JP5365394B2 - Manufacturing method of high-pressure gas tank - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To restrain the occurrence of noise when high pressure gas permeates a high pressure gas tank. <P>SOLUTION: Fiber is wound around a liner outer peripheral part of a resin-made container by an FW (filament winding) method to form a fiber-reinforced resin layer impregnated with thermosetting resin. The thermosetting resin is then heated and thermally set by a thermosetting device. Shot blasting treatment using an abrasive B is then performed to a resin thermosetting layer formed by thermosetting at an outermost peripheral part of the fiber-reinforced resin layer. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

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

  Conventionally, various techniques have been proposed for manufacturing a high-pressure gas tank. For example, Patent Document 1 described below describes a method for manufacturing a composite high-pressure tank in which a belt-like carbon fiber reinforced plastic material is wound around a plurality of layers on the outer surface of a metal tank as a liner.

  In recent years, vehicles that are driven by combustion energy of fuel gas or electric energy generated by electrochemical reaction of fuel gas have been developed. Fuel gas such as natural gas or hydrogen is stored in the high-pressure gas tank, and the vehicle May be installed. For this reason, weight reduction of a high-pressure gas tank is required, and a resin container is used as a liner for covering with carbon fiber reinforced plastic or glass fiber reinforced plastic (hereinafter collectively referred to as a fiber reinforced resin layer). Use is under consideration.

  In general, such a high-pressure gas tank has a fiber reinforced resin layer impregnated with a thermosetting resin such as an epoxy resin formed on the outer periphery of the liner. When forming such a fiber reinforced resin layer, a fiber impregnated with a thermosetting resin is repeatedly wound around the outer periphery of a resin container to form a fiber reinforced resin layer, and then the thermosetting resin contained in the resin layer is thermally cured. . Thus, a high-pressure gas tank in which the liner of the resin container is covered with the fiber reinforced resin layer is manufactured.

JP-A-9-203497 JP-A-7-276538 JP-A-6-254974

  By the way, when winding the fiber for forming the above-described fiber reinforced resin layer on the outer periphery of the liner, tension is applied to the fiber and the fiber is wound around the liner so that excessive thermosetting resin is raised on the surface. The For this reason, the raised thermosetting resin becomes rich in the outermost layer portion of the thermosetting resin layer. Such enrichment of the thermosetting resin in the outermost layer portion of the thermosetting resin layer also occurs in the subsequent thermosetting process. In other words, in the thermosetting process, the thermosetting resin is subjected to centrifugal force accompanying the rotation of the tank for uniform heating of the high-pressure gas tank in a state in which the viscosity is lowered and the fluidity is increased by heating. It becomes easy to stay in the outermost layer part of the layer. For this reason, in the manufactured high-pressure tank, a resin thermosetting layer obtained by thermosetting the thermosetting resin is formed in the outermost layer portion of the thermosetting resin layer covering the liner.

  In such a high-pressure gas tank, when a resin container is used as a liner for weight reduction, the gas stored in the high-pressure gas tank may be slightly permeated through the liner because it is filled with high pressure. In particular, when the gas stored in the high-pressure gas tank is a gas having a low molecular weight such as hydrogen, the gas can easily pass through the liner of the resin container. The gas that has passed through the liner also passes through the fiber reinforced resin layer, stays at the interface between the fiber reinforced resin layer and the resin thermosetting layer, peels off the interface, and further, the resin pressure is increased by the pressure of the retained gas. Cracks in the thermoset layer. Such cracks in the resin thermosetting layer do not directly reduce the performance of the high-pressure gas tank, but abnormal noise may occur when the resin thermosetting layer cracks. In some cases, the user feels uncomfortable or uncomfortable.

  The present invention has been made to solve the above-described problems, and in a high-pressure gas tank having a fiber-reinforced resin layer impregnated with a thermosetting resin on the outer periphery of a resin container, the high-pressure gas permeates the high-pressure gas tank. The purpose is to suppress the occurrence of abnormal noise.

  In order to achieve at least a part of the above object, the present invention adopts the following configuration.

[Application 1: Manufacturing method of high-pressure gas tank]
A method for manufacturing a high-pressure gas tank, comprising:
Preparing a resin container as a liner;
A fiber reinforced resin layer forming step for forming a fiber reinforced resin layer impregnated with a thermosetting resin on the outer periphery of the liner;
A thermosetting step for thermosetting the fiber reinforced resin layer;
A thin-walled material that reduces the thickness of the thermosetting resin contained in the fiber-reinforced resin layer to the resin thermoset layer formed by thermosetting the outermost peripheral portion of the fiber-reinforced resin layer through the thermosetting step. And a thinning process for applying a thinning process.

