JP5741006B2 - High pressure tank manufacturing method and high pressure tank - Google Patents

Description

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

  In recent years, vehicles driven by combustion energy of fuel gas and electric energy generated by electrochemical reaction of fuel gas have been developed. Such a vehicle may be equipped with a high-pressure tank in which fuel gas such as natural gas or hydrogen is stored. In this case, in order to extend the cruising range of the vehicle while reducing the size of the high-pressure tank in consideration of the mountability of the high-pressure tank in the vehicle, the high-pressure tank is filled with fuel gas at a higher filling pressure. Is required.

  In order to fill the high pressure tank with fuel gas at a higher filling pressure, it is necessary to improve the strength of the high pressure tank. And as a technology to improve the strength of the high-pressure tank, a fiber reinforced plastic (FRP: Fiber Reinforced Plastics) layer is formed on the outer surface of a metal or resin liner (inner container) using the filament winding method. The technology to do is known. When the liner has a cylindrical portion having a cylindrical shape and dome portions having a dome shape and provided at both ends of the cylindrical portion, the fiber-reinforced plastic layer by the filament winding method generally has a hoop. In many cases, a hoop layer formed by winding and a helical layer formed by helical winding are included. The hoop layer is mainly used to improve the strength against internal pressure acting in the circumferential direction of the liner (hereinafter also referred to as “strength in the circumferential direction of the liner”). On the other hand, the helical layer is mainly used to improve the strength against the internal pressure acting in the axial direction of the liner (hereinafter also referred to as “the strength of the liner in the axial direction”).

  By the way, conventionally, various techniques for improving the strength of a high-pressure tank have been proposed for a high-pressure tank having a fiber-reinforced plastic layer on the outer surface of a liner. For example, in the technique described in Patent Document 1 below, a step of forming a filament winding layer by winding resin-impregnated fibers around a hollow body (liner) and a step of curing a resin contained in the filament winding layer are repeated a plurality of times. In this way, a fiber reinforced plastic layer is formed on the outer surface of the liner to improve the strength of the high-pressure tank. Further, in this technique, since the filament winding layer and the resin are cured in a plurality of times, the resin-impregnated fiber generated at the edge of the hoop layer when forming the filament winding layer, particularly the hoop layer. It is also possible to suppress the collapse of the roll.

JP 2007-320193 A

  However, in the technique described in Patent Document 1, since the filament winding layer is formed and the resin is cured in a plurality of times, the number of steps required for manufacturing the high-pressure tank is increased, and the high-pressure tank is expensive. Invite

  The present invention has been made in order to solve the above-described problems. In a manufacturing process of a high-pressure tank having a fiber-reinforced plastic layer on the outer surface of a liner, a fiber using a filament winding method can be used with a relatively small number of steps. It aims at suppressing the collapse of the fiber at the time of forming a reinforced plastic layer.

