JP5716905B2 - Gas tank manufacturing method and thermosetting device - Google Patents

Description

  The present invention relates to a gas tank manufacturing method and a thermosetting device.

  For example, in a fuel cell system mounted on a vehicle such as an automobile, a high-pressure gas tank is used as a fuel gas supply source.

  When manufacturing this type of gas tank, a fiber reinforced resin (FRP (Fiber Reinforced Plastics)) layer is formed by wrapping a fiber impregnated with a thermosetting resin around the outer periphery of a substantially elliptical inner container. The fiber reinforced resin layer is thermally cured (see Patent Document 1). This thermosetting is conventionally performed by blowing hot air on the outer peripheral surface of the fiber reinforced resin layer.

JP 2009-191904 A JP 63-165275 A

  However, when thermosetting is performed with hot air as described above, the hot air is directly applied to the fiber reinforced resin layer, and thus the temperature of the hot air is limited from the viewpoint of heat resistance of the fiber reinforced resin layer. For this reason, it takes several hours for the thermosetting of the fiber reinforced resin layer.

  Moreover, the outermost surface of the fiber reinforced resin layer to which hot air is applied is cured first. For this reason, voids (pores) tend to remain inside the fiber reinforced resin layer. If many voids remain inside the fiber reinforced resin layer, the strength of the gas tank is affected.

  Therefore, in order to shorten the thermosetting time and suppress the residual voids in the fiber reinforced resin layer, the inventors propose to thermoset the fiber reinforced resin layer by induction heating instead of hot air. As a thermosetting method using induction heating, for example, an induction heating coil may be arranged so as to cover the entire inner container, and a current may be passed through the induction heating coil.

  However, in this case, the axial length of the induction heating coil is required to be approximately the same as that of the inner container, and the number of turns of the coil increases. Further, a mechanism and a space for inserting the inner container into the induction heating coil that is long in the axial direction are required. Furthermore, in order to heat the fiber reinforced resin layer uniformly, a positioning mechanism for accurately arranging the inner container at the axial center of the induction heating coil is required. As a result, the apparatus for performing the heat curing is increased in size, and in addition, other types of functions are required, so that the equipment cost increases.

  Further, since the induction heating coil covers the entire inner container, heat is always supplied to the entire inner container when a current is passed through the induction heating coil. For this reason, there exists a problem that a fiber reinforced resin layer will be heated too much. If the fiber reinforced resin layer is heated too much, the resin deteriorates and affects the strength of the gas tank. If this problem is solved by controlling the induction heating coil to be turned on and off, the control becomes complicated and the cost increases.

  This invention is made | formed in view of this point, and makes it the objective to carry out the thermosetting of the fiber reinforced resin layer using induction heating appropriately, restraining cost.

  The present invention for achieving the above object is a method for producing a gas tank, wherein a fiber reinforced resin layer is formed on the outer periphery of an inner container by winding a fiber impregnated with a thermosetting resin around the outer periphery of the inner container. 1 and a second step of thermosetting the fiber reinforced resin layer, wherein the fiber reinforced resin layer has the fibers wound around the axis of the inner container in a direction perpendicular to the axis. In the second step, an induction heating coil is disposed on the outer periphery of the fiber reinforced resin layer around the axis of the inner container, and the induction heating coil is disposed on the surface of the fiber reinforced resin layer. In the axial direction of the inner container, and inductively heating the fiber reinforced resin layer.

  According to the present invention, the induction heating coil disposed on the outer periphery of the inner container is moved in the axial direction of the inner container to thermally cure the fiber reinforced resin layer. Therefore, the induction heating coil is guided in comparison with the induction heating coil that covers the entire inner container. The size of the heating coil can be reduced. Moreover, the apparatus and space for inserting an inner container in an induction heating coil are not required like the case where the induction heating coil which covers the whole inner container is used. Further, there is no need for a positioning device for arranging the inner container in the axial center of the induction heating coil. Therefore, equipment cost can be reduced. Moreover, since the induction heating coil is moved along the surface of the fiber reinforced resin layer, each portion of the fiber reinforced resin layer can be intermittently heated, and overheating of the fiber reinforced resin layer can be prevented. Therefore, thermosetting of the fiber reinforced resin layer using induction heating can be performed appropriately at a reduced cost.

