CN110871577A - 罐的制造方法 - Google Patents
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- CN110871577A CN110871577A CN201910454337.2A CN201910454337A CN110871577A CN 110871577 A CN110871577 A CN 110871577A CN 201910454337 A CN201910454337 A CN 201910454337A CN 110871577 A CN110871577 A CN 110871577A
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- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- 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
- B29C70/70—Completely encapsulating inserts
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract
罐的制造方法是通过向具有主体部和设置于主体部的两端的圆顶部的内衬的外周卷绕多层浸渍有环氧树脂的纤维来制造罐的方法。在制造方法中,包括从靠近主体部的外周的一侧朝向远离主体部的外周的一侧将纤维环向卷绕而依次层叠多个环层。在层叠环层时,使主体部的与圆顶部相邻的端部的温度比主体部中除了所述端部以外的其它部分的温度低。
Description
技术领域
本发明涉及罐的制造方法,该方法通过向内衬的外周卷绕多层浸渍有树脂的纤维来制造罐。
背景技术
搭载于燃料电池汽车的氢罐等罐为了确保安全性而要求高耐压强度等。作为这样的罐的制造方法,已知有纤维缠绕/长丝缠绕(FW)法。具体而言,一边使具有主体部和设置于主体部的两端的圆顶部的内衬旋转,一边以一定的张力(即,卷绕纤维的力)将浸渍有未固化的热固性树脂的纤维反复卷绕于该内衬的外周,由此形成由环层和螺旋层构成的加强层,然后使热固性树脂热固化。
作为一例,在国际公开第2010/116526中,公开了如下的罐的制造方法:能够通过使环层与螺旋层的层叠方式最佳化而提高卷绕的纤维所带来的强度显现(改进)的效率,将纤维环向卷绕而形成的环层从靠近内衬的主体部的外周的一侧朝向远离内衬的主体部的外周的一侧依次层叠。
发明内容
但是,在将多个环层从靠近主体部的外周的一侧朝向远离主体部的外周的一侧依次层叠于主体部的外周时,利用卷绕外侧环层(即,远离内衬的外周的一侧的环层)的纤维的力,向内侧环层(即,靠近内衬的外周的一侧的环层)的纤维施加压力,因此内侧环层的纤维被向内衬的中心轴线的轴向压出。由此,内侧环层的纤维有可能横向滑动而使配置位置偏移(转移、移动)。特别是,在主体部的与圆顶部相邻的端部,容易产生这样的纤维的位置偏移。若发生纤维的位置偏移,则会导致罐的初始强度、疲劳强度的降低。
本发明是一种罐的制造方法,其能够在环向卷绕时抑制主体部的与圆顶部相邻的端部处的纤维的位置偏移。
本发明的一方式的罐的制造方法是通过向具有主体部和设置于所述主体部的两端的圆顶部的内衬的外周卷绕多层浸渍有树脂的纤维来制造罐的罐的制造方法,包括从靠近所述主体部的外周的一侧朝向远离所述主体部的外周的一侧将所述纤维环向卷绕而依次层叠多个环层,在层叠所述环层时,使所述主体部的与所述圆顶部相邻的端部的温度比所述主体部中除了所述端部以外的其它部分的温度低。
在本发明的一方式的罐的制造方法中,通过在层叠环层时使主体部的与圆顶部相邻的端部的温度比主体部中除了端部以外的其它部分的温度低,从而能够提高浸渍在卷绕于该端部的纤维中的树脂的粘度,因此能够提高树脂的粘着性。由此,能够抑制主体部的与圆顶部相邻的端部处的纤维的位置偏移。
