CN108312571A - 罐的制造方法以及罐 - Google Patents

罐的制造方法以及罐 Download PDF

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Publication number
CN108312571A
CN108312571A CN201711480594.0A CN201711480594A CN108312571A CN 108312571 A CN108312571 A CN 108312571A CN 201711480594 A CN201711480594 A CN 201711480594A CN 108312571 A CN108312571 A CN 108312571A
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China
Prior art keywords
fibre bundle
tank
resin
layer
manufacturing
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Granted
Application number
CN201711480594.0A
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CN108312571B (zh
Inventor
上田直树
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Toyota Motor Corp
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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
    • 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
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/545—Perforating, cutting or machining during or after moulding
    • 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
    • B29C70/323—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 on the inner surface of a rotating mould
    • B29C70/326—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 on the inner surface of a rotating mould by rotating the mould around its axis of symmetry
    • 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
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • 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
    • 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
    • B29C53/62—Winding and joining, e.g. winding spirally helically using internal forming surfaces, e.g. mandrels rotatable about the winding axis
    • 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
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    • 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
    • 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
    • B29C70/323—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 on the inner surface of a rotating mould
    • 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
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    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • 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
    • F17C1/00—Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge
    • F17C1/02—Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge involving reinforcing arrangements
    • F17C1/04—Protecting sheathings
    • F17C1/06—Protecting sheathings built-up from wound-on bands or filamentary material, e.g. wires
    • 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
    • F17C1/00—Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge
    • F17C1/16—Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge constructed of plastics materials
    • 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
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C2037/80—Identifying, e.g. coding, dating, marking, numbering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/10—Cords, strands or rovings, e.g. oriented cords, strands or rovings
    • B29K2105/101—Oriented
    • B29K2105/103—Oriented helically
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B29L2031/7154—Barrels, drums, tuns, vats
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • 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
    • F17C2223/00—Handled fluid before transfer, i.e. state of fluid when stored in the vessel or before transfer from the vessel
    • F17C2223/03—Handled fluid before transfer, i.e. state of fluid when stored in the vessel or before transfer from the vessel characterised by the pressure level
    • F17C2223/036—Very high pressure (>80 bar)
    • 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
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • 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
    • F17C2270/00—Applications
    • F17C2270/01—Applications for fluid transport or storage
    • F17C2270/0165—Applications for fluid transport or storage on the road
    • F17C2270/0168—Applications for fluid transport or storage on the road by vehicles
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
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Abstract

本发明提供一种具备能够在罐的表面容易且牢固地粘贴薄叶状的标签的外表面性状的罐的制造方法以及罐。在包含在内衬(11)的外表面以所需的间距宽度(a)缠绕多层包含未固化的树脂成分的纤维束来形成纤维增强树脂层(12)的工序的罐(10)的制造方法中，以在最外侧的层(20)缠绕所述纤维束时形成在相邻的纤维束与纤维束之间不存在纤维束的所需宽度(c)的间隙的方式，以更宽的第二间距宽度(b)缠绕纤维束。然后，将渗出到所述间隙的树脂固化而形成的凸部(30)的顶端部以留下规定高度的方式削去。利用削去后的面(50)来粘贴标签(60)。

Description

罐的制造方法以及罐
技术领域
本发明涉及罐，尤其涉及用纤维增强树脂层覆盖内衬的外表面的形状的罐的制造方法以及罐。
背景技术