  In the second step, the induction heating coil is moved in the axial direction of the inner container at a first speed, and then the induction heating coil is moved in the inner container at a second speed larger than the first speed. You may make it move to an axial direction.

  In the second step, the induction heating coil is moved from one end of the inner container to the other end at the first speed, and then the induction heating coil is moved to the inner container at the second speed. You may make it move between the other edge part and one edge part in multiple times. Here, the term “move from one end of the inner container to the other end” includes the case of moving from the outer side of the one end to the outer side of the other end. In addition, moving between the other end of the container and the one end a plurality of times includes the case of moving between the outside of the other end and the outside of the one end.

  In the second step, the inner container may be rotated about an axis.

  According to another aspect of the present invention, there is provided a thermosetting apparatus for thermosetting a fiber reinforced resin layer formed by winding a fiber containing a thermosetting resin around an outer periphery of an inner container of a gas tank, the shaft of the inner container An induction heating coil disposed on an outer periphery of the surrounding fiber reinforced resin layer, and a coil moving device that moves the induction heating coil in the axial direction of the inner container along the surface of the fiber reinforced resin layer. It is a thermosetting device.

  According to the present invention, the induction heating coil arranged on the outer periphery of the inner container can be moved in the axial direction of the inner container and the fiber reinforced resin layer can be thermoset by induction heating. In comparison, the size of the induction heating coil can be reduced. Moreover, the apparatus and space for inserting an inner container in an induction heating coil are not required like the case where the induction heating coil which covers the whole inner container is used. Further, there is no need for a positioning device for arranging the inner container in the axial center of the induction heating coil. Therefore, equipment cost can be reduced. Moreover, since the induction heating coil is moved along the surface of the fiber reinforced resin layer, each portion of the fiber reinforced resin layer can be intermittently heated, and overheating of the fiber reinforced resin layer can be prevented. Therefore, thermosetting of the fiber reinforced resin layer using induction heating can be performed appropriately at a reduced cost.

  The thermosetting device may be capable of changing a moving speed of the induction heating coil by the coil moving device.

  The thermosetting device may further include a rotating device that rotates the inner container around an axis.

  ADVANTAGE OF THE INVENTION According to this invention, thermosetting of the fiber reinforced resin layer using induction heating can be performed appropriately at a reduced cost.

It is a schematic diagram of the fuel cell vehicle carrying a gas tank. It is a longitudinal cross-sectional view which shows the outline of a structure of a gas tank. It is explanatory drawing which shows the hoop winding layer of a gas tank. It is a schematic diagram which shows the outline of a structure of a thermosetting apparatus. It is explanatory drawing which shows a mode that an induction heating coil is moved from one edge part of an inner container to another edge part. It is a schematic diagram which shows the temperature change of the hoop winding layer at the time of the movement of an induction heating coil, and a helical winding layer. It is explanatory drawing which shows a mode that an induction heating coil is moved between the other edge part of an inner container, and one edge part.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a schematic diagram of a fuel cell vehicle 1 equipped with a gas tank.

  In the fuel cell vehicle 1, for example, three gas tanks 2 are mounted on the rear part of the vehicle body. The gas tank 2 constitutes a part of the fuel cell system 3, and fuel gas can be supplied from each gas tank 2 to the fuel cell 5 through the gas supply line 4. The fuel gas stored in the gas tank 2 is a combustible high-pressure gas, for example, hydrogen gas. The gas tank according to the present invention is not only used for the fuel cell vehicle 1 but also for vehicles such as electric vehicles and hybrid vehicles, as well as various mobile objects (for example, ships, airplanes, robots, etc.) and stationary equipment (housing, buildings). Applicable.