  In the manufacturing method of the high-pressure gas tank having the above configuration, the fiber reinforced resin layer is formed in the outermost peripheral portion of the fiber reinforced resin layer through the formation of the fiber reinforced resin layer on the outer peripheral portion of the liner of the resinous container and the subsequent thermosetting. The resin thermosetting layer in which the thermosetting resin contained in the resin layer is thermoset remains. And this resin thermosetting layer uses a thinning process, for example, a blasting process in which a fine abrasive material is put on a high-pressure air stream, a water blasting process in which water is jetted in high pressure, or a polishing paper such as sandpaper. Therefore, the thickness of the resin thermosetting layer is reduced. For this reason, the gas in the high-pressure gas tank that has passed through the liner of the resin container and the fiber reinforced resin layer is likely to pass through the resin thermosetting layer. The generation of sound can be suppressed.

  In this case, the resin thermosetting layer is preferably thinned so as to be as thin as possible. However, since the fiber reinforced resin layer uses fibers such as carbon fiber and glass fiber for its formation, there are many spiny fluffs on the surface layer of the fiber reinforced resin layer. For this reason, from the viewpoint of ensuring the handleability of the high-pressure gas tank, it is preferable that the fluff is embedded in the resin thermosetting layer and thinned so as not to protrude from the surface of the resin thermosetting layer.

  In addition, when performing blasting as a thinning process, the resin thermoset layer covering the fiber reinforced resin layer in a thin state is applied to the surface layer of the fiber reinforced resin layer by the impact of a fine abrasive or high-pressure water collision. It is possible to leave a crack that reaches Therefore, the gas that has permeated through the liner and the fiber reinforced resin layer passes through the cracks left in the layer in the resin thermosetting layer, so that the noise caused by the gas permeation can be more reliably suppressed.

  In addition, if the blasting process as the thinning process is performed until the resin thermosetting layer is removed, it is possible to avoid the generation of abnormal noise accompanying gas permeation. As the resin thermosetting layer is removed by the blast treatment, the fine abrasive or high-pressure water removes the fluff on the surface of the fiber-reinforced resin layer due to the collision, so there is no problem in handling the tank.

  The present invention can be configured as an invention of a high-pressure gas tank manufactured by this manufacturing method in addition to the above-described configuration as a manufacturing method of a high-pressure gas tank.

It is explanatory drawing which shows typically the manufacturing process of the high pressure gas tank as one Example of this invention. It is explanatory drawing which shows typically the mode of thickness reduction by shot blasting. It is explanatory drawing which shows the modification of the shot blasting process using the abrasives B. It is explanatory drawing which shows the modification of another shot blast process.

  Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is an explanatory view schematically showing a manufacturing process of a high-pressure gas tank as an embodiment of the present invention. In this embodiment, the high-pressure gas tank is a high-pressure hydrogen tank that stores high-pressure hydrogen.

  In the tank manufacturing process of the present embodiment, first, as shown in FIG. 1A, a resin container is prepared as a liner. In this embodiment, a resin container made of a nylon resin is used as the resin container. As the resin container, a resin container made of another resin may be used.

  Next, as shown in FIG.1 (b), a fiber reinforced resin layer is formed in the outer peripheral part of a liner (fiber reinforced resin layer formation process). In this embodiment, as a fiber reinforced resin layer forming step, carbon fibers impregnated with an epoxy resin as a thermosetting resin are repeatedly wound around the outer periphery of a liner by a filament winding method (FW method). A layer is formed (FIG. 1B-1). Thereafter, the glass fiber layer is overlapped on the carbon fiber layer by repeatedly winding the glass fiber impregnated with an epoxy resin as a thermosetting resin by the filament winding method (FW method) around the outer periphery of the carbon fiber layer. It forms (FIG.1 (b-2)). The overlapped carbon fiber layer and glass fiber layer become a fiber reinforced resin layer. Since the glass fiber layer has higher mechanical strength than the carbon fiber layer, the mechanical strength of the high-pressure hydrogen tank can be increased. In this example, in the fiber reinforced resin layer forming step, excess epoxy resin impregnated in the carbon fiber or glass fiber is removed by squeezing with a force that does not cause mechanical damage to these fibers. Meanwhile, each fiber was wound. By carrying out like this, the thickness of the epoxy resin layer which is raised and formed on the surface of the glass fiber layer can be reduced to some extent in advance. Instead of the epoxy resin, a thermosetting resin such as a polyester resin or a polyamide resin can be used. Also, any resin that can be cured by receiving heat in the thermosetting process described below can be used. If the resin is further heated after thermosetting, the resin can be deformed and retain its shape when the heat is removed. But you can.

