JP2018099828A - Method for manufacturing high pressure tank - Google Patents

Abstract

PROBLEM TO BE SOLVED: To form a shape at both end portion of a hoop layer so as to be a continuous curved surface shape from the curved surface shape of the dome portion.SOLUTION: A method of manufacturing a high-pressure tank having a reinforcing layer having a hoop layer on an outer peripheral surface of a cylinder portion in a liner having the cylinder portion and a dome portion, involves a preparing step of preparing a composite body having an end portion molding portion provided with a protruding portion surrounding an end portion of a mandrel at both end portions in an axial direction of the mandrel, a first forming step of winding fibers around the composite body by hoop winding to form a hoop layer, a separating step of separating the hoop layer from the composite body, and an engaging step of engaging the separated hoop layer into the cylinder portion, where a surface of the protruding portion facing the mandrel is a curved surface formed so as to have a curved shape continuous with the curved shape of the dome portion when the hoop layer is engaged in the cylinder portion.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for manufacturing a high-pressure tank.

  Some high-pressure tanks filled with a high-pressure fluid include a liner serving as an inner shell of the high-pressure tank and a reinforcing layer covering the outer surface of the liner. The liner includes a cylindrical cylinder portion and a pair of dome portions provided at both end portions in the axial direction of the cylinder portion. Of the reinforcing layers, the hoop layer is formed on the surface of the cylinder portion.

JP 2004-144172 A

  In the high-pressure tank of Patent Document 1, the hoop layer is formed by winding the fiber by hoop winding around the cylinder portion of the liner. However, in such a high-pressure tank, the curved shape of the dome portion and the end portion of the hoop layer in the axial direction of the cylinder portion may not have a continuous curved shape. In order to solve such a problem, a technique has been desired in which the end of the hoop layer in the axial direction of the cylinder portion can be formed into a curved shape that is continuous with the curved shape of the dome portion.

  SUMMARY An advantage of some aspects of the invention is to solve at least a part of the problems described above, and the invention can be implemented as the following forms.

  (1) According to one form of this invention, the manufacturing method of a high pressure tank is provided. This high-pressure tank manufacturing method has a hoop layer on the outer peripheral surface of the cylinder part in a liner having a cylindrical cylinder part and a pair of dome parts provided at both ends in the axial direction of the cylinder part. A method of manufacturing a high-pressure tank including a reinforcing layer, wherein the mandrel is a cylindrical member having a rigidity higher than that of the liner. Preparing a composite in which a pair of end molding portions each having a projecting portion having an open portion exposing the mandrel is exposed in a part of the composite, rotating the mandrel in the composite, and the pair In a state where the end molding portion of the composite is not rotated, a fiber impregnated with a thermosetting resin is wound around the composite by hoop winding, and then wound. A first forming step of forming a hoop layer by heating and curing the cut fibers, a separating step of separating the hoop layer from the composite, and fitting the separated hoop layer into the cylinder portion A helical process is performed by winding a fiber in which a thermosetting resin is impregnated in the hoop layer and the dome portion fitted in the cylinder portion and helically winding the wound fiber, and then curing the wound fiber by heating. A surface of the protruding portion that faces the mandrel is continuous with the curved shape of the dome portion when the hoop layer is assumed to be fitted to the cylinder portion. A curved surface formed to have a curved shape. With such a configuration, the shape of both end portions in the axial direction of the hoop layer can be formed so as to be a curved surface shape that is continuous from the curved surface shape of the dome portion when the hoop layer is fitted to the cylinder portion.

  The form of the present invention is not limited to the method for manufacturing a high-pressure tank, and can be applied to various forms such as a manufacturing apparatus for a high-pressure tank having a hoop layer. Further, the present invention is not limited to the above-described embodiments, and it is needless to say that the present invention can be implemented in various forms without departing from the spirit of the present invention.

It is sectional drawing which shows schematic structure of a tank. It is process drawing which shows the manufacturing method of a tank. It is explanatory drawing which showed the composite_body | complex. It is sectional drawing which looked at the mandrel and the edge part molding part from arrow IV-IV in FIG. It is explanatory drawing which showed the state of the composite_body | complex after finishing a 1st formation process. It is explanatory drawing which shows the state by which the hoop layer was fitted by the cylinder part. It is the enlarged view to which the periphery of the edge part in a hoop layer was expanded.

