JP2017110669A - Tank manufacturing method and tank - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a tank 1 which can suppress the lowering of the rigidity of the tank 1 resulting from a step L which is formed by a wall thickness of a cylindrical part 4 composed of a fiber-reinforced resin even when the cylindrical part 4 is molded on a liner 2, and the tank 1.SOLUTION: A tank 1 having a liner 2 which has a cylindrical flank part 21 and dome-shaped side end parts 22 formed at both sides of the flank part 21 is manufactured. A liner 2 having a cylindrical part 4 around which one sheet-shaped fiber-reinforced resin layer 41 is wound a plurality of times from a direction orthogonal to an axial core CL of the flank part 21 over both the sides of the flank part 21 so as to give a prescribed wall thickness from a surface of the liner 2. The side end parts 22 are covered with a pair of caps 5,5 from both sides of the liner 2 so as to fill a step L which is formed by the wall thickness of the cylindrical part 4 between a surface of the cylindrical part 4 and surfaces of the side end parts 22 of the liner 2. The cylindrical part 4 and the pair of caps 5,5 are then helically wound by a continuous fiber which is impregnated with resin.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a tank manufacturing method and a tank suitable for storing gas and the like.

  For example, a tank for storing fuel gas is used for a natural gas vehicle or a fuel cell vehicle. In this type of tank, a fiber reinforced resin is coated on a liner corresponding to the shape of the tank in order to reduce the weight and increase the strength.

  As such a tank manufacturing method, for example, Patent Document 1 proposes a tank manufacturing method described below. In this manufacturing method, first, a liner having a cylindrical body portion and dome-shaped side end portions formed on both sides of the body portion is prepared. Next, a first helical layer is formed by helically winding continuous fibers impregnated with resin on the liner. Next, a sheet-like fiber reinforced resin is wound around the surface of the helical layer to form a hoop layer (tubular portion). Furthermore, a second helical layer is formed by helically winding a continuous fiber impregnated with a resin in a portion where the first helical layer is exposed from the cylindrical portion and the cylindrical portion.

JP 2010-265931 A

  However, in the manufacturing method shown in Patent Document 1, when the cylindrical part is molded, the thickness of the cylindrical part causes a gap between the surface of the cylindrical part and the surface of the first helical layer exposed from the cylindrical part. A step is formed on the surface. When the second helical layer is formed in a portion where such a step is formed, a hole is formed in the portion where the second helical layer and the step are formed, and the strength of the tank decreases due to the hole. It is assumed that Further, if both the peripheral edges of the cylindrical portion are scraped to eliminate such a step, the reinforcing fibers in the cylindrical portion are cut, and the tank strength of this portion is reduced.

  The present invention has been made in view of such points, and even if a cylindrical portion made of fiber reinforced resin is formed on a liner, the tank strength is reduced due to a step due to the thickness of the cylindrical portion. An object of the present invention is to provide a tank manufacturing method and a tank that can be suppressed.

  In view of the above problems, a method for manufacturing a tank according to the present invention is a method for manufacturing a tank including at least a liner having a cylindrical body and dome-shaped side ends formed on both sides of the body. A sheet-like fiber-reinforced resin layer from a direction perpendicular to the axis of the body part over both sides of the body part so as to have a predetermined thickness from the surface of the liner, Formed between the surface of the tubular portion and the surface of the side end portion of the liner by the step of preparing a liner provided with a tubular portion that has been turned around a plurality of times, and the thickness of the tubular portion. A step of covering the side end portion with a pair of caps from both sides of the liner, and helically winding the cylindrical portion and the pair of caps with a continuous fiber impregnated with a resin so as to fill the step. And a step of performing.

  According to the present invention, in a state where the step formed between the surface of the cylindrical portion and the surface of the side end portion of the liner is filled with the pair of caps, the cylindrical portion and the pair of caps are Can be helically wound with continuous fibers. Thereby, in the tank after the helical winding, no void is formed due to the step formed between the surface of the cylindrical portion and the surface of the side end portion of the liner. As a result, it is possible to suppress a decrease in the strength of the tank due to the holes (steps).

  As a more preferred embodiment, in the step of preparing the liner, the tubular portion is formed by winding a single fiber-reinforced resin sheet a plurality of times from a direction orthogonal to the axis of the body portion of the liner. To do. According to this aspect, one fiber-reinforced resin sheet can be wound around the liner, and the cylindrical portion can be integrally formed with the liner.