作为用于氢等的储藏或供给的高压罐的制造方法，已知有如下的制造方法：在内衬的外周面以规定的间距宽度缠绕了包含CFRP这样的未固化的树脂成分的纤维束后，使树脂固化来形成纤维增强树脂层。在专利文献1中记载了：在这样制造出的高压罐的圆筒主干部粘贴记载有制造者名、制造日、燃料种类等关联信息的薄叶状的标签。
另外，在专利文献2中记载了一种高压罐的制造方法，具备在树脂制的内衬的外表面以规定的间距宽度缠绕包含未固化的树脂成分的纤维束来形成未固化纤维增强树脂层的工序，其中，该制造方法还包含在未固化纤维增强树脂层的未固化的树脂成分向外侧渗出而形成的未固化表面树脂层涂敷溶剂并使其浸透的工序、和使未固化纤维增强树脂层的树脂成分固化并且将溶剂蒸发除去而使表面树脂层发泡从而实现多孔化的加热处理工序。
现有技术文献
专利文献
专利文献1：日本特开2013-167298号公报
专利文献2：日本特开2011-144860号公报
发明内容
发明要解决的问题
图7示出通过专利文献1或专利文献2所记载的具备在内衬的外表面以规定的间距宽度缠绕包含未固化的树脂成分的纤维束来形成未固化纤维增强树脂层的工序的高压罐的制造方法而制造出的高压罐的示意性的局部图。在图7中，1是内衬，在该内衬1的外表面形成有由缠绕的纤维束构成的纤维增强树脂层2。而且，在该纤维增强树脂层2的外侧表面形成有表面树脂层3。所述表面树脂层3是仅由通过在将含浸有未固化的树脂的纤维束缠绕于内衬1而形成纤维增强树脂层2时多余的树脂向外侧渗出而形成的树脂构成的层。
在如上述那样实际制造的高压罐中，所述表面树脂层3不是平坦面。理由在于：从纤维束渗出的树脂的量以及部位是随机的，没有无规则性，因而，渗出的树脂固化后的表面性状为不规则地存在大小不同的许多凸部的凹凸面。
通常，要求对高压罐如上述那样粘贴记载有制造者名、制造日、燃料种类等关联信息的标签，但在具有凹凸的面上粘贴了标签的情况下，无法得到稳定的贴付状态，所以在粘贴时需要进行将所述凸部的顶端部削去而使其实质上成为平坦面的作业。
而且，所述表面树脂层3在大多情况下是透明的树脂的层，光的透过率高。因而，难以通过激光等来准确地掌握表面的凹凸形状或凸部的位置，实情是一边以目视或触觉确认形状一遍利用手工作业来进行所述削去作业。
这些作业成为了高压罐制造时的大的作业负担。另外，还存在如下课题：在标签的粘贴时，需要在进行削去后的平坦面涂敷粘合剂的作业，并且在粘合后会产生标签的背纸(backing sheet)等不用品。
本发明是鉴于上述的情况而完成的，其课题在于在经过在内衬的外表面以规定的间距宽度缠绕多层包含未固化的树脂成分的纤维束来形成未固化纤维增强树脂层的工序而制造的罐的制造方法中，提供一种能够具备能够在该罐的表面上容易且牢固地粘贴适当的薄叶状的标签的外表面性状的罐的制造方法。另外，其课题在于提供具备这样的外表面的罐。
用于解决课题的手段
本发明的罐的制造方法基本上是至少包含在内衬的外表面以所需的间距宽度缠绕多层包含未固化的树脂成分的纤维束来形成纤维增强树脂层的工序的罐的制造方法，其特征在于，还包含：至少在最外侧的层缠绕所述纤维束时形成一处以上的如下区域的工序，该区域是以宽度比所述间距宽度宽的第二间距宽度缠绕纤维束以形成在相邻的纤维束与纤维束之间不存在纤维束的所需宽度的间隙的区域；和将由渗出到所述间隙的树脂固化而形成的固化树脂构成的凸部的顶端部以留下规定高度的方式削去的工序。
根据该罐的制造方法，薄叶状的标签相对于制造出的罐的外表面的粘贴变得容易，且粘贴状态也变得稳定。
在该罐的制造方法中，优选的方案是，以使进行削去后的残存部的削去面成为平坦面的方式进行所述削去工序。另外，在该罐的制造方法中，优选的方案是，还包含至少在所述凸部的表面涂敷形成光的反射层的材料来形成光反射层的工序、和对所述光反射层照射激光来测定所述凸部的位置以及形状的工序，基于从所述测定得到的信息来进行所述削去工序。而且，在该罐的制造方法中，优选的方案是，作为形成所述光反射层的材料，使用包含粘合剂的材料。
在该罐的制造方法中，优选的方案是，还包含利用通过所述削去工序进行削去后的残存部的削去面来粘贴薄叶状的标签的工序。而且，在该罐的制造方法中，优选的方案是，以所述第二间距宽度缠绕纤维束的区域包含所述罐的至少圆筒主干部。
本发明的罐是具备在内衬的外表面缠绕多层包含未固化的树脂成分的纤维束而形成的纤维增强树脂层的罐，其特征在于，所述纤维增强树脂层的至少最外层具有一处以上的形成有在纤维束与纤维束之间不存在纤维束的间隙的区域，在所述间隙中存在渗出而固化后的树脂，所述固化后的树脂的上表面为平坦面。
在该罐中，优选的方案是，对所述平坦面赋予了粘合性。另外，在该罐中，优选的方案是，形成有所述间隙的区域至少包含于罐的圆筒主干部。而且，在该罐中，优选的方案是，利用所述平坦面粘贴有薄叶状的标签。
发明效果
根据本发明，能够得到在内衬的外表面具有纤维增强树脂层且能够在罐表面容易且可靠地粘贴薄叶状的标签的罐。
附图说明
图1是示出高压罐的一例的图。
图2是说明一实施方式的作业顺序的第一图。
图3是说明一实施方式的作业顺序的第二图。
图4是说明一实施方式的作业顺序的第三图。
图5是说明一实施方式的作业顺序的第四图。
图6是说明一实施方式的作业顺序的第五图。
图7是说明现有的高压罐的构造的局部图。
具体实施方式
以下，参照附图，对本发明的一实施方式进行说明。
图1是示出罐的一例的概略图。在该例子中，罐10是高压罐，示出搭载于燃料电池车辆的填充有高压的氢气的高压罐的例子。但是，罐10的用途是任意的。填充物也不限定于高压的氢气。