A. First embodiment:
FIG. 1 is a cross-sectional view showing a schematic configuration of a tank 10 manufactured by a manufacturing method according to an embodiment of the present invention. FIG. 1 shows XYZ axes orthogonal to each other. An axis AX shown in FIG. 1 is an axis along the X axis, and is the axis center of the tank 10. The XYZ axes in FIG. 1 correspond to the XYZ axes in the other drawings. In the XYZ axes, the direction indicated by the arrow is the + side, and the direction opposite to the direction indicated by the arrow is the − side. The tank 10 stores high-pressure hydrogen gas of about 70 MPa, for example. The tank 10 includes a liner 20 and a reinforcing layer 30.

  The liner 20 is a resin-made hollow liner. The liner 20 is made of a thermoplastic resin such as polyethylene, nylon, polypropylene, or polyester. The liner 20 includes a cylinder portion 21 and dome portions 22 and 23, and bases 13 and 14 are disposed at both ends of the liner 20.

  The cylinder part 21 has a cylindrical shape extending along the X-axis direction. The dome portion 22 is provided at the end of the cylinder portion 21 on the negative side in the X-axis direction. The dome portion 23 is provided at the end of the cylinder portion 21 on the + side in the X-axis direction. The dome portions 22 and 23 are formed in a curved shape that is convex toward the outside of the liner 20.

  At the vertices of the dome portions 22 and 23, caps 13 and 14 made of metal such as aluminum or stainless steel are provided. The base 13 is provided with a through-hole 15 and is used for taking out gas from the tank 10 or replenishing gas into the tank 10. The base 14 is used for reinforcing the liner 20 or rotating the liner when forming the reinforcing layer 30. The base 14 can be omitted.

  The reinforcing layer 30 is a layer that covers the periphery of the liner 20 and is a layer for reinforcing the liner 20. The reinforcing layer 30 includes a hoop layer 32 and a helical layer 34.

  The hoop layer 32 is a layer that covers the outer surface of the cylinder portion 21 in the liner 20. The hoop layer 32 is formed by heating and curing a composite 100 (shown in FIG. 3) obtained by hoop-wrapping a fiber impregnated with a thermosetting resin. The hoop layer 32 includes end portions 36 and 37.

  The end portion 36 is an end portion on the negative side in the X-axis direction of the hoop layer 32. The end portion 37 is an end portion on the + side in the X-axis direction of the hoop layer 32. The end portions 36 and 37 are formed to have a curved surface shape that is continuous with the curved surface shape of the dome portions 22 and 23. As used herein, “continuous curved surface shape” refers to the curved surface shape of the dome portion 22 and the curved surface shape of the end portion 36 when the hoop layer 32 is disposed at a set position for manufacturing with respect to the cylinder portion 21. The curved surface shape of the dome portion 23 and the curved surface shape of the end portion 37 are integrated to form a smooth curved surface having no corners.

  The helical layer 34 is a layer that covers the outer surfaces of the hoop layer 32 and the dome portions 22 and 23. The helical layer 34 is formed by helically winding a fiber in which the hoop layer 32 and the dome portions 22 and 23 are impregnated with a thermosetting resin.

  FIG. 2 is a process diagram showing a method for manufacturing the tank 10. In the manufacturing method of the present embodiment, first, a step of preparing the composite 100 is performed (step P110).

  FIG. 3 is an explanatory view showing the complex 100. The composite 100 is a mold for forming the hoop layer 32. The composite 100 includes a mandrel 110, an end molding part 120, and an end molding part 130. In the composite 100, the axis AX is the axis center of the mandrel 110 and the axis center of the end molding part 120 and the end molding part 130.

  The mandrel 110 is a hollow cylindrical member having higher rigidity than the liner 20. “Rigidity” as used herein refers to resistance to fiber winding. The mandrel 110 is made of a metal having a high expansion coefficient and thermal conductivity. In the present embodiment, the mandrel 110 is mainly composed of aluminum. The end molding portion 120 is a member that becomes a mold for forming the end portion 36 of the hoop layer 32 together with the mandrel 110. The end molding portion 130 is a member that becomes a mold for forming the end portion 37 of the hoop layer 32 together with the mandrel 110. An end molding portion 120 is disposed at the − side end portion in the X-axis direction of the mandrel 110 and an end molding portion 130 is disposed at the + side end portion in the X-axis direction of the mandrel 110, thereby providing a composite. 100 is formed.