  FIG. 2 is a longitudinal sectional view showing an outline of the configuration of the gas tank 2. The gas tank 2 is formed, for example, in a substantially elliptical shape, and has a cylindrical body portion 2a having the same diameter, and a substantially hemispherical dome portion that is connected to both ends of the body portion 2a and decreases in diameter as the distance from the body portion 2a increases. 2b. A base 10 is provided at both ends of the gas tank 2 on the tank shaft.

  The gas tank 2 has a substantially ellipsoidal resin inner container (liner) 20 inside. The inner container 20 is formed of, for example, a polyamide resin such as nylon 6 or nylon 6, 6, and a polyethylene resin. In the present embodiment, the inner container of the gas tank 2 is made of resin, but may be made of aluminum. A fiber reinforced resin layer 21 is formed on almost the entire outer periphery of the inner container 20 (the portion excluding the base 10).

  The fiber reinforced resin layer 21 is formed by winding a fiber impregnated with a thermosetting resin around the outer periphery of the inner container 20 by a filament wiping (FW) method. The fiber reinforced resin layer 21 is formed of, for example, a plurality of layers having different fiber winding directions. For example, as shown in FIG. 3, the fiber reinforced resin layer 21 of the trunk portion 2a is at least perpendicular to the axis around the axis of the tank. The hoop winding layer 21a is wound in the direction. Since the fiber reinforced resin layer 21 is cured by dielectric heating, the present invention is suitable for curing a hoop winding layer wound in the same direction as the winding direction of the induction heating coil 40. In particular, in the fiber reinforced resin layer 21 in which the hoop winding layers are collected in the inner layer, the inner layer that is difficult to transmit heat from the outside can be reliably and effectively cured. The fiber reinforced resin layer 21 may include a hoop winding layer and a helical winding layer wound obliquely with respect to the axis of the tank in the thickness direction, or a hoop winding layer on the inside. A healthy winding layer may be provided on the outside, and the winding method and winding position can be arbitrarily selected. As the resin of the fiber reinforced resin layer 21, for example, an epoxy resin, a modified epoxy resin, an unsaturated polyester resin, or the like is used. Moreover, as a fiber, carbon fiber is used, for example.

  In FIG. 4, the thermosetting apparatus 30 which thermosets the fiber reinforced resin layer 21 formed in the outer periphery of the inner container 20 is shown. The thermosetting device 30 includes an induction heating coil 40 disposed on the outer periphery of the fiber reinforced resin layer 21 around the axis of the inner container 20, and the induction heating coil 40 along the surface of the fiber reinforced resin layer 21. A coil moving device 41 for moving in the direction and a rotating device 42 for rotating the inner container 20 around the axis are provided.

  The induction heating coil 40 is formed by winding a conductive wire around the axis of the inner container 20 a plurality of times. The induction heating coil 40 generates an eddy current around the coil by power feeding from a current supply source (not shown).

  The coil moving device 41, for example, supports the induction heating coil 40 with a support member 50, moves the support member 50 along a rail 51 by a drive source such as a motor (not shown), and moves the induction heating coil 40 of the inner container 20. It can be moved in the axial direction. The coil moving device 41 can change the moving speed of the induction heating coil 40 by changing the output of a motor or the like.

  The rotating device 42 can rotate the inner container 20 by supporting the bases 10 on both sides on the axis of the inner container 20 by a support body 60 and rotating the support body 60 by a drive source 61 such as a motor. .

  Next, the manufacturing method of a gas tank is demonstrated. First, the fiber impregnated with the thermosetting resin is wound around the outer periphery of the inner container 20 by the filament winding method, and the fiber reinforced resin layer 21 is formed on the outer periphery of the inner container 20 (first step). At this time, the hoop winding layer 21 a is formed on at least a part of the fiber reinforced resin layer 21. In the present embodiment, for example, the hoop wound layer 21a is formed on the inner layer of the fiber reinforced resin layer 21, and the helical wound layer is formed on the outer layer.