在本发明的一方式的罐的制造方法中,也可以是,所述树脂为环氧树脂。这样,通过利用环氧树脂的优异的粘接性,能够提高抑制主体部的与圆顶部相邻的端部处的纤维的位置偏移的效果。
另外,在本发明的一方式的罐的制造方法中,也可以是,在层叠所述环层时,使所述主体部的与所述圆顶部相邻的所述端部的温度为16℃以下。这样,能够将主体部的与圆顶部相邻的端部处的纤维的位置偏移量抑制在2mm以下。
在本发明的一方式的罐的制造方法中,也可以是,在层叠所述环层时,使所述主体部的与所述圆顶部相邻的所述端部的温度为16℃以下且5℃以上。
在本发明的一方式的罐的制造方法中,也可以是,在层叠所述环层时,使所述主体部中除了所述端部以外的其它部分的温度为20℃以上且25℃以下。
在本发明的一方式的罐的制造方法中,也可以是,在层叠所述环层时,将所述纤维从所述主体部的所述端部中的第1端部环向卷绕至所述端部中的第2端部而形成第N层的环层,在所述第2端部将所述纤维折返并环向卷绕而在所述第N层的环层的外侧形成第N+1层的环层,其中N为1以上的整数。
根据以上的方式,能够在环向卷绕时抑制主体部的与圆顶部相邻的端部处的纤维的位置偏移。
附图说明
以下将参照附图来说明本发明的示例性实施方式的特征、优点、以及技术和工业重要性,其中同样的附图标记表示同样的构件,并且附图中:
图1是示出罐的构造的剖视图。
图2是说明实施方式的罐的制造方法的示意图。
图3是示出树脂的粘着力与温度的关系的图。
图4是示出纤维的位置偏移量与温度的关系的图。
图5是示出与实施例的罐及比较例的罐相关的爆破压力的测定结果的图。
图6A是用于说明基于环向卷绕的环层的形成的示意图。
图6B是用于说明基于螺旋卷绕的螺旋层的形成的示意图。
具体实施方式
以下,参照附图对罐的制造方法的实施方式进行说明,在此之前基于图1对罐1的构造进行说明。
图1是示出罐1的构造的剖视图。罐1是例如搭载于燃料电池车辆的高压罐,能够在内部贮存高压氢。罐1具备具有流体的贮存空间的内衬10和与该内衬10的外周紧贴(紧密接触)的FRP层(纤维强化塑料层)20。
内衬10具有对氢气的气体阻隔性。内衬10是具有大致圆筒状的主体部11和分别设置于主体部11的左右两端的大致半球状的圆顶部12的中空的容器。在两个圆顶部12的顶部分别形成有开口部,在这些开口部中的一方内插有阀侧端口环13,在另一方内插有端侧端口环14。
该内衬10例如使用聚乙烯、尼龙等树脂构件,通过旋转吹塑成形法一体地形成。另外,内衬10也可以代替树脂构件而由铝等轻金属形成。而且,内衬10也可以通过利用注射挤压成形等将分割成多个的构件接合而形成,来代替旋转吹塑成形法那样的一体成形的制造方法。
FRP层20具有以覆盖内衬10的主体部11的外周的方式层叠的多个环层21、以包覆这些环层21和圆顶部12的方式整体覆盖内衬10的多个螺旋层22。
如图6A所示,环层21是如下纤维层:通过以与内衬10的中心轴线L大致垂直的卷绕角度在主体部11的周向上对浸渍有环氧树脂的纤维15进行环向卷绕而形成。在此,“大致垂直”包括90°和以纤维15彼此不重叠的方式使纤维15的卷绕位置偏移而可能产生的90°前后的角度这两者。
另一方面,如图6B所示,螺旋层22通过相对于内衬10的中心轴线L以大于0°且小于90°的卷绕角度在主体部11以及圆顶部12的周向上螺旋卷绕纤维15而形成。此外,螺旋卷绕根据卷绕角度进一步分为低角度螺旋卷绕和高角度螺旋卷绕。低角度螺旋卷绕即卷绕角度小(例如大于0°且为30°以下)的情况下的螺旋卷绕,是在纤维15绕中心轴线L一周前产生圆顶部12中的纤维15的卷绕方向的折返的卷绕方法。高角度螺旋卷绕即卷绕角度大(例如大于30°且小于90°)的情况下的螺旋卷绕,是在产生圆顶部12中的纤维15的卷绕方向的折返之前,在主体部11中纤维15绕中心轴线L至少一周的卷绕方法。此外,图6B示出低角度螺旋卷绕。
具有以上构造的罐1的制造方法主要包括:在主体部11的外周依次层叠多个环层21的环层层叠工序、将整体覆盖内衬10的螺旋层22层叠多层的螺旋层层叠工序、以及使层叠的环层21以及螺旋层22热固化的热固化工序。