  The end molding part 120 includes a cylindrical part 122 and a protruding part 124. The cylindrical portion 122 is a cylindrical portion of the end molding portion 120. The protruding portion 124 is a portion protruding from the cylindrical portion 122 into a shape surrounding the end portion 116 on the negative side in the X-axis direction of the mandrel 110 in a state where the composite body 100 is formed. In a state where the composite body 100 is formed, the protruding portion 124 protrudes from the cylindrical portion 122 toward the + side in the X axis direction and surrounds the end portion 116 on the − side in the X axis direction of the mandrel 110. The protruding part 124 has an opening part 126.

  4 is a cross-sectional view of the mandrel 110 and the end molding portion 120 as viewed from the direction of arrows IV-IV in FIG. The open part 126 is a part opened in order to expose the mandrel 110 in a part of the circumferential direction in the protruding part 124. In other words, the open portion 126 is a portion of the protruding portion 124 that protrudes from the outer periphery of the end portion of the cylindrical portion 122 on the + side in the X-axis direction toward the + side in the X-axis direction. That is. In the present embodiment, the open portion 126 is a portion of the protruding portion 124 that is a negative side in the Y-axis direction and a portion near the center in the Z-axis direction.

  The cylindrical portion 132 and the protruding portion 134 in the end molding portion 130 are provided in the same manner as the cylindrical portion 122 and the protruding portion 124 in the end molding portion 120. The protruding portion 134 is a portion protruding from the cylindrical portion 132 into a shape surrounding the end portion 118 on the + side in the X-axis direction of the mandrel 110 in a state where the composite body 100 is formed. In the present embodiment, the protruding portion 134 protrudes from the cylindrical portion 132 toward the − side in the X-axis direction in a state where the composite body 100 is formed, and the end portion 118 on the + side in the X-axis direction of the mandrel 110 is formed. Surrounding.

  The protruding part 134 has an open part 136. The opening 136 in the protrusion 134 is provided in the same manner as the opening 126 in the protrusion 124. The open part 136 is a part opened to expose the mandrel 110 in the same direction as the open part 126.

  After preparing the composite 100 (process P110), a first formation process in which the hoop layer 32 is formed is performed (process P120). The first forming step is performed by winding the fiber impregnated with the thermosetting resin around the mandrel 110 by hoop winding, and then heating and curing the wound fiber. The position where the fiber impregnated with the thermosetting resin is wound is the outer surface of the mandrel 110. In the present embodiment, since the mandrel 110 is mainly composed of aluminum, which is a metal having high thermal conductivity, and has a hollow shape, the curing time for heating and curing the fibers can be shortened.

  In the first forming step, the mandrel 110 of the composite 100 is rotated about the axis AX and the end molding part 120 and the end molding part 130 are not rotated, and the fiber is wound around the composite 100. In the composite body 100, in the outer peripheral portion of the portion where the mandrel 110 is in contact with the end molding portion 120 and the end molding portion 130, the fibers to be wound are formed between the mandrel 110, the end molding portion 120, and the end molding portion 130. The mandrel 110, the end molding part 120, and the end molding part 130 are brought into contact with each other with low friction so as not to enter between them. In the portion of the composite 100 where the mandrel 110 is in contact with the end molding part 120 and the end molding part 130, the mandrel 110, the end molding part 120, and the end molding part 130 are in contact with each other inside the outer periphery. It is in a state where it has not been allowed.

  The fiber wound around the mandrel 110 is supplied toward the composite 100 from the negative side in the Y-axis direction in FIG. The fiber wound around the composite 100 is wound around the composite 100 while being moved along the X-axis direction with respect to the composite 100, thereby forming a hoop layer 32 on the outer surface of the mandrel 110 in the composite 100. To do. Fibers are wound around the composite 100 via the opening 126 and the opening 136 at the portion of the mandrel 110 where the end 36 and the end 37 in the hoop layer 32 are formed.