  In the fiber reinforced resin layer forming step described above, while removing excess epoxy resin, the carbon fiber and the glass fiber are repeatedly wound around the liner to form the carbon fiber layer and the glass fiber layer. Excess epoxy resin still stands out on the surface of the glass fiber layer. This raised epoxy resin is thermally cured at the outermost peripheral portion of the fiber reinforced resin layer through a thermosetting process described later to become a resin thermosetting layer (epoxy resin cured layer). The degree of the resin protrusion is determined by the fiber winding condition by the FW method, for example, the winding speed and the degree of resin impregnation, and is normally assumed to be 1 to 2 mm. With this thickness, the resin thermosetting layer (epoxy resin curing) Layer) will be formed. In this embodiment, the fiber reinforced resin layer is formed of carbon fibers and glass fibers overlapping with the carbon fibers. However, the fiber reinforced resin layer may be formed of carbon fibers or the fiber reinforced resin layer may be formed of glass fibers. . Moreover, the fiber reinforced resin layer formation with an aramid fiber can also be performed.

  Following the formation of the fiber reinforced resin layer, as shown in FIG. 1 (c), the intermediate product tank with the resin layer formed is carried into a thermosetting furnace (not shown), and the intermediate temperature up to the curing temperature of the epoxy resin is reached. Heat while rotating the product tank (thermosetting process). By this heating, the epoxy resin contained in the fiber reinforced resin layer is thermoset, and the fibers are bonded to each other to form the fiber reinforced resin layer by thermosetting. The epoxy resin that is raised from the fiber reinforced resin layer when the fiber is wound by the FW method and the epoxy resin that is raised from the fiber reinforced resin layer due to the centrifugal force accompanying the tank rotation during the heating are fiber reinforced. A resin thermosetting layer (epoxy resin cured layer) is formed on the outermost peripheral portion of the fiber reinforced resin layer by thermosetting at the outermost peripheral portion of the resin layer. The thermosetting furnace includes heating sources at a plurality of locations in the tank axial direction and heats the outer surface of the tank evenly in the tank axial direction.

  Subsequent to the above-described thermosetting process, after passing through cooling curing, the intermediate product tank is carried into a shot blasting apparatus, and as shown in FIG. 1 (d), the abrasive B is placed on the high-pressure air stream from the ejection part BS. The abrasive B is made to collide with the surface of the intermediate product tank. At this time, the intermediate product tank receives the ejection of the abrasive B while rotating. The abrasive B is a fine-grained abrasive such as alumina, silicon carbide, glass beads, iron powder, steel powder, polyamide resin particles, polycarbonate resin particles, etc., and the ejection conditions of the abrasive B, such as air ejection pressure and ejection time (Blast treatment time), selection of abrasive, etc. are determined according to the degree of thinning of the resin thermosetting layer (epoxy resin cured layer) formed by thermosetting on the outermost peripheral portion of the fiber reinforced resin layer. For example, when this resin thermosetting layer (epoxy resin curing layer) is about 0.2 mm from the thickness (1-2 mm) at the time of formation as described above, depending on the degree of thinning, Set the ejection time (blasting time) and select the abrasive. The degree of thinning of the resin thermosetting layer (epoxy resin curing layer) is not limited to 0.2 mm as described above, and is appropriately set according to the tank capacity, internal pressure, and the like. Through the above steps, the high-pressure hydrogen tank of this example is manufactured.

  As described above, in the manufacturing method of the present embodiment, shot blasting using the abrasive B for the resin thermosetting layer (epoxy resin curing layer) formed by thermosetting the outermost peripheral portion of the fiber reinforced resin layer. Apply processing. FIG. 2 is an explanatory view schematically showing a state of thinning by shot blasting. As shown in the figure, the high-pressure hydrogen tank 100 includes a fiber reinforced resin layer 120 reinforced with carbon fibers and glass fibers on the outer periphery of a liner 110 of a resin container, and includes an epoxy resin cured layer 130 outside the resin layer. . This epoxy resin cured layer 130 remains in the outermost peripheral portion of the fiber reinforced resin layer 120 that is cured and formed through fiber winding by the FW method in the thermosetting step (c) of FIG. The thickness of the fiber reinforced resin layer 120 was reduced to about 0.2 mm through thinning by shot blasting. For this reason, in the high-pressure hydrogen tank 100 obtained through the manufacturing method of the present embodiment, the hydrogen gas in the tank that has permeated the liner 110 and the fiber reinforced resin layer 120 around the liner 110 is a thin epoxy resin having a thickness of about 0.2 mm. The cured layer 130 is easily transmitted. Therefore, according to the manufacturing method of the present embodiment, it is possible to easily manufacture the high-pressure hydrogen tank 100 that suppresses generation of cracks in the cured epoxy resin layer 130 and generation of large abnormal noise when cracks occur.