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 or application examples.
The first aspect of the present invention is:
A method for manufacturing a high-pressure tank for storing fluid, comprising:
Preparing a liner having a cylindrical portion having a cylindrical shape, and a dome portion having a dome shape and provided at both ends of the cylindrical portion;
A fiber reinforced plastic layer forming step of forming a fiber reinforced plastic layer on the outer surface of the liner using a filament winding method;
With
The fiber reinforced plastic layer forming step includes:
A first hoop layer forming step of forming a first hoop layer by winding a plurality of layers of fibers impregnated with a thermosetting resin only on the outer surface of the cylindrical portion;
The thermosetting resin is impregnated on at least a part of the outer surface of the dome portion and the outer surface of the first hoop layer without heat-curing the thermosetting resin contained in the first hoop layer. A helical layer forming step of forming a helical layer by helically winding the formed fibers;
On the outer surface of the helical layer on the first hoop layer without heat curing the thermosetting resin contained in the first hoop layer and the thermosetting resin contained in the helical layer, A second hoop layer forming step of forming a second hoop layer by winding a plurality of layers of the fiber impregnated with the curable resin with a hoop;
A heat-curing step of heat-curing the thermosetting resin contained in the first hoop layer, the thermosetting resin contained in the helical layer, and the thermosetting resin contained in the second hoop layer; ,
Including
In the first hoop layer forming step, the cylindrical portion and the dome portion are formed on the cylindrical portion.
The first hoop layer is reduced so that the thickness of the first hoop layer becomes thinner as the boundary is closer.
Including the step of forming,
The first hoop layer forming step and the second hoop layer forming step are performed in the axial direction of the cylindrical portion.
The end of the outermost layer of the first hoop layer is the end of the innermost layer of the second hoop layer.
The first hoop layer and the second hoop so as to be disposed closer to the boundary side than
A method of manufacturing a high-pressure tank, including a step of forming a layer.
The second aspect of the present invention is:
A method for manufacturing a high-pressure tank for storing fluid, comprising:
Preparing a liner having a cylindrical portion having a cylindrical shape, and a dome portion having a dome shape and provided at both ends of the cylindrical portion;
A fiber reinforced plastic layer forming step of forming a fiber reinforced plastic layer on the outer surface of the liner using a filament winding method;
With
The fiber reinforced plastic layer forming step includes:
A first hoop layer forming step of forming a first hoop layer by winding a plurality of layers of fibers impregnated with a thermosetting resin only on the outer surface of the cylindrical portion;
The thermosetting resin is impregnated on at least a part of the outer surface of the dome portion and the outer surface of the first hoop layer without heat-curing the thermosetting resin contained in the first hoop layer. A helical layer forming step of forming a helical layer by helically winding the formed fibers;
On the outer surface of the helical layer on the first hoop layer without heat curing the thermosetting resin contained in the first hoop layer and the thermosetting resin contained in the helical layer, A second hoop layer forming step of forming a second hoop layer by winding a plurality of layers of the fiber impregnated with the curable resin with a hoop;
A heat-curing step of heat-curing the thermosetting resin contained in the first hoop layer, the thermosetting resin contained in the helical layer, and the thermosetting resin contained in the second hoop layer; ,
Including
In the second hoop layer forming step, the cylindrical portion and the dome portion are formed on the cylindrical portion.
The second hoop layer is arranged so that the thickness of the second hoop layer becomes thinner as the boundary is closer.
Including the step of forming,
The first hoop layer forming step and the second hoop layer forming step are performed in the axial direction of the cylindrical portion.
The end of the outermost layer of the first hoop layer is the end of the innermost layer of the second hoop layer.
The first hoop layer and the second hoop so as to be disposed closer to the boundary side than
A method of manufacturing a high-pressure tank, including a step of forming a layer.

[Application Example 1]
A method for manufacturing a high-pressure tank for storing fluid, comprising:
Preparing a liner having a cylindrical portion having a cylindrical shape, and a dome portion having a dome shape and provided at both ends of the cylindrical portion;
A fiber reinforced plastic layer forming step of forming a fiber reinforced plastic layer on the outer surface of the liner using a filament winding method;
With
The fiber reinforced plastic layer forming step includes:
A first hoop layer forming step of forming a first hoop layer by winding a plurality of layers of fibers impregnated with a thermosetting resin only on the outer surface of the cylindrical portion;
The thermosetting resin is impregnated on at least a part of the outer surface of the dome portion and the outer surface of the first hoop layer without heat-curing the thermosetting resin contained in the first hoop layer. A helical layer forming step of forming a helical layer by helically winding the formed fibers;
On the outer surface of the helical layer on the first hoop layer without heat curing the thermosetting resin contained in the first hoop layer and the thermosetting resin contained in the helical layer, A second hoop layer forming step of forming a second hoop layer by winding a plurality of layers of the fiber impregnated with the curable resin with a hoop;
A heat-curing step of heat-curing the thermosetting resin contained in the first hoop layer, the thermosetting resin contained in the helical layer, and the thermosetting resin contained in the second hoop layer; ,
A method for manufacturing a high-pressure tank.

  In the manufacturing method of the high-pressure tank of Application Example 1, after forming the first hoop layer on the outer surface of the cylindrical portion of the liner, the helical layer is formed so as to cover the outer surface of the first hoop layer, A second hoop layer is formed on the outer surface of the helical layer on the one hoop layer. Therefore, the first hoop layer can be pressed by the helical layer, and the fiber collapse at the edge of the first hoop layer can be suppressed. Further, by sandwiching the helical layer between the first hoop layer and the second hoop layer, the second hoop layer can be formed after the first hoop layer is fixed by the helical layer. Suppress fiber collapse at the edges of the first hoop layer and the second hoop layer as compared to the case where the first hoop layer and the second hoop layer are continuously formed without sandwiching the layers. be able to. Moreover, in the manufacturing method of the high pressure tank of the application example 1, it is included in each layer between the first hoop layer forming step and the helical layer forming step, and between the helical layer forming step and the second hoop layer forming step. The process of heat-curing thermosetting is not included. Therefore, the number of steps in the production of the high-pressure tank can be shortened as compared with the case where the thermosetting resin contained in each layer is heat-cured each time each layer is formed. That is, the manufacturing method of the high-pressure tank of Application Example 1 can suppress the collapse of the fibers when forming the fiber-reinforced plastic layer using the filament winding method with a relatively small number of steps.