  Next, the inner container 20 is conveyed to the thermosetting device 30 shown in FIG. 4, and the inner container 20 is supported by the support body 60. Next, the inner container 20 is rotated by the rotating device 42, and a current is passed through the induction heating coil 40. In this state, the induction heating coil 40 is moved from one end A of the inner container 20 to the other end B by the coil moving device 41 as shown in FIG. By this induction heating coil 40, the hoop wound layer 21a of the fiber reinforced resin layer 21 is induction heated (second step). At this time, the first movement from one end A to the other end B is performed at a relatively low first speed. Thereby, sufficient heat is supplied to the thermosetting resin of each part of the fiber reinforced resin layer 21, and self-heating (reaction heat) of the resin is induced. An example of the temperature change of the hoop winding layer 21a and the helical winding layer 21b during the movement of the dielectric heating coil 40 is shown in FIG. As shown in FIG. 6, when the induction heating coil 40 is moved at the first speed, the hoop winding layer 21a is intensively heated and hardened. Further, the helical winding layer 21b is slightly heated by the heat from the hoop winding layer 21a.

  Next, as shown in FIG. 7, the induction heating coil 40 is reciprocated between the other end B of the inner container 20 and the one end A in a state where a current is continuously passed. By this induction heating coil 40, the hoop winding layer 21a of the fiber reinforced resin layer 21 is also induction heated. At this time, the reciprocating movement between the other end portion B and the one end portion A is performed at a relatively high second speed. Thereby, the heat supply to the thermosetting resin of each part of the fiber reinforced resin layer 21 is restricted, and the self-heating state of the resin is maintained, and as a result, the temperature of the entire fiber reinforced resin layer 21 is uniformly leveled. The More specifically, for example, as shown in FIG. 6, the hoop winding layer 21a maintains the temperature by the reaction heat of self-heating induced at the low speed even when the induction heating coil 40 passes at the second high speed. However, the temperature is equalized over the entire gas tank 2 by the reciprocating movement of the induction heating coil 40. Further, the helical winding layer 21b is gradually heated by the reaction heat of the hoop winding layer 21a, and curing is started while the temperature is equalized over the entire gas tank 2 by the reciprocating movement of the induction heating coil 40. Thus, the entire fiber reinforced resin layer 21 is cured.

  After reciprocating a plurality of times at the second speed, the supply of current to the induction heating coil 40 is stopped, the induction heating is finished, and the thermosetting treatment of the fiber reinforced resin layer 21 is finished.

  According to the above embodiment, the induction heating coil 40 arranged on the outer periphery of the fiber reinforced resin layer 21 of the inner container 20 is moved in the axial direction of the inner container 20 to heat cure the fiber reinforced resin layer 21 by induction heating. Therefore, the number of turns of the induction heating coil can be significantly reduced as compared with the induction heating coil that covers the entire inner container 20. Moreover, the apparatus and space for inserting the inner container 20 in an induction heating coil are not required like the case where the induction heating coil which covers the whole inner container 20 is used. Further, there is no need for a positioning device for arranging the inner container 20 at the center in the axial direction of the induction heating coil. Therefore, the equipment cost of the thermosetting device 30 can be reduced. Moreover, since the induction heating coil 40 is moved along the surface of the fiber reinforced resin layer 21, heat can be intermittently supplied to each part of the fiber reinforced resin layer 21, and overheating of the fiber reinforced resin layer 21 can be prevented. Therefore, the thermosetting of the fiber reinforced resin layer 21 using induction heating can be appropriately performed at a reduced cost.

  Further, in the second step, the induction heating coil 40 is moved in the axial direction of the inner container 20 at a relatively slow first speed, and then the induction heating coil 40 is moved at a relatively fast second speed. Therefore, first, sufficient heat is supplied to each part of the fiber reinforced resin layer 21 at a slow speed to induce self-heating (reaction heat) of the resin, and then the fiber reinforced resin layer 21 at a fast speed. A small amount of heat can be supplied to each of the portions to equalize the temperature of the entire fiber reinforced resin layer 21. Thereby, the thermosetting of the fiber reinforced resin layer 21 can be performed effectively and uniformly.

