JP2023114362A - Manufacturing method for tank - Google Patents

Abstract

To provide a manufacturing method for a tank that can shorten the curing time of a formed in place gasket (FIPG), and can save energy.SOLUTION: A manufacturing method for a tank 1 includes a step of forming an intermediate body comprising a liner 2 and a reinforcing layer 3, a step of applying a formed in place gasket (FIPG) to a position in an outer surface of the reinforcing layer 3 corresponding to a dome part, a step of arranging a protector 4 on the outer surface of the reinforcing layer 3 so that an inner surface 43 of the protector 4 is in contact with the position in the reinforcing layer 3 corresponding to the dome part, and a step of curing the FIPG by supplying high-temperature steam into the protector 4 via a blind hole 44 provided in the protector 4 and a pipe 82 of a pressing jig 8.SELECTED DRAWING: Figure 3

Description

TECHNICAL FIELD The present invention relates to a method for manufacturing a tank, and more particularly to a method for manufacturing a tank with a protector.

As a tank such as a hydrogen tank mounted on a fuel cell vehicle, one is known that includes a liner having a cylindrical body portion and dome portions provided at both axial ends of the body portion, and a reinforcing layer covering the liner. It is Further, protectors are arranged on the outer surface of the reinforcing layer at both ends of the liner in order to ensure the impact resistance of the tank (see, for example, Patent Document 1).

When manufacturing a tank having such a structure, first, a plurality of fiber bundles impregnated with resin are wound around the outer peripheral surface of the liner by a filament winding (FW) method to form a reinforcing layer. A protector made for the body is fixed to the outer surface of the reinforcing layer with an adhesive.

JP 2014-190495 A

Recently, in order to improve airtightness and liquid tightness between the protector and the reinforcing layer, fixing the protector to the outer surface of the reinforcing layer using FIPG (Formed In Place Gasket) has been considered. However, curing FIPG requires a high-temperature and high-humidity environment, and it takes time for the protector and the reinforcing layer to adapt to the high-temperature and high-humidity atmosphere. A big problem arises.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a tank manufacturing method capable of shortening the curing time of FIPG and realizing energy saving.

A method for manufacturing a tank according to the present invention includes a liner having a cylindrical body and dome portions provided at both axial ends of the body, a reinforcing layer covering the liner, and an outer surface of the reinforcing layer. and a protector fixed and made of a breathable resin material, wherein a position corresponding to the dome portion on the outer surface of the reinforcing layer, an outer surface to be the outside, and the applying FIPG to at least one of the inner surface of the protector having an inner surface facing the reinforcing layer and a plurality of holes extending from the outer surface toward the inner surface; arranging the protector on the outer surface of the reinforcing layer so as to abut against the dome portion; and C. curing.

In the tank manufacturing method according to the present invention, by supplying high-temperature steam to the inside of the protector through the holes of the protector, the FIPG applied between the reinforcing layer and the protector can be humidified at a high temperature. In addition, since the protector is made of an air-permeable resin material, high-temperature steam can easily spread over the entire area of the FIPG and harden the FIPG. As a result, the curing time of FIPG can be shortened. In addition, since heat energy can be reduced accordingly, energy saving can be realized.

According to the present invention, the curing time of FIPG can be shortened, and energy saving can be realized.

It is a schematic sectional drawing which shows the structure of a tank. It is process drawing which shows the manufacturing method of the tank which concerns on embodiment. It is a schematic sectional drawing for demonstrating the manufacturing method of the tank which concerns on embodiment.

An embodiment of a tank manufacturing method according to the present invention will be described below with reference to the drawings. In the embodiments, the tank will be described as an example in which it is mounted on a fuel cell vehicle and filled with high-pressure hydrogen gas, but it may also be applied to other uses. In addition, the gas that can be filled in the tank is not limited to high-pressure hydrogen gas, and various compressed gases such as CNG (compressed natural gas), LNG (liquefied natural gas), and various liquefied gases such as LPG (liquefied petroleum gas). , and other gases may be filled.

[Tank structure]
First, the structure of the tank will be explained based on FIG. As shown in FIG. 1, the tank 1 is a substantially cylindrical high-pressure gas storage container with rounded dome-shaped ends, and includes a liner 2 having gas barrier properties and a reinforcing layer 3 covering the outer surface of the liner 2. , and protectors 4 arranged on the outer surface of the reinforcing layer 3 at both ends of the liner 2 .