  The tank according to the present invention has a cylindrical body part, a liner provided with dome-shaped side end parts formed on both sides of the body part, and a predetermined thickness from the surface of the liner, Over both sides of the body part, one sheet-like fiber reinforced resin layer from the direction orthogonal to the axis of the body part is rotated a plurality of times, and the wall thickness of the tubular part, A pair of caps for covering the side end portions so as to fill a step formed between the surface of the cylindrical portion and the surface of the side end portion of the liner; The cap includes a reinforcing layer that is helically wound with continuous fibers impregnated with a resin.

  According to the present invention, since the cylindrical portion of such a tank is a portion in which one sheet-like fiber reinforced resin layer circulates a plurality of times, a single fiber reinforced resin sheet is used for a simple and short time. In addition, the cylindrical portion can be formed.

  Further, a pair of caps that cover the side end portions of the liner are in a state of being helically wound with continuous fibers impregnated with resin in a state in which a step between the cylindrical portion and the side end portion of the liner is filled. Since the layer is formed, the tank does not have a void due to a step. Thereby, the fall of the intensity | strength of the tank resulting from a void | hole (step) can be suppressed.

  According to the present invention, even if a cylindrical portion made of a fiber reinforced resin is formed on the liner, it is possible to suppress the strength of the tank from being lowered due to the step formed by the thickness of the cylindrical portion. .

It is a typical perspective view of the tank concerning this embodiment of the present invention. It is AA arrow sectional drawing of FIG. (A) is the BB arrow sectional drawing of FIG. 2, (b) is the figure which showed the state of the reinforced fiber of the cylindrical part shown to (a). (A)-(d) is a figure for demonstrating the manufacturing method of the tank which concerns on embodiment of this invention. It is a figure for demonstrating the process shown to Fig.4 (a). It is a figure for demonstrating another process shown to Fig.4 (a).

  Hereinafter, a tank and a manufacturing method thereof according to an embodiment of the present invention will be described with reference to the drawings.

1. About Tank 1 FIG. 1 is a schematic perspective view of a tank 1 according to this embodiment of the present invention, and FIG. 2 is a cross-sectional view taken along line AA in FIG. 3A is a cross-sectional view taken along line B-B in FIG. 2, and FIG. 3B is a diagram illustrating a state of the reinforcing fiber of the cylindrical portion illustrated in FIG. 3A is a cross section orthogonal to the axis CL of the body portion 21 of the liner 2 described later.

  As shown in FIGS. 1 and 2, the tank 1 according to this embodiment is a tank that accommodates (fills) high-pressure hydrogen gas of, for example, about 70 MPa. The tank 1 includes a liner 2. The liner 2 is substantially in the shape of the tank 1 and includes a cylindrical body portion 21 and dome-shaped side end portions 22 formed on both sides of the body portion 21. A storage space S for storing high-pressure hydrogen gas is formed inside the liner 2.

  The material of the liner 2 is polyester resin, polypropylene resin, nylon resin (for example, 6-nylon resin or 6,6-nylon resin), polyamide resin, polycarbonate resin, polyamide resin, acrylic resin, or ABS. A thermoplastic resin such as a resin may be used. Other than these, metals such as aluminum alloy and stainless steel may be used. By using such a material, it is possible to prevent the hydrogen gas accommodated in the accommodation space S from passing therethrough.

  In the present embodiment, the bases 3 and 3 are attached to both sides of the liner 2 so that the side end portions 22 of the liner 2 are folded back toward the accommodation space S. Each base 3 is formed with a tubular portion 31, and a through hole 32 is formed in the tubular portion 31.

  When the tank 1 is used, the through-hole 32 formed in one base 3 is sealed, and hydrogen gas is supplied and discharged from the other through-hole 32 to the accommodation space S. The material of the base 3 is made of a metal such as an aluminum alloy, but may also be a thermoplastic resin exemplified as the material of the liner 2.

  A cylindrical portion 4 is formed on the circumferential surface of the body portion 21 of the liner 2 so as to cover the body portion 21 across both ends of the body portion 21. As shown in FIG. 3A, the tubular portion 4 includes a plurality of sheet-like fiber reinforced resin layers 41 extending from both sides of the body portion 21 in a direction orthogonal to the axis CL of the body portion 21. It is the part that went around.