在该例子中，高压罐10是圆筒主干部17的两端呈圆顶状地带有圆弧的形状，具备具有气体阻隔性的内衬11和包含表面树脂层13的纤维增强树脂层12。另外，在高压罐10的两端形成有开口部，在一个开口部安装有具备阀15的接口14，在另一个开口部安装有端毂(end boss)16。并且，中央部设为圆筒主干部17。
内衬11例如是形成供高压的氢气填充的收容空间18的树脂制构件。一般来说，内衬11由能够加工成大致圆筒形状等的热可塑性树脂构成。构成内衬11的树脂优选是加工性良好且将氢气保持于收容空间18内的性能即气体阻隔能力良好的树脂。作为这样的树脂，例如可举出聚酯、聚酰胺、聚乙烯、以及乙烯‐乙烯醇共聚树脂(EVOH)等热可塑性树脂。
如上所述，内衬11具有在圆筒主干部17的两端具有圆顶部的大致圆筒形状。在内衬11的各圆顶部分别如上述那样形成有开口部，在该开口部分别设置有接口14以及端毂16。纤维增强树脂层12沿着内衬11的外表面形成。
纤维增强树脂层12是覆盖内衬11的外表面的层，具有加强内衬11而提高高压罐10的刚度、耐圧性等机械强度的功能。纤维增强树脂层12由热固化性树脂以及增强纤维束构成。作为热固化性树脂，优选使用酚醛树脂、三聚氰胺树脂、尿素树脂以及环氧树脂等热固化性树脂，从机械强度等的观点出发，尤其优选使用环氧树脂。作为增强纤维，可以使用玻璃纤维、芳纶纤维、硼纤维以及碳纤维等，从轻量性、机械强度等的观点出发，尤其优选使用碳纤维。
一般来说，环氧树脂是指通过将双酚A和氯甲代氧丙环的共聚体等预聚物与聚胺等固化剂混合并进行热固化而得到的树脂。环氧树脂在未固化状态下具有流动性，在热固化后形成强韧的交联构造而变得不溶于甲基乙基酮(MEK)等溶剂。
纤维增强树脂层12通过将含浸有未固化的树脂(例如，环氧树脂)的纤维(例如，碳纤维)的束以一定的间距宽度(以下，称作第一间距宽度a)在内衬11的外表面上缠绕多层然后使树脂固化而形成。例如，在内衬11的接口14和端毂16安装轴而以旋转自如的方式进行支撑，一边旋转一般缠绕含浸树脂的纤维束。然后，以树脂的固化温度进行加热而使树脂成分固化。在纤维束的卷绕中，使用螺旋卷绕或环形卷绕。所述第一间距宽度a一般设为与使用的纤维束的宽度大致相等的值。
在将树脂含浸的纤维束缠绕多层时，如图2所示，在缠绕纤维增强树脂层12的至少最外侧的层20时，将一部分区域以宽度比所述第一间距宽度a宽的第二间距宽度b进行缠绕。以第二间距宽度b进行缠绕的区域没有限制，但优选是高压罐10的圆筒主干部17。
图2～图6是将本实施方式的高压罐10的在图1中由A表示的部位放大示出的示意图。在该例子中，除了纤维增强树脂层12的最上层20以外的部分12a的整体例如以所述第一间距宽度a卷绕了多层含浸有未固化树脂的纤维束。此处，第一间距宽度a是与该纤维束的横向宽度大致相等的宽度。
在卷绕最上层的纤维束层20时，在预定在高压罐完成时粘贴标签的区域中，以宽度比所述第一间距宽度a宽的第二间距宽度b缠绕树脂含浸的纤维束。在图2所示的例子中，所述第二间距宽度b是“第一间距宽度a+间隙c”的宽度。作为一例，第一间距宽度a一般是12～20mm左右，第二间距宽度b是20～24mm左右。
通过这样卷绕最上层的纤维束层20，在最上层20的以第一间距宽度a卷绕有纤维束的一般部中，实质上成为在纤维束与纤维束之间没有间隙的状态下纤维束排列成多列的状态，在以所述第二间距宽度b进行了卷绕的区域中，如图2所示，在相邻的纤维束与纤维束之间形成不存在纤维束的宽度c的间隙。在本发明人的实验中，在将纤维束的宽度设为1时，若该间隙c的宽度是其0.25～0.5倍左右，则能够达成预期的目的。
此外，在图示的例子中，虽然仅在最上层的纤维束层20中进行第二间距宽度b下的卷绕，但也可以在比最上层靠下层的若干卷绕层中也形成第二间距宽度b下的卷绕部。不过，此时，优选以使各层中的不存在所述纤维束的宽度c的间隙与从罐的中心轴的放射方向一致的方式进行各层的卷绕。
在将含浸了未固化的树脂(例如环氧树脂)的纤维束多级地卷绕而形成的纤维增强树脂层12中，如图1所示，未固化的树脂向外侧渗出而形成表面树脂层13。如上所述，一般来说，该表面树脂层13的表面不是平坦面，由于渗出的树脂的量和部位无规则地随机进行，所以表面成为不规则地存在大小不同的许多凸部的凹凸面。此外，在图2～图6中，为了容易理解而省略了所述表面树脂层13的图示。
在上述实施方式中示出的高压罐10中，如上所述，且如图2所示，纤维增强树脂层12的最上层20局部具有在相邻的纤维束与纤维束之间不存在纤维束的宽度c的间隙。因而，含浸于纤维束的未固化的树脂向阻力更小的区域即不存在纤维束的所述宽度c的间隙更多地渗出。并且，如图3所示，渗出的树脂成为山形，成为从所述间隙c向来自罐中心轴的放射方向溢出的状态，形成凸部30。此外，通过适当调整使纤维束含浸的树脂量，并且适当调节间隙的宽度c即第二间距宽度b的宽度，能够适当调整渗出树脂固化而形成的所述凸部30的高度。通过实验来确定最佳值即可。
在该状态下，使树脂固化。树脂固化后的凸部30的顶部带有圆弧，不方便在其上粘贴薄叶状的标签。因而，进行通过适当的手段将凸部30的顶端部以留下规定高度的方式削去的处理。更优选的是，以使进行削去后的残存部的削去面成为平坦面的方式进行削去处理。此外，如上所述，由渗出的树脂形成的凸部30是透明的热固化性树脂，光的透过率高。因而，对于将所述凸部30的顶端部平坦地削去的处理，照射激光来读取凹凸的形状并基于该信息来进行机械处理是极其困难的。