The liner 2 is a hollow container having a storage space for storing high-pressure hydrogen, and is made of a resin material or the like having gas barrier properties against hydrogen gas. The liner 2 is composed of a cylindrical body portion 21 and a pair of dome portions (a first dome portion 22 and a second dome portion 23) provided at both ends of the body portion 21 in the axial direction. The body portion 21 extends along the direction of the axis L of the tank 1 with a predetermined length. The first dome portion 22 and the second dome portion 23 are continuously formed on both sides of the body portion 21 and have a hemispherical shape so that the diameter thereof decreases with distance from the body portion 21 . In the following description, the first dome portion 22 and the second dome portion 23 may be collectively referred to as "dome portions" in order to avoid complication of the description.

Openings are formed in the tops of the first dome portion 22 and the second dome portion 23, respectively. A first end cap 5 is attached to the opening of the first dome portion 22 , and a second end cap 6 is attached to the opening of the second dome portion 23 .

The liner 2 is integrally formed by a rotary blow molding method using a resin member such as polyethylene or nylon. Also, the liner 2 may be formed by connecting a plurality of divided members by injection molding, extrusion molding, etc., instead of the integral molding manufacturing method such as the rotary blow molding method. Furthermore, the liner 2 may be made of a metal material such as aluminum instead of the resin member.

The reinforcing layer 3 has a function of reinforcing the liner 2 and improving mechanical strength such as rigidity and pressure resistance of the tank 1. formed. The fiber-reinforced resin is formed by impregnating a fiber bundle formed by bundling fibers having a diameter of about several μm with a thermosetting resin. Examples of fibers include reinforcing fibers such as glass fibers, carbon fibers, aramid fibers, alumina fibers, boron fibers, steel fibers, PBO fibers, natural fibers, or high-strength polyethylene fibers. It is preferable to use carbon fiber from the viewpoint of strength and the like.

Examples of thermosetting resins include epoxy resins, modified epoxy resins represented by vinyl ester resins, phenol resins, melamine resins, urea resins, unsaturated polyester resins, alkyd resins, polyurethane resins, and thermosetting polyimide resins. can. A thermoplastic resin may be used as the resin with which the fiber bundle is impregnated.

The first end cap 5 and the second end cap 6 are each formed by processing a metal material such as stainless steel or aluminum into a predetermined shape. It has flanges 52 and 62 inserted between the reinforcement layer 3 . The first end cap 5 and the second end cap 6 may have the same shape or different shapes. Also, the tank 1 does not necessarily have two caps, and may have only one cap.

The protector 4 is a buffer member for protecting the tank 1 from impact and stress due to the internal pressure of the tank 1 , and is fixed on the outer surface of the reinforcing layer 3 at a position corresponding to the dome portion of the liner 2 . As shown in FIG. 1, the protector 4 has a bowl-like shape with an opening 41 in the center. and a plurality of blind holes 44 extending toward the .

The opening 41 has a size that allows the first end cap 5 (or the second end cap 6) to be inserted therethrough. The outer surface 42 extends from the side of the first end mouthpiece 5 (or the second end mouthpiece 6 ) toward the connecting portion side between the dome portion of the liner 2 and the body portion 21 . The inner surface 43 is arc-shaped so as to fit the shape of the reinforcing layer 3 covering the dome portion of the liner 2 .

The blind holes 44 are multiple and regularly arranged. For example, when viewed from the direction of the axis L of the tank 1, these blind holes 44 are arranged radially outward from the center of the tank 1 at regular intervals. The blind hole 44 is a so-called non-through hole, and is formed such that one end (open end) is open to the outside of the protector 4 and the other end (closed end) remains inside the protector 4 .

These blind holes 44 have different depths depending on their position. Specifically, the blind hole 44 of the present embodiment is arranged parallel to the direction of the axis L of the tank 1 and is formed so as to gradually become deeper as the distance from the axis L of the tank 1 increases. . In other words, the blind hole 44 located near the first end cap 5 (or the second end cap 6) is formed relatively shallow, and the first end cap 5 (or the second end cap 6) is relatively shallow. Blind holes 44 positioned farther from are formed relatively deep.

The protector 4 is made of an air-permeable resin material. As the resin material having air permeability, a foamed resin having open cells such as open-cell foamed urethane is preferable. The protector 4 is fixed to the outer surface of the reinforcing layer 3 by FIPG.