  In the second step, the induction heating coil 40 is moved at a first speed from one end A of the inner container 20 to the other end B, and then the induction heating coil 40 is moved at the second speed to the inner container. The other end portion 20 and the one end portion A are moved a plurality of times. Thereby, the induction | guidance | derivation of the self-heating of the said resin and subsequent equalization of temperature can be performed efficiently and appropriately.

  In the second step, since the inner container 20 is rotated around the axis, it is possible to prevent the uncured resin from flowing down to the lower portion of the inner container 20 due to gravity.

  The preferred embodiments of the present invention have been described above with reference to the accompanying drawings, but the present invention is not limited to such examples. It is obvious for those skilled in the art that various modifications or modifications can be conceived within the scope of the idea described in the claims, and these naturally belong to the technical scope of the present invention. It is understood.

DESCRIPTION OF SYMBOLS 1 Fuel cell vehicle 2 Gas tank 20 Inner container 21 Fiber reinforced resin layer 21a Hoop winding layer 30 Thermosetting device 40 Induction heating coil 41 Coil moving device 42 Rotating device

Claims (7)

A gas tank manufacturing method comprising:
A first step of winding a fiber impregnated with a thermosetting resin around the outer periphery of the inner container to form a fiber reinforced resin layer on the outer periphery of the inner container;
A second step of thermosetting the fiber reinforced resin layer,
The fiber reinforced resin layer has at least a hoop winding layer in which the fiber is wound around the axis of the inner container in a direction perpendicular to the axis,
In the second step, an induction heating coil is arranged on the outer periphery of the fiber reinforced resin layer around the axis of the inner container, and the induction heating coil is disposed along the surface of the fiber reinforced resin layer. Moving in the direction, induction heating the fiber-reinforced resin layer ,
In the second step, the induction heating coil is moved in the axial direction of the inner container at a first speed, and then the induction heating coil is moved in the inner container at a second speed larger than the first speed. A method of manufacturing a gas tank that moves in the axial direction . In the second step, the induction heating coil is moved from one end of the inner container to the other end at the first speed, and then the induction heating coil is moved to the inner container at the second speed. The method for producing a gas tank according to claim 1 , wherein the gas tank is moved a plurality of times between the other end and the one end. The method for manufacturing a gas tank according to claim 1 or 2 , wherein, in the second step, the inner container is rotated about an axis. A gas tank manufacturing method comprising:
A first step of winding a fiber impregnated with a thermosetting resin around the outer periphery of the inner container to form a fiber reinforced resin layer on the outer periphery of the inner container;
A second step of thermosetting the fiber reinforced resin layer,
The fiber reinforced resin layer has at least a hoop winding layer in which the fiber is wound around the axis of the inner container in a direction perpendicular to the axis,
In the second step, an induction heating coil is arranged on the outer periphery of the fiber reinforced resin layer around the axis of the inner container, and the induction heating coil is disposed along the surface of the fiber reinforced resin layer. Moving in the direction, induction heating the fiber-reinforced resin layer ,
In the second step, the method for producing a gas tank , wherein the inner container is rotated around an axis . A thermosetting device for thermosetting a fiber reinforced resin layer formed by winding a fiber containing a thermosetting resin around the outer periphery of an inner container of a gas tank,
An induction heating coil disposed on the outer periphery of the fiber reinforced resin layer around the axis of the inner container;
The induction heating coil, have a, a coil moving device that moves in the axial direction of the inner container along the surface of the fiber reinforced resin layer,
A thermosetting device capable of changing a moving speed of the induction heating coil by the coil moving device. The thermosetting device according to claim 5 , further comprising a rotating device that rotates the inner container around an axis. A thermosetting device for thermosetting a fiber reinforced resin layer formed by winding a fiber containing a thermosetting resin around the outer periphery of an inner container of a gas tank,
An induction heating coil disposed on the outer periphery of the fiber reinforced resin layer around the axis of the inner container;
A coil moving device for moving the induction heating coil in the axial direction of the inner container along the surface of the fiber reinforced resin layer ;
And a rotating device that rotates the inner container about an axis .

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