在环层层叠工序中,如图2所示,从靠近内衬10的主体部11的外周的一侧向远离内衬10的主体部11的外周的一侧将浸渍有环氧树脂的纤维15环向卷绕而依次层叠多个环层21。具体而言,在将内衬10安装于旋转驱动部(未图示)的状态下,一边使内衬10以内衬10的中心轴线L为中心旋转,使卷绕浸渍有环氧树脂的纤维15的卷轴(未图示)沿着中心轴线L方向往复移动,一边向内衬10侧放出纤维15。
然后,通过从主体部11的一端部(第1端部)朝向另一端部(第2端部)将纤维15环向卷绕,从而在主体部11的外周形成第1层的环层21。主体部11的一端部例如是在图2中位于纸面的右侧的端部,另一端部例如是在图2中位于纸面的左侧的端部。接着,通过将纤维15在主体部11的另一端部折返,从主体部11的另一端部朝向一端部将纤维15环向卷绕,从而在第1层的环层21的外侧(即,远离内衬10的外周的一侧)层叠第2层的环层21。接着,依次地,在第2层的环层21的外侧层叠第3层的环层21,在第3层的环层21的外侧层叠第4层的环层21,…在第N层的环层21的外侧层叠第N+1层的环层21。此外,之后,存在将主体部11的一端部以及另一端部总称为“主体部11的端部”的情况。主体部11的一端部及另一端部与圆顶部12相邻。
在此,为了降低主体部11与圆顶部12的边界处的台阶差,优选以层叠的环层21的左右两端分别朝向中心轴线L方向阶段性地向内侧偏移地倾斜的方式层叠多个环层21。即,沿着第N+1层的环层21的中心轴线L剖开得到的截面的长度比沿着第N层的环层21的中心轴线L剖开得到的截面的长度短。
另外,在环层层叠工序中,在使主体部11的与圆顶部12相邻的端部的温度比主体部11中除了所述端部以外的其它部分的温度低的状态下,层叠多个环层21。具体而言,如图2所示,在内衬10的上方,在与主体部11的与圆顶部12相邻的一端部以及另一端部对应的位置各配置有1个冷风吹送部30,在与主体部11中除了一端部以及另一端部以外的其它部分对应的位置配置有暖风吹送部31。
冷风吹送部30具有向主体部11的端部的表面吹送冷风的喷嘴。暖风吹送部31具有多个喷嘴,所述多个喷嘴沿着内衬10的中心轴线L方向以预定的间隔设置,并向除了端部以外的主体部11的其它部分的表面吹送暖风。并且,在环层层叠工序中,通过使用冷风吹送部30来控制主体部11的与圆顶部12相邻的端部的温度,并使用暖风吹送部31来控制除了所述端部以外的主体部11的其它部分的温度,从而实现主体部11的端部与除了所述端部以外的其它部分的温度差。
在此,根据以下的理由,优选使主体部11的与圆顶部12相邻的端部的温度为16℃以下。即,在环层的层叠时纤维的位置偏移的发生对浸渍于纤维中的树脂的粘度及树脂的粘着性产生大的影响,特别是树脂的粘着性的影响最大。此外,此处的温度是指罐1的表面温度。
图3是示出树脂的粘着力与温度的关系的图,图4是示出纤维的位置偏移量与温度的关系的图。如图3所示,通常的FW在室温(约20℃)下进行,因此此时的粘着力为1500gF以下,当温度为16℃以下时,粘着力超过1500gF。另外,如图4所示,当温度为16℃以下时,纤维位置的偏移量为2mm以下,小于纤维宽度的规格宽度,因此能够将该程度的纤维位置的偏移量视作大致为零。因此,通过使主体部11的与圆顶部12相邻的端部的温度为16℃以下,能够抑制所述端部处的纤维的位置偏移。
在此,更优选使主体部11的与圆顶部12相邻的端部的温度为5~16℃。如上所述,通过使主体部11的与圆顶部12相邻的端部的温度为16℃以下,能够抑制所述端部处的纤维的位置偏移,因此,例如也可以使左右两端部的温度为0℃或负,但在该情况下,产生用于使温度成为0℃或负的设备的变更、追加等,存在成本上升的问题。在考虑仅通过现有的设备能够应对的情况下,优选使主体部11的与圆顶部12相邻的端部的温度为5℃以上。
另一方面,在环层层叠工序中,使除了所述端部以外的主体部11的其它部分的温度为20℃~25℃。这样,通过降低浸渍于纤维15中的树脂的粘度,能够提高树脂的渗透性,因此能够减少环层21整体的空隙残留量。其结果是,能够防止由空隙引起的裂纹的扩展(蔓延),能够期待提高罐1的耐压强度的效果。