  Moreover, since the epoxy resin cured layer 130 is left even if it is as thin as 0.2 mm, the fluff on the surface layer of the fiber reinforced resin layer 120 is embedded in the epoxy resin cured layer 130 and does not protrude from the surface of the epoxy resin cured layer 130. You can For this reason, the handleability of the high-pressure gas tank is not impaired, which is preferable.

  Further, the thin epoxy resin cured layer 130 outside the fiber reinforced resin layer 120 is formed on the surface layer of the fiber reinforced resin layer 120 by the impact of the blown abrasive B by the shot blasting process using the abrasive B. The reaching crack can be left in advance. Therefore, the gas that has permeated through the liner 110 and the fiber reinforced resin layer 120 passes through the cracks left in advance in the epoxy resin cured layer 130, so that it is possible to more reliably suppress abnormal noise associated with gas permeation.

  Although the embodiments of the present invention have been described above, the present invention is not limited to such embodiments, and can be implemented in various modes without departing from the scope of the present invention. For example, the following modifications are possible.

  FIG. 3 is an explanatory view showing a modification of the shot blasting process using the abrasive B. As shown in the drawing, in this modification, the ejection parts BS are arranged on the upper and lower sides and the left and right sides of the intermediate product tank, and the abrasive B is ejected from the respective ejection parts BS toward the intermediate product tank. In this case, it is not necessary to rotate the intermediate product tank.

  FIG. 4 is an explanatory view showing another modified example of the shot blasting process. As shown in the figure, in this modified example, the ejection part BS and the ejection part BSD are installed in association with the straight part of the intermediate product tank and the dome parts at both ends thereof, and the abrasive B is ejected from the respective ejection parts. According to this modification, since each ejection part is separated from the outer surface of the tank by substantially the same distance, the collision situation of the abrasive B in the straight part of the intermediate product tank and the collision situation of the abrasive B in the dome part Can be almost the same. For this reason, the thickness of the epoxy resin cured layer 130 can be made substantially the same between the straight portion and the dome portion of the tank.

  In the above embodiment, in the fiber reinforced resin layer forming step (FIG. 1 (b)) of the manufacturing process of the high-pressure hydrogen tank 100, the carbon fiber and the glass fiber are repeatedly wound around the liner 110 by the filament winding method, respectively. Although the layer 120 is formed, the present invention is not limited to this. In this fiber reinforced resin layer forming step, for example, a woven fabric impregnated with a thermosetting resin such as an epoxy resin is used instead of a fiber (thread) impregnated with a thermosetting resin such as an epoxy resin. You may make it wrap around and wind.

  In the above embodiment, in the fiber reinforced resin layer forming step of the manufacturing process of the high-pressure hydrogen tank 100, the excess epoxy resin impregnated in the carbon fiber or the glass fiber is used with a force that does not cause mechanical damage to these fibers. While each fiber is wound while being removed by squeezing, the present invention is not limited to this. You may make it abbreviate | omit the process of squeezing and removing the excess epoxy resin impregnated in carbon fiber or glass fiber. However, through this process, the thickness of the epoxy resin cured layer 130 can be reduced to some extent in advance, so that the degree of thinning by the shot blasting process can be reduced, and the blasting process can be shortened. .

  In the said Example, although the epoxy resin was used as a thermosetting resin, it is good also as what uses another thermosetting resin.

  In the above embodiment, the high-pressure gas tank is the high-pressure hydrogen tank 100, but the present invention is not limited to this. For example, a high-pressure gas tank that stores other high-pressure gas such as natural gas may be used.

  Further, instead of the shot blasting process using the abrasive B, a water blasting process for jetting water at a high pressure can be applied to the epoxy resin cured layer 130 (see FIG. 2). In addition, the epoxy resin cured layer 130 may be subjected to a polishing process in which polishing paper such as sandpaper is pressed against the outer surface of the rotating high-pressure hydrogen tank 100 and the pressed portion is moved in the tank axial direction. If it carries out like this, the epoxy resin hardened layer 130 can be thinned through grinding | polishing by the paper for grinding | polishing.

DESCRIPTION OF SYMBOLS 100 ... High pressure hydrogen tank 110 ... Liner 120 ... Fiber reinforced resin layer 130 ... Epoxy resin hardened layer B ... Abrasive material BS ... Spout part BSD ... Spout part

Claims (1)

A method for manufacturing a high-pressure gas tank, comprising:
Preparing a resin container as a liner;
A fiber reinforced resin layer forming step for forming a fiber reinforced resin layer impregnated with a thermosetting resin on the outer periphery of the liner;
A thermosetting step for thermosetting the fiber reinforced resin layer;
A thin-walled material that reduces the thickness of the thermosetting resin contained in the fiber-reinforced resin layer to the resin thermoset layer formed by thermosetting the outermost peripheral portion of the fiber-reinforced resin layer through the thermosetting step. And a thinning process for performing the crystallization treatment.

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