  The starting point at which the fiber is wound around the mandrel 110 is preferably on the end side of the mandrel 110 on the negative side in the X-axis direction (near the portion where the mandrel 110 is in contact with the end molding portion 120). If such a position is a starting point, the end point when the fiber is wound around the mandrel 110 due to the end molding part 120 being arranged on the negative side in the X-axis direction when viewed from the mandrel 110 is X It can prevent shifting to the negative side in the axial direction. Further, the starting point at which the fiber is wound around the mandrel 110 may be the end side on the + side in the X-axis direction of the mandrel 110 (near the portion where the mandrel 110 is in contact with the end molding portion 130). If such a position is taken as the starting point, the end point when the fiber is wound around the mandrel 110 by the end molding portion 130 being arranged on the + side in the X-axis direction when viewed from the mandrel 110 is X It can prevent shifting to the + side in the axial direction.

  The surface of the composite body 100 that faces the mandrel 110 out of the protrusions 124 and 134 is the dome part of the liner 20 when it is assumed that the hoop layer 32 is fitted to the cylinder part 21 of the liner 20 in the fitting step of Step P140. 22 and a surface formed to have a curved surface shape that is continuous with the curved surface shape of the dome portion 23. That is, the surface of the protrusion 124 and the protrusion 134 that faces the mandrel is formed such that the end 36 and the end 37 have a curved shape that is continuous with the curved shape of the dome 22 and the dome 23. And a surface forming a curved mold at the end portion 37.

  In the composite 100, the surface of the protrusion 124 and the protrusion 134 that faces the mandrel 110 is a curved surface shape of the dome parts 22 and 23 when it is assumed that the dome parts 22 and 23 are arranged at both ends in the X-axis direction of the mandrel 110. It can also be said that the surface has a shape for forming the end portion 36 and the end portion 37 having a continuous curved shape.

  FIG. 5 is an explanatory view showing the state of the composite 100 after the first formation step. Two broken lines extending along the X-axis direction in FIG. 5 indicate the surface of the mandrel 110. A hoop layer 32 is formed on the outer surface of the mandrel 110 in the composite 100.

  After the first formation process (process P120 in FIG. 2) is performed, a separation process for separating the hoop layer 32 from the composite 100 is performed (process P130). The separation step is executed by pulling out the hoop layer 32 from the mandrel 110 in a state where any one of the end molding part 120 and the end molding part 130 is disassembled from the composite 100. In addition, the mandrel 110 that has been heated and expanded when the fiber is heated and cured in the first forming step (step P120) contracts at the room temperature in the separation step (step P130). In the present embodiment, since the mandrel 110 is mainly composed of aluminum, which is a metal having a high expansion coefficient, the hoop layer 32 can be easily pulled out from the mandrel 110.

  After the separation step (step P130) is performed, a fitting step of fitting the hoop layer 32 separated from the composite 100 into the cylinder portion 21 in the liner 20 is performed (step P140).

  FIG. 6 is an explanatory view showing a state in which the hoop layer 32 is fitted to the cylinder portion 21 by the fitting process. Two broken lines extending along the X-axis direction in FIG. 6 indicate the surface of the cylinder portion 21 in the liner 20. In the present embodiment, since the hoop layer 32 is formed using the mandrel 110 having a slightly larger outer diameter than the outer diameter of the cylinder portion 21, the liner 20 can be easily fitted into the hoop layer 32. For example, when the outer diameter of the cylinder portion 21 of the liner 20 and the inner diameter of the hoop layer 32 are approximately the same, the liner 20 may be cooled in advance and contracted before being inserted into the hoop layer 32.

  After the fitting process (process P140) is performed, a second formation process in which the helical layer 34 is formed is performed (process P150). In the second forming step, the hoop layer 32 fitted in the cylinder part 21, the dome part 22, and the dome part 23 were wound after helically winding a fiber impregnated with a thermosetting resin. This is done by heating and curing the fiber. Through the second formation process (process P150), the tank 10 is completed (shown in FIG. 1).

  FIG. 7 is an enlarged view enlarging the periphery of the end 36 in the cross section of the completed tank 10. The shape of the end portion 36 is a curved surface shape that is continuous with the curved surface shape of the dome portion 22. Similarly, the end portion 37 has a curved shape continuous with the curved shape of the dome portion 23 (shown in FIG. 1). In the present embodiment, the curved surface shape of the dome portions 22 and 23 is an isotonic curve shape. In addition, the end portions 36 and 37 have the same tension when the curved surface shape of the dome portion 22 and the curved surface shape of the end portion 36 and the curved surface shape of the dome portion 23 and the curved shape of the end portion 37 are integrated. It is a curved surface shape formed to be a curved curved surface. The term “isotension curve-shaped curved surface” as used herein means that when gas is supplied to the inside of the tank 10, the contact surface between the dome portions 22, 23, the hoop layer 32, and the helical layer 34 changes from the contact surface to the helical layer 34. This is a curved surface in which the generated tension is equal throughout the helical layer 34.