  Thus, by providing the cylindrical portion 4 in which the sheet-like fiber reinforced resin layer 41 is circulated a plurality of times, the body portion 11 of the tank 1 has a more uniform pressure resistance in a cross section orthogonal to the axis CL. Can have.

  The fiber reinforced resin layer 41 that forms the tubular portion 4 is a sheet-like layer in which a reinforced fiber is impregnated with a thermoplastic resin or a thermosetting resin. The reinforcing fiber may be a short fiber, a long fiber, a continuous fiber (continuous reinforcing fiber), or a cloth-like fiber, but in this embodiment, the reinforcing fiber is a continuous reinforcing fiber.

  Specifically, the reinforcing fibers of the fiber reinforced resin layer 41 are continuous reinforcing fibers aligned along the circumferential direction of the body part 21, and the reinforcing fibers are in a direction orthogonal to the axis CL of the body part 21. Oriented. More specifically, as shown in FIG. 3 (b), the reinforcing fiber 42 has a cross section orthogonal to the axis CL of the body part 21 and a plurality of continuous reinforcing fibers 42 around the axis CL of the body part 21. It is circling. In other words, the winding direction of the reinforcing fiber 42 coincides with the winding direction of the fiber reinforced resin layer 41.

  Thereby, the reinforcing fiber 42 of the cylindrical portion 4 continuously circulates a plurality of times in the direction in which the hoop stress acts on the body portion 11 due to the internal pressure of the tank 1 to the body portion 11 of the tank 1. The strength of the body portion 11 of the tank 1 can be increased.

  Here, examples of the reinforcing fiber 42 include glass fiber, carbon fiber, aramid fiber, alumina fiber, boron fiber, steel fiber, PBO fiber, natural fiber, and high-strength polyethylene fiber.

  When the resin contained in the fiber reinforced resin layer 41 is a thermoplastic resin, the thermoplastic resin exemplified for the material of the liner 2 described above can be used. When the resin contained in the fiber reinforced resin layer 41 is a thermosetting resin, for example, epoxy resin, modified epoxy resin typified by vinyl ester resin, phenol resin, melamine resin, urea resin, unsaturated polyester Examples thereof include resins, alkyd resins, polyurethane resins, and thermosetting polyimide resins.

  Thus, if the cylindrical part 4 is formed in the surrounding surface of the trunk | drum 21 of the liner 2, the cylindrical part 4 has predetermined | prescribed thickness. Due to this thickness, a step L is formed between the surface of the tubular portion 4 and the surface of the side end portion 22 of the liner 2 exposed from the tubular portion 4 (for example, FIG. 4A described later). reference).

  Therefore, in the present embodiment, the side end 22 of the tank 1 is filled so as to fill the step formed between the surface of the cylindrical portion 4 and the surface of the side end 22 by the thickness of the cylindrical portion 4. , 22 is provided with a pair of caps 5, 5.

  A through hole 51 through which the tubular portion 31 of the base 3 is passed is formed in the cap 5, and a concave portion 52 having a shape corresponding to the side end portion 22 is formed. The peripheral end surface 53 of the cap 5 is in contact with the peripheral end surface 45 of the tubular portion 4, and the peripheral end surfaces 53, 45 may be joined together by welding or the like.

  The material of the cap 5 is not particularly limited as long as the step L described above can be filled. For example, the thermoplastic resin or metal exemplified in the liner 2 or the fiber reinforced resin layer 41 is exemplified. A thermoplastic resin etc. can be mentioned.

  Further, the tank 1 includes a reinforcing layer 6 in a state where the cylindrical portion 4 and the pair of caps 5 and 5 are helically wound with continuous fibers impregnated with resin. As shown in FIG. 1, the reinforcing layer 6 has a cylindrical portion 4 and a pair of caps 5 so that continuous fiber filaments impregnated with resin are arranged on both sides of the tank 1 and cover the caps 5, 5. 5 is a layer wound around helically. The material exemplified by the above-described reinforcing fibers can be exemplified as the continuous fiber material, and the thermoplastic resin or thermosetting resin exemplified in the fiber reinforced resin layer 41 can be exemplified as the resin material.

  According to the present embodiment, the pair of caps 5, 5 covering the side end portions 22, 22 of the liner 2 is formed between the surface of the tubular portion 4 and the surface of the side end portion of the liner 2. In a state where L is buried, a reinforcing layer 6 is formed which is helically wound with continuous fibers. For this reason, the tank 1 does not have a hole due to the step L. Thereby, the fall of the intensity | strength of the tank 1 resulting from a void | hole can be suppressed.