[Tank manufacturing method]
Next, a method for manufacturing the tank 1 will be described with reference to FIGS. 2 and 3. FIG. As shown in FIG. 2, the method of manufacturing the tank 1 mainly includes a step of forming an intermediate body having a liner 2 and a reinforcing layer 3 (hereinafter referred to as “first step S1”), and FIPG for the reinforcing layer 3. (hereinafter referred to as "second step S2"), placing the protector 4 on the outer surface of the reinforcing layer 3 (hereinafter referred to as "third step S3"), and curing the FIPG (hereinafter referred to as "third step S3"). (hereinafter referred to as "fourth step S4").

In the first step S1, first, the liner 2 having the body portion 21 and the dome portion is integrally formed by a rotary blow molding method using a resin member such as polyethylene or nylon. Subsequently, the first end cap 5 is attached to the opening of the first dome portion 22, and the second end cap 6 is attached to the opening of the second dome portion 23, respectively. Subsequently, a reinforcing layer 3 is formed by winding a plurality of fiber-reinforced resins around the outer peripheral surface of the liner 2 to which the mouthpiece is attached by the FW method. Next, the thermosetting resin or thermoplastic resin contained in the fiber reinforced resin is cured. This forms an intermediate having liner 2 and reinforcing layer 3 .

In the second step S2, FIPG is applied to the outer surface of the reinforcing layer 3 at a position corresponding to the dome portion. Specifically, for example, as shown in FIG. 3, FIPG 7 having a predetermined thickness is applied to the outer surface of the reinforcing layer 3 at a position corresponding to the first dome portion 22 (or the second dome portion 23). The FIPG 7 is applied so that the thickness of the FIPG 7 gradually decreases from the central portion toward both ends in a cross-sectional view such as that shown in FIG. 3, for example.

In the third step S3, the protector 4 is arranged on the outer surface of the reinforcing layer 3 so that the inner surface 43 of the protector 4 and the position corresponding to the dome portion of the reinforcing layer 3 are in contact with each other. Specifically, the protector 4 is arranged on the outer surface of the reinforcing layer 3 so that the inner surface 43 of the protector 4 covers the position of the reinforcing layer 3 to which the FIPG 7 is applied from the outside. In addition, the protector 4 is manufactured in advance.

In the fourth step S4, as shown in FIG. 3, a pressing jig 8 is brought into contact with the outer surface 42 of the protector 4, and a pressing force F (see the arrow in FIG. 3) is applied to the protector 4 via the pressing jig 8. In the applied state, high-temperature steam is supplied to the inside of the protector 4 to harden the FIPG 7 .

Specifically, the pressing jig 8 is provided with an opening 81 through which the first end cap 5 (or the second end cap 6) can be inserted. The pressing jig 8 is provided with a plurality of pipes 82 for supplying high-temperature steam.

The pipe 82 is arranged parallel to the direction of the axis L of the tank 1 . The interval between the adjacent pipes 82 is the same as the arrangement interval of the blind holes 44 of the protector 4 . Further, the pipe 82 has an internal portion provided inside the pressing jig 8 and an exposed portion exposed from the pressing jig 8 . The end of the inner portion of the pipe 82 is connected with a gallery 83 built into the pressing jig 8 . Galleries 83 are further connected to pipes 84 to distribute hot steam supplied by pipes 84 to each pipe 82 . In addition, the pipe 84 is connected to a steam device (not shown).

At least the exposed portion of the inner portion and the exposed portion of the pipe 82 has a thickness that allows it to be inserted inside the blind hole 44 of the protector 4 . The tip of the exposed portion of the pipe 82 is open.

The pipes 82 having such a configuration are formed to have different lengths corresponding to the blind holes 44 of the protector 4 to be inserted. That is, the pipe 82 corresponding to the relatively shallow blind hole 44 is relatively short. On the other hand, the pipe 82 corresponding to the relatively deep blind hole 44 is relatively long.

Further, inside the pressing jig 8, a plurality of heaters 85 are built in at predetermined intervals. The heaters 85 are arranged between adjacent pipes 82 as shown in FIG. 3, for example.

Therefore, in the fourth step S4, first, the pressing jig 8 and the protector 4 are aligned so that the exposed portions of the pipes 82 are inserted into the corresponding blind holes 44 of the protector 4, and then the pressing jig is inserted. The tool 8 is brought into contact with the outer surface 42 of the protector 4 . Subsequently, high-temperature steam is supplied to the interior of the protector 4 through the pipe 82 of the pressing jig 8 and the blind hole 44 of the protector 4 while applying the pressing force F to the protector 4 via the pressing jig 8 .