  According to the embodiment described above, the shape of the end portion 36 and the end portion 37 in the X-axis direction of the hoop layer 32 is the curved surface of the dome portion 22 and the dome portion 23 when the hoop layer 32 is fitted to the cylinder portion 21. It can be formed to have a continuous curved shape from the shape.

  In the manufacturing method according to the first embodiment, a hoop layer 32 formed by winding fibers around a mandrel 110 having higher rigidity than the resin liner 20 is fitted into the liner 20. For this reason, compared with the manufacturing method of the form which forms a hoop layer by winding fiber around resin-made liners, hoop winding can be performed, raising the tension of a fiber.

  In the manufacturing method in which the hoop layer is formed by winding the fiber around the liner, a release agent that prevents the liner and the hoop layer from sticking is used for the purpose of preventing the hoop layer from being broken due to shrinkage and expansion of the liner. In some cases, the hoop layer is formed by winding the fiber after coating on the surface of the film. Compared to such a manufacturing method, in the manufacturing method according to the first embodiment, the hoop layer 32 that has been cured in advance is fitted to the liner 20, so that the liner and the hoop layer can be formed without applying a release agent. Releasability can be secured.

B. Variation:
In the first embodiment, in a state where the composite 100 is formed, the surface of the mandrel 110 facing the end molding part 120 (130) side and the end molding part 120 (130) facing the mandrel 110 side. Each surface is a plane, but the present invention is not limited to this. For example, the surface of the mandrel 110 facing the end molding portion 120 (130) side and the surface of the end molding portion 120 (130) facing the mandrel 110 side are partially depressed. You may protrude in the form in which a part of other surface fits into a hollow.

  The present invention is not limited to the above-described embodiments, examples, and modifications, and can be realized with various configurations without departing from the spirit thereof. For example, the technical features in the embodiments, examples, and modifications corresponding to the technical features in each embodiment described in the summary section of the invention are to solve some or all of the above-described problems, or In order to achieve part or all of the above-described effects, replacement or combination can be performed as appropriate. Further, if the technical feature is not described as essential in the present specification, it can be deleted as appropriate.

DESCRIPTION OF SYMBOLS 10 ... Tank 13 ... Base 14 ... Base 15 ... Through-hole 20 ... Liner 21 ... Cylinder part 22 ... Dome part 23 ... Dome part 30 ... Reinforcement layer 32 ... Hoop layer 34 ... Helical layer 36, 37 ... End part 100 ... Composite DESCRIPTION OF SYMBOLS 110 ... Mandrel 116,118 ... End part 120 ... End part molding part 122 ... Cylindrical part 124 ... Protrusion part 126 ... Opening part 130 ... End part molding part 132 ... Cylindrical part 134 ... Protrusion part 136 ... Opening part AX ... Shaft

Claims (1)

Manufacture of a high-pressure tank provided with a reinforcing layer having a hoop layer on an outer peripheral surface of the cylinder portion in a liner having a cylindrical cylinder portion and a pair of dome portions provided at both ends in the axial direction of the cylinder portion. A method,
At both ends in the axial direction of the mandrel, which is a cylindrical member having higher rigidity than the liner, there are provided projecting portions surrounding the end of the mandrel and exposing the mandrel in part of the circumferential direction. A preparation step of preparing a composite in which a pair of end molding portions each having a protrusion is arranged;
In the state where the mandrel is rotated and the pair of end molding portions are not rotated in the composite, the fiber impregnated with the thermosetting resin is wound around the composite by hoop winding, and then the wound fiber is wound. A first forming step of forming a hoop layer by heating and curing;
A separation step of separating the hoop layer from the composite;
A fitting step of fitting the separated hoop layer into the cylinder part;
The helical layer is formed by winding the hoop layer fitted in the cylinder part and the fiber impregnated with the thermosetting resin around the dome part by helical winding, and then heating and hardening the wound fiber. 2 forming steps,
The surface of the protruding portion that faces the mandrel is a high-pressure tank that is formed to have a curved surface shape that is continuous with the curved surface shape of the dome portion when the hoop layer is assumed to be fitted to the cylinder portion. Manufacturing method.

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