2. About the manufacturing method of the tank 1 Fig.4 (a)-FIG.4 (d) are the figures for demonstrating the manufacturing method of the tank which concerns on embodiment of this invention. FIG. 5 is a diagram for explaining the process shown in FIG. FIG. 6 is a diagram for explaining another process shown in FIG.

  First, as shown in FIG. 4A, a liner 2 having bases 3 and 3 is prepared, and as shown in FIG. 5, the liner 2 is used as a mandrel so as to rotate around an axis CL of the liner 2. Attach to the winding machine.

  Next, a fiber reinforced resin sheet 41A (FRP sheet) in which the reinforcing fibers 42 are impregnated with resin is prepared. Here, the width of the fiber reinforced resin sheet 41 </ b> A is substantially the same as the length of the body portion 21 of the liner 2.

  The fiber reinforced resin sheet 41A may be, for example, one obtained by impregnating the above-described woven fiber with resin, but in this embodiment, the fiber reinforced resin sheet 41A is reinforced along the longitudinal direction (one direction) of the fiber reinforced resin sheet 41A. A fiber reinforced resin sheet 41A in which the fibers 42 are aligned and impregnated with a resin is used. Such a fiber reinforced resin sheet 41A can be obtained, for example, by opening a fiber bundle made of continuous fibers and impregnating the opened continuous fibers with a resin.

  Next, while rotating the liner 2, the fiber reinforced resin sheet 41A is wound on the peripheral surface of the liner 2 from a direction orthogonal to the axis CL of the body portion 21 of the liner 2, and one fiber reinforced resin sheet 41A is wound. From this, the cylindrical portion 4 is formed by a sheet winding method. Thereby, the reinforcing fibers 42 can be oriented in a direction orthogonal to the axis CL of the body part 21.

  When the resin of the fiber reinforced resin sheet 41A is a thermoplastic resin, the fiber reinforced resin sheet 41A is heated above the softening point of the thermoplastic resin by the heaters 7 and 7 shown in FIG. In a state where the plastic resin is melted, the fiber reinforced resin sheet 41A is wound around the cylindrical body portion 21 of the liner 2 a plurality of times. The wound fiber-reinforced resin sheet 41A is cooled by cooling or forced cooling, and the thermoplastic resin becomes harder than the softening point.

  When the resin of the fiber reinforced resin sheet 41A is a thermosetting resin, the fiber reinforced resin sheet 41A is wound around the liner 2 and then heated to cure the thermosetting resin.

  Thus, by winding one fiber-reinforced resin sheet 41 </ b> A around the liner 2, the cylindrical portion 4 can be integrally formed with the liner 2 easily and in a short time.

  Here, as shown in FIG. 4A, a step L is formed between the surface of the obtained cylindrical portion 4 and the surface of the side end portion 22 of the liner 2. Therefore, as shown in FIGS. 4B and 4C, the liner 2 is filled so as to fill the step L formed between the surface of the cylindrical portion 4 and the surface of the side end portion 22 of the liner 2. The side ends 22 and 22 are covered with a pair of caps 5 and 5 from both sides.

  Specifically, the through hole 51 of the cap 5 is passed through the tubular portion 31 of the base 3 attached to the liner 2, and the side end portion 22 is accommodated in the recess 52 of the cap 5, and these are brought into contact with each other. In this state, the peripheral end surface 53 of the cap 5 abuts on the peripheral end surface 45 of the cylindrical portion 4, and the step L can be filled with the cap 5. At this time, when the resin of the fiber reinforced resin layer 41 of the cylindrical portion 4 is a thermoplastic resin, the peripheral end surface 45 of the cylindrical portion 4 is heated until the thermoplastic resin is softened, thereby The shaped part 4 may be welded to the cap 5.

  Next, as shown in FIG. 4 (d), the cylindrical portion 4 and the pair of caps 5 and 5 are helically wound by filament winding with filaments of continuous fibers 61 impregnated with resin. And the reinforcement layer 6 as shown in FIG. 2 is shape | molded. Specifically, in this embodiment, before the continuous fiber 61 makes a round around the axis CL of the body part 21 between the pair of caps 5 and 5, the continuous fiber 61 is wound around the cap 5. Wrap so that the direction is folded.