As described above, the protector 4 is made of a foamed resin having open cells such as open-cell foamed urethane, and the foamed resin having open cells has a sponge structure in which the cells are connected to each other. Therefore, the high-temperature steam supplied through the pipe 82 and the blind hole 44 of the protector 4 is released inside the protector 4 via the connected air bubbles, and easily spreads over the entire area of the coated FIPG 7, thereby removing the FIPG 7. Can be heated and humidified. Thereby, the FIPG 7 can be cured uniformly. Also, at this time, by simultaneously heating the pressing jig 8 using the heater 85 built into the pressing jig 8, the temperature drop of the supplied high-temperature steam can be suppressed, and the heat is transmitted to the FIPG 7 via the protector 4. FIPG can be heated by heating.

After the applied FIPG 7 is completely cured, the pressing jig 8 is slid and removed from the protector 4 . The tank 1 is manufactured by this.

In the above description, an example of applying FIPG to a position corresponding to the dome portion on the outer surface of the reinforcing layer 3 was given. FIPG may be applied both on the outer surface of the layer 3 at the position corresponding to the dome portion and on the inner surface 43 of the protector 4 .

In the method of manufacturing the tank 1 according to the present embodiment, the high-temperature steam is supplied to the inside of the protector 4 through the blind hole 44 of the protector 4 and the pipe 82 inserted into the blind hole 44, whereby the reinforcing layer 3 and the The FIPG 7 applied between the protector 4 can be humidified at a high temperature. In addition, since the blind hole 44 is used, the high-temperature steam emitted from the tip of the pipe 82 is dammed by the closed end of the blind hole 44 and diffuses in the radial direction of the tank 1, so that it can easily reach the entire range of the FIPG 7. It can spread and harden the FIPG7. Furthermore, since the protector 4 is made of a foamed resin having open cells, high-temperature steam easily spreads over the entire range of the FIPG 7 via the open cells, and the FIPG 7 can be cured efficiently. As a result, the curing time of FIPG 7 can be shortened.

Also, by shortening the curing time of the FIPG 7, the thermal energy required for curing can be reduced, so energy can be saved. Furthermore, the curing time of the FIPG 7 can be shortened, which contributes to the reduction of product inventories in the manufacturing process. In addition, in this embodiment, high-temperature steam (including steam that cools and turns into a white mist) is used instead of the low-temperature fog generated by the vibrating element. can.

Furthermore, since the high-temperature steam easily spreads over the entire range of the FIPG 7, it is possible to prevent uneven heating of the FIPG 7 and sufficiently secure the hardening of the FIPG 7. As a result, an effect of improving the adhesion quality between the protector 4 and the reinforcing layer 3 can be expected.

The hole provided in the protector 4 may be a through hole passing through the protector 4 instead of the blind hole 44, or a combination of the blind hole 44 and a through hole. When the through-holes are used, the high-temperature steam emitted from the tip of the pipe 82 can directly heat and humidify the FIPG 7, and furthermore, it can be blocked by the reinforcing layer 3 and diffused in the radial direction of the tank 1. It can easily spread over and harden FIPG7.

Although the embodiments of the present invention have been described in detail above, the present invention is not limited to the above-described embodiments, and various designs can be made without departing from the spirit of the invention described in the claims. Changes can be made.

1: tank, 2: liner, 3: reinforcing layer, 4: protector, 5: first end cap, 6: second end cap, 7: FIPG, 8: pressing jig, 21: body, 22: first Dome part 23: Second dome part 41: Opening part 42: Outer surface 43: Inner surface 44: Blind hole 51, 61: Base body part 52, 62: Flange part 81: Opening part 82: Pipe, 83: Gallery, 84: Piping, 85: Heater

Claims (1)

A liner having a cylindrical body and dome portions provided at both ends in the axial direction of the body, a reinforcing layer covering the liner, and a breathable resin material fixed to the outer surface of the reinforcing layer. A method of manufacturing a tank comprising: a formed protector;
The inner surface of the protector having a position corresponding to the dome portion on the outer surface of the reinforcing layer, an outer surface serving as the outside, an inner surface facing the reinforcing layer, and a plurality of holes extending from the outer surface toward the inner surface. A step of applying FIPG to at least one of
disposing the protector on the outer surface of the reinforcing layer so that the inner surface of the protector and the position corresponding to the dome portion of the reinforcing layer are in contact;
a step of curing the FIPG by supplying high-temperature steam to the inside of the protector through the holes of the protector;
A method for manufacturing a tank, comprising:

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