在继环层层叠工序之后的螺旋层层叠工序中,层叠多个以包覆层叠的环层21以及圆顶部12的方式整体覆盖内衬10的螺旋层22。
在继螺旋层层叠工序之后的热固化工序中,将具有层叠的环层21及螺旋层22的内衬10放入恒温槽中,例如在85℃左右的温度下加热,使纤维15中的环氧树脂热固化。由此,制造罐1。
在本实施方式的罐1的制造方法中,在环层层叠工序中,通过使主体部11的与圆顶部12相邻的端部的温度比主体部11中除了所述端部以外的其它部分的温度低,从而能够提高浸渍在卷绕于所述端部的纤维15中的树脂(在本实施方式中为环氧树脂)的粘度,因此能够提高树脂的粘着性(即,粘着力)。由此,能够抑制主体部11的与圆顶部12相邻的端部处的纤维的位置偏移,因此能够提高罐1的耐压强度,能够制造高品质的罐1。
另外,在本实施方式的罐的制造方法中,树脂为环氧树脂,因此通过利用环氧树脂的优异的粘接性,能够提高抑制主体部11的与圆顶部12相邻的端部处的纤维的位置偏移的效果。而且,在环层层叠工序中,使主体部11的与圆顶部12相邻的端部的温度为16℃以下,因此能够将左右两端部处的纤维的位置偏移量抑制在2mm以下。
此外,本申请发明人利用本实施方式的罐的制造方法试制实施例的罐,进行了与比较例的罐的爆破压力的比较评价。将其结果示于图5。在图5中,右侧的数据是实施例的罐、即在使主体部的与圆顶部相邻的端部的温度(16℃以下)比主体部中除了所述端部以外的其它部分的温度低的状态下制造的罐的爆破压力的测定结果。另一方面,左侧的数据是比较例的罐、即在主体部整体的温度相同的状态下制造的罐的爆破压力的测定结果。从图5可知,在使主体部的与圆顶部相邻的端部的温度为16℃以下的情况下,纤维位置的偏移量减少,爆破压力(即耐压强度)变高。
以上,对本发明的实施方式进行了详述,但本发明并不限定于上述实施方式,在不脱离权利要求书所记载的本发明的精神的范围内,能够进行各种设计变更。例如,在上述实施方式中,作为浸渍于纤维中的树脂,说明了环氧树脂的例子,但也可以是聚酯树脂、聚酰胺树脂等。
另外,在上述实施方式中,使用冷风吹送部及热风吹送部来分别控制主体部的与圆顶部相邻的端部的温度以及其它部分的温度,但也可以使用空调机来代替吹送部,或者也可以使用二氧化碳来控制所述端部的温度。
Claims (6)
1.一种罐的制造方法,所述罐的制造方法通过向具有主体部和设置于所述主体部的两端的圆顶部的内衬的外周卷绕多层浸渍有树脂的纤维来制造罐,其特征在于,包括从靠近所述主体部的外周的一侧朝向远离所述主体部的外周的一侧将所述纤维环向卷绕而依次层叠多个环层,其中,在层叠所述环层时,使所述主体部的与所述圆顶部相邻的端部的温度比所述主体部中除了所述端部以外的其它部分的温度低。
2.根据权利要求1所述的罐的制造方法,其特征在于,
所述树脂为环氧树脂。
3.根据权利要求1或2所述的罐的制造方法,其特征在于,
在层叠所述环层时,使所述主体部的与所述圆顶部相邻的所述端部的温度为16℃以下。
4.根据权利要求1~3中任一项所述的罐的制造方法,其特征在于,
在层叠所述环层时,使所述主体部的与所述圆顶部相邻的所述端部的温度为16℃以下且5℃以上。
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,
在层叠所述环层时,使所述主体部中除了所述端部以外的其它部分的温度为20℃以上且25℃以下。
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,
在层叠所述环层时,将所述纤维从所述主体部的所述端部中的第1端部环向卷绕至所述端部中的第2端部而形成第N层的环层,在所述第2端部将所述纤维折返并环向卷绕而在所述第N层的环层的外侧形成第N+1层的环层,其中N为1以上的整数。
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