化。此外，也可适当地进行绕线法所进行的FRP层21的形成。 
在转轴51的连接部52的前端侧随着靠近前端而使外径逐渐变小，因此在连接部52的外周面52b形成FRP层21后，可将该连接部52从盖11、端包套12和FRP层21容易地取下。 
在转轴51的连接部52的外周面52b，粘贴脱模膜52c，因此更可容易地将连接部52从FRP层21取下。 
以上，虽然参照附图对本发明的优选实施方式进行了说明，但本发明并不限于该实例。本领域技术人员显然可在权利要求的范围记载的思想范畴内想到各种变形例或修正例，这当然也属于本发明的技术范围内。 
例如，在以上的实施方式中，在盖11和端包套12两者形成凹部A、B，但是也可在任一方形成。可仅在端包套12侧形成，在该情况下，可在使气体流入流出的盖侧连接现有形状的阀等。此外，连接部52可与转轴51一体形成，也可用分体的连接夹具。 
产业上的利用可能性 
本发明在气罐中可适当地进行绕线法所进行的外周层的形成，并且在使盖轻量化而实现气罐的轻量化时有用。 
附图标记的说明： 
2高压气罐  10气罐主体  11盖(接口管，金属盖，口金)12 端包套  20树脂内衬  21FRP层  51转轴  52连接部A、B凹部 

Claims (3)

1.一种气罐的制造方法，其特征在于，具有：
在形成于气罐主体的轴向的端部的盖上，连接具有与所述盖的外周面平滑地连续的外周面的转轴的连接部的工序；
一边通过所述转轴使气罐主体旋转，一边在所述气罐主体的外周面、所述盖的外周面以及所述连接部的外周面的一部分上卷绕纤维，从而通过绕线法在所述气罐主体的外周面和所述盖的外周面以及所述连接部的外周面的一部分上形成外周层的工序；和
将所述转轴的连接部从所述盖取下，在所述气罐主体的轴向的端部形成所述盖的所述轴向的外侧端面比所述外周层的所述轴向的外侧端面向内侧凹陷的凹部的工序。
2.根据权利要求1所述的气罐的制造方法，其特征在于，
所述转轴的连接部的前端侧随着接近前端外径逐渐变小。
3.根据权利要求1或2所述的气罐的制造方法，其特征在于，
在所述转轴的连接部的外周面粘贴有脱模膜。
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