因而，在本实施方式中，还进行在以所述第二间距宽度b进行了纤维束的卷绕的区域涂敷形成光的反射层的材料来形成光反射层40的工序。从涂敷作业的容易性的观点来看，所述涂敷优选在以第二间距宽度b进行了纤维束的卷绕的整个区域进行，但即使至少仅在所述凸部30的表面部涂敷所述材料，也能够达成预期的目的。
作为所述“形成光的反射层的材料”，可以例示包含金属粉末的材料。其中，氧化钛是优选的材料。图4示出涂敷形成光的反射层的材料而形成了光反射层40的状态。光反射层40的厚度只要是例如20μm左右，就能够充分地达成预期的目的。
通过形成光反射层40，能够使用激光进行凸部30的形状以及位置的测定，基于得到的信息，能够将所述凸部30的顶端部机械地削去成任意的形状。图5示出将顶端部削去后的状态，在该例子中，通过进行机械的削去，来得到削去后的残存部的削去面平坦的削去面50。通过得到平坦的削去面50，如图6所示，能够容易地向该面粘贴薄叶状的标签60。
作为粘贴的标签60，也可以使用在背面具备粘合剂层或粘着剂层的标签。另外，也可以在削去面50涂敷粘合剂之后，粘贴在背面不具有粘合剂层的标签。不管在哪种情况下，由于削去面50是平坦的面，所以都容易进行粘合剂向削去面50的涂敷作业，同时也容易进行在涂敷后粘贴标签60的作业。另外，粘贴界面是平坦面，能够得到稳定的粘贴状态。
在上述的实施方式的其他方案中，作为形成所述涂敷层40的形成光的反射层的材料，使用混入有粘合剂的材料。作为混入的粘合剂，可以例示环氧树脂、改性硅、聚氨酯树脂、丙烯酸树脂、氰基丙烯酸酯这样的材料。其中，环氧树脂是优选的材料。通过使用混入有粘合剂的材料，在标签60的粘贴时，无需另外使用粘合剂，标签的粘贴变得更加容易且可靠。
如上所述，根据本实施方式，在内衬11的外表面具有纤维增强树脂层12的高压罐10的制造方法中，能够制造能够容易且可靠地在罐表面粘贴薄叶状的标签60的高压罐10。另外，能够得到在制造出的高压罐10的以所述第二间距宽度b缠绕有纤维束的区域以稳定的状态粘贴有标签的高压罐。
作为其他的实施方式，也可以除了上述的处理手段之外，还进行所述专利文献2所记载的处理，即在未固化纤维增强树脂层的未固化的树脂成分向外侧渗出而形成的未固化的表面树脂层13涂敷溶剂而使其浸透的工序、和使未固化纤维增强树脂层的树脂成分固化并且将溶剂蒸发除去而使表面树脂层13发泡从而实现多孔化的加热处理工序。还包含该方法的罐的制造方法以及这样制造的罐也是本发明的范围。
此时，作为所述溶剂，优选与未固化状态的树脂的相溶性良好且沸点比热固化时的加热温度低的溶剂。在构成纤维增强树脂层12(表面发泡树脂层13)的树脂是环氧树脂的情况下，可以应用甲基乙基酮(MEK)、甲苯、二甲基乙酰胺、丙酮等，尤其优选使用MEK。另外，也可以混合两种以上的溶剂来调整相溶性和蒸发温度。
标号说明
10…高压罐，
11…内衬，
12…纤维增强树脂层，
18…收容空间，
20…纤维增强树脂层的最上层，
30…树脂固化后的凸部，
40…由形成光的反射层的材料构成的光反射层，
50…平坦的削去面，
60…粘贴的薄叶状的标签，
a…纤维束的第一缠绕间距宽度，
b…纤维束的第二缠绕间距宽度，
c…第二缠绕间距宽度与第一缠绕间距宽度之差(纤维束间的间隙)。

Claims (10)

1.一种罐的制造方法，至少包含在内衬的外表面以所需的间距宽度缠绕多层包含未固化的树脂成分的纤维束来形成纤维增强树脂层的工序，其特征在于，还包含：
至少在最外侧的层缠绕所述纤维束时形成一处以上的如下区域的工序，该区域是以宽度比所述间距宽度宽的第二间距宽度缠绕纤维束以形成在相邻的纤维束与纤维束之间不存在纤维束的所需宽度的间隙的区域；和
削去工序，将由渗出到所述间隙的树脂固化而形成的固化树脂构成的凸部的顶端部以留下规定高度的方式削去。
2.根据权利要求1所述的罐的制造方法，其特征在于，
以使进行削去后的残存部的削去面成为平坦面的方式进行所述削去工序。
3.根据权利要求1或2所述的罐的制造方法，其特征在于，
还包含至少在所述凸部的表面涂敷形成光的反射层的材料来形成光反射层的工序、和对所述光反射层照射激光来测定所述凸部的位置以及形状的工序，基于从所述测定得到的信息来进行所述削去工序。
4.根据权利要求3所述的罐的制造方法，其特征在于，
作为形成所述光反射层的材料，使用包含粘合剂的材料。
5.根据权利要求1～4中任一项所述的罐的制造方法，其特征在于，
还包含利用通过所述削去工序进行削去后的残存部的削去面来粘贴薄叶状的标签的工序。
6.根据权利要求1～5中任一项所述的罐的制造方法，其特征在于，
以所述第二间距宽度缠绕纤维束的区域包含所述罐的至少圆筒主干部。
7.一种罐，具备在内衬的外表面缠绕多层包含未固化的树脂成分的纤维束而形成的纤维增强树脂层，其特征在于，
所述纤维增强树脂层的至少最外层具有一处以上的形成有在纤维束与纤维束之间不存在纤维束的间隙的区域，在所述间隙中存在渗出而固化后的树脂，所述固化后的树脂的上表面为平坦面。
8.根据权利要求7所述的罐，其特征在于，
对所述平坦面赋予了粘合性。
9.根据权利要求7或8所述的罐，其特征在于，
形成有所述间隙的区域至少包含于罐的圆筒主干部。
10.根据权利要求7～9中任一项所述的罐，其特征在于，
利用所述平坦面粘贴有薄叶状的标签。
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