  In the high-pressure tank manufacturing method of Application Example 1, the thermosetting resin contained in the first hoop layer, the thermosetting resin contained in the helical layer, and the thermosetting resin contained in the second hoop layer. May be the same type or at least one different type. Also, the fibers contained in the first hoop layer, the fibers contained in the helical layer, and the fibers contained in the second hoop layer may all be the same type, or at least one of the different types. There may be.

[Application Example 2]
A method for manufacturing a high-pressure tank according to Application Example 1,
In the helical winding in the helical layer forming step, the winding direction of the fibers in the dome portion is changed before the fibers constituting the helical layer make a round of the central axis of the liner on the outer surface of the first hoop layer. A helical winding that is folded back,
Manufacturing method of high-pressure tank.

  The helical winding is a helical winding having a relatively large winding angle (hereinafter referred to as “high angle”) in which the fiber winding direction is turned back at the dome portion of the liner after the fiber makes at least one round of the central axis of the liner in the cylindrical portion of the liner. Helical winding (hereinafter also referred to as “helical winding”) having a relatively small winding angle (hereinafter referred to as “winding direction of fiber” in the dome portion of the liner) before the fiber goes around the central axis of the liner in the cylindrical portion of the liner. , Also called “low-angle helical winding”). The low-angle helical winding has a greater effect of improving the axial strength of the liner than the high-angle helical winding.

  In the manufacturing method of the high-pressure tank of Application Example 2, since the low-angle helical winding is used in the helical layer forming step, the collapse of the first hoop layer can be suppressed and the axial strength of the liner can be improved. . Moreover, in the low angle helical winding, in order to obtain the same strength with respect to the strength in the axial direction of the liner, the number of windings, in other words, the amount of the fiber used can be reduced, compared to the high angle helical winding. The high-pressure tank can be reduced in size, weight, and cost.

[Application Example 3]
A method for producing a high-pressure tank according to Application Example 1 or 2,
In the first hoop layer forming step, the first hoop layer is formed on the cylindrical portion so that the thickness of the first hoop layer decreases as the distance from the boundary between the cylindrical portion and the dome portion increases. Forming a layer,
Manufacturing method of high-pressure tank.

  By the manufacturing method of the high-pressure tank of Application Example 3, the edge of the first hoop layer can be slanted to prevent the fibers from collapsing at the edge of the first hoop layer. Also, by forming the edge of the first hoop layer into a slant shape, when using low-angle helical winding for forming the helical layer, the fiber meandering when winding the fiber, that is, the deviation of the winding position of the fiber It is also possible to effectively utilize the effect of improving the axial strength of the liner of the low-angle helical winding.

  In addition, as an aspect which makes the edge part of a 1st hoop layer into slant shape, in the boundary part with the dome part of the cylindrical part of a liner, the aspect which changes partially the winding number of the fiber wound, or the thickness of fiber The aspect which changes partially is mentioned. The thickness of parts other than the edge of the first hoop layer is substantially constant.

[Application Example 4]
A method for manufacturing a high-pressure tank according to any one of Application Examples 1 to 3,
In the second hoop layer forming step, the second hoop layer is formed such that the thickness of the second hoop layer is reduced on the cylindrical portion as it is closer to the boundary portion between the cylindrical portion and the dome portion. Forming a layer,
Manufacturing method of high-pressure tank.

  By the manufacturing method of the high-pressure tank of Application Example 4, the edge of the second hoop layer can be formed into a slant shape, and the above-described fiber collapse at the edge of the second hoop layer can be suppressed. Further, by forming the edge of the second hoop layer into a slant shape, fiber meandering when the fiber is wound on the second hoop layer by low-angle helical winding, that is, deviation of the winding position of the fiber is suppressed. In addition, the effect of improving the axial strength of the liner of the low-angle helical winding can be effectively used.

  In addition, as an aspect which makes the edge part of a 2nd hoop layer into slant shape, in the boundary part with the dome part of the cylindrical part of a liner, the aspect which changes partially the winding number of the fiber wound, or the thickness of a fiber The aspect which changes partially is mentioned. The thickness of the portion other than the edge of the second hoop layer is substantially constant.

[Application Example 5]
A method for producing a high-pressure tank according to Application Example 3 or 4,
In the first hoop layer forming step and the second hoop layer forming step, the end portion of the outermost layer of the first hoop layer is the innermost layer of the second hoop layer in the axial direction of the cylindrical portion. Including the step of forming the first hoop layer and the second hoop layer so as to be disposed closer to the boundary side than the end of
Manufacturing method of high-pressure tank.

  According to the manufacturing method of the high-pressure tank of Application Example 5, these edges are slanted from the first hoop layer to the second hoop layer, and at the edges of the first hoop layer and the second hoop layer. It is possible to prevent the fiber from collapsing.

  Note that the high-pressure tanks of Application Examples 3 to 5 can reduce the weight of the high-pressure tank particularly when the ratio (L / D ratio) between the axial length L of the liner and the diameter D of the cylindrical portion of the liner is small. Great effect.

[Application Example 6]
A method for producing a high-pressure tank according to any one of Application Examples 1 to 5,
In the fiber reinforced plastic layer forming step, a fiber impregnated with a thermosetting resin is further wound around an outer surface of an inner layer composed of the first hoop layer, the helical layer, and the second hoop layer. Including an outer layer forming step of forming an outer layer,
The first hoop layer forming step, the helical layer forming step, the second hoop layer forming step, and the outer layer forming step are the sum of the thickness of the inner layer and the thickness of the outer layer on the cylindrical portion. 90% or more of the sum of the thickness of the first hoop layer and the thickness of the second hoop layer is disposed within a range of 75% on the inner layer side of the inner layer and Forming the outer layer,
Manufacturing method of high-pressure tank.

  Hoop winding has a greater effect of improving the circumferential strength of the liner than helical winding. Further, when the high-pressure tank is filled with high-pressure gas, in the fiber-reinforced plastic layer formed on the outer surface of the cylindrical portion of the liner, the stress acting in the circumferential direction of the liner increases toward the inner layer side (inner side) ( Thick-walled cylinder theory).

  In the manufacturing method of the high-pressure tank of Application Example 6, since the hoop winding having a large effect of improving the strength in the circumferential direction of the liner is collected and laminated on the inner layer side where the stress acting in the circumferential direction of the liner is relatively large, the liner The strength in the circumferential direction can be effectively improved. The thicknesses of the inner layer and the outer layer on the cylindrical portion of the liner are the thicknesses in a region where the thickness of the inner layer and the outer layer is substantially constant on the cylindrical portion of the liner. The same applies to the thickness of the first hoop layer and the thickness of the second hoop layer on the cylindrical portion of the liner.

  Moreover, since the effect of improving the strength of the high-pressure tank of each layer in the fiber reinforced plastic layer can be used more effectively than before, in order to obtain the performance (pressure resistance performance and durability performance) equivalent to the conventional one, The total number of layers constituting the fiber reinforced plastic layer can be reduced. Therefore, the high-pressure tank can be reduced in size, weight, and cost. Moreover, in order to obtain the performance of a high-pressure tank equivalent to the conventional one, if low-grade fibers are used for strength and rigidity, the cost of the high-pressure tank can be reduced. In addition, when the number of fiber reinforced plastic layers is the same as the conventional one, the strength of the high-pressure tank can be improved. Further, when the outer diameter shape of the high-pressure tank is the same as the conventional one, the volume of the liner can be increased. Therefore, when this high-pressure tank is filled with fuel gas and mounted on a vehicle, for example, the cruising distance of this vehicle can be extended.

[Application Example 7]
A method for manufacturing a high-pressure tank according to Application Example 5,
In the fiber reinforced plastic layer forming step, a fiber containing a thermosetting resin is further helically wound on an outer surface of an inner layer composed of the first hoop layer, the helical layer, and the second hoop layer. A second helical layer forming step of forming a second helical layer by
The liner has a discontinuous shape at the boundary between the cylindrical portion and the dome portion,
In the first hoop layer forming step, the helical layer forming step, and the second hoop layer forming step, the outer surface of the helical layer on the dome portion and the second hoop layer are curved with constant tension. Forming the first hoop layer, the helical layer, and the second hoop layer so as to form
Manufacturing method of high-pressure tank.

  In the manufacturing method of the high-pressure tank of Application Example 7, the outer surface of the helical layer on the dome and the second hoop layer form an isotonic curved surface, so the second helical layer formed on the outer surface of the inner layer Can be formed with equal tension and can be effectively used to improve the strength of the high-pressure tank.

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

It is explanatory drawing which shows schematic structure of the high pressure tank 10 as one Example of this invention. It is explanatory drawing which shows the various winding method of the fiber used when shape | molding a fiber reinforced plastic layer. 4 is an explanatory view showing a part of a manufacturing method of the high-pressure tank 10. It is explanatory drawing which shows schematic structure of the high pressure tank 10R as a comparative example. Description showing the layer configuration of the fiber reinforced plastic layers 50R and 50 in the high pressure tank 10R of the comparative example and the high pressure tank 10 of the example, and the evaluation results of the high pressure tank 10R of the comparative example and the high pressure tank 10 of the example FIG.

Hereinafter, embodiments of the present invention will be described based on examples.
A. High pressure tank configuration:
FIG. 1 is an explanatory diagram showing a schematic configuration of a high-pressure tank 10 as an embodiment of the present invention. FIG. 1A shows a cross-sectional view of the high-pressure tank 10. FIG. 1B shows a partially enlarged view of FIG. In addition, in FIG.1 (b), illustration of the fiber reinforced plastic layer 50 mentioned later is abbreviate | omitted.

  As shown in FIG. 1A, the high-pressure tank 10 includes a liner 40, a fiber reinforced plastic layer 50 that covers the surface of the liner 40, and two base parts 14. The base part 14 has an opening part 14a. In the present embodiment, the high-pressure tank 10 is provided with two base parts 14, but may be provided with one base part 14.

  The liner 40 is a hollow member that forms an inner shell of the high-pressure tank 10 and is also referred to as an inner container, and has a space 25 for storing a fluid therein. The liner 40 has a gas barrier property and suppresses permeation of gas such as hydrogen gas to the outside. The liner 40 is manufactured using a synthetic resin such as a nylon resin or a polyethylene resin, or a metal such as aluminum or stainless steel. In this embodiment, the liner 40 is integrally molded using a nylon resin. The liner 40 may be formed by joining a plurality of members.

  The fiber reinforced plastic layer 50 is a layer formed on the outer surface of the liner 40 and reinforced with a thermosetting resin. In this embodiment, the fiber reinforced plastic layer 50 is formed by using a filament winding method. The filament winding method is a method in which a fiber impregnated with a thermosetting resin is wound around a mandrel (in this embodiment, a liner 40) to thermoset the thermosetting resin. The fiber winding method will be described later. As the thermosetting resin, an epoxy resin, a polyester resin, a polyamide resin, or the like can be used. In this embodiment, an epoxy resin is used. Further, as the fiber, it is possible to use inorganic fibers such as metal fibers, glass fibers, carbon fibers, and alumina fibers, synthetic organic fibers such as aramid fibers, or various kinds of natural organic fibers such as cotton. These fibers may be used alone or in combination of two or more. In this embodiment, carbon fibers are used as the fibers.

  The high-pressure tank 10 has a substantially cylindrical cylindrical portion 20 and dome-shaped dome portions 30 located on both sides of the cylindrical portion 20. The dome part 30 is reduced in diameter in the direction of the central axis AX of the liner cylindrical part 42 as the distance from the cylindrical part 20 increases. The portion with the smallest diameter is opened, and the base portion 14 is inserted into the opening.

  As shown in FIG. 1B, the liner 40 has a liner cylindrical portion 42 having a cylindrical shape and liner dome portions 44 having a dome shape and provided at both ends of the liner cylindrical portion 42. doing. The liner dome portion 44 is reduced in diameter in the direction of the central axis AX of the liner cylindrical portion 42 as the distance from the liner cylindrical portion 42 increases. Further, the outer surface of the liner dome portion 44 is an isotonic curved surface. In the liner 40, the tangent line 42f on the outer surface of the liner cylindrical portion 42 and