  As another winding method, the continuous fiber 61 is wound around the axis CL of the body portion 21 at least a plurality of times between the pair of caps 5 and 5, and then the continuous fiber 61 is wound around one cap 5. You may wind so that a direction may be return | folded.

  When the resin impregnated in the continuous fiber 61 is a thermoplastic resin, the continuous fiber 61 is wound in a state where the thermoplastic resin is softened while being heated. On the other hand, when the resin impregnated in the continuous fiber 61 is a thermosetting resin, after winding the continuous fiber 61, the (uncured) thermosetting resin is heated to be cured.

  In this way, the tank 1 shown in FIGS. 1 and 2 can be manufactured. In the present embodiment, the stepped portion L formed between the surface of the tubular portion 4 and the surface of the side end portion 22 of the liner 2 is filled with the pair of caps 5, 5, A pair of caps can be helically wound with continuous fibers 61.

  Thereby, in the tank 1 after the helical winding, no void is formed due to the step L formed between the surface of the cylindrical portion 4 and the surface of the side end portion 22 of the liner 2. As a result, it is possible to suppress a decrease in the strength of the tank 1 due to the holes (steps L).

  In this embodiment, as shown in FIG. 4A and FIG. 5, the liner 2 equipped with the caps 3 and 3 is prepared, and the fiber reinforced resin sheet 41 </ b> A is wound around the liner 2. However, for example, the fiber reinforced resin sheet 41A is wound around a cylindrical mandrel to form the cylindrical body 4A shown in FIG. 6A, and then as shown in FIGS. 6B and 6C. The liner 2 may be inserted into the internal space 48 of the cylindrical body 4A.

  Thereafter, as shown in FIGS. 6 (c) and 6 (d), the caps 3 and 3 may be attached from both sides of the liner 2. Thus, the tank 1 can be manufactured from the liner 2 in which the cylindrical part 4 is formed through the steps shown in FIGS. 6B to 6D described above.

  Although the embodiment of the present invention has been described in detail above, the specific configuration is not limited to this embodiment, and even if there is a design change within a scope not departing from the gist of the present invention, they are not limited to this embodiment. It is included in the invention.

  In this embodiment, as shown in FIG. 5, the fiber reinforced resin sheet is wound around the liner on which the base is mounted. However, after the fiber reinforced resin sheet is wound on the liner, the base may be mounted on the liner.

  In addition to this, after the fiber reinforced resin sheet is wound around a member corresponding to a part of the body part of the liner, a part corresponding to the side end part which is a part of the liner may be attached. A portion corresponding to the base may be formed in advance.

1: tank, 2: liner, 21: body part, 22: side end part, 3: base, 31: tubular part, 32: through-hole, 4: cylindrical part, 41: fiber reinforced resin layer, tubular part 41A: Fiber reinforced resin sheet, 5: cap, 51: through hole, 6: reinforcing layer, 61: continuous fiber, 7: heater, CL: axial center, L: step, S: accommodation space

Claims (3)

A method for producing a tank comprising at least a liner having a cylindrical body part and dome-shaped side end parts formed on both sides of the body part,
A tube in which one sheet-like fiber reinforced resin layer is circulated a plurality of times from both sides of the body portion so as to have a predetermined thickness from the surface of the liner from a direction orthogonal to the axis of the body portion. A step of preparing a liner provided with a shape part,
With a pair of caps from both sides of the liner so as to fill a step formed between the surface of the cylindrical portion and the surface of the side end portion of the liner by the thickness of the cylindrical portion, Covering the side ends;
And a step of helically winding the cylindrical portion and the pair of caps with a continuous fiber impregnated with a resin.   In the step of preparing the liner, the tubular portion is formed by winding a single fiber-reinforced resin sheet a plurality of times from a direction orthogonal to the axis of the body portion of the liner. The method for manufacturing a tank according to claim 1. A liner having a cylindrical body portion and dome-shaped side end portions formed on both sides of the body portion;
A tube in which one sheet-like fiber reinforced resin layer is circulated a plurality of times from both sides of the body portion so as to have a predetermined thickness from the surface of the liner from a direction orthogonal to the axis of the body portion. And
A pair of caps covering the side end portions so as to fill a step formed between the surface of the cylindrical portion and the surface of the side end portion of the liner by the thickness of the cylindrical portion; ,
A tank comprising: a reinforcing layer in a state in which the cylindrical portion and the pair of caps are helically wound with continuous fibers impregnated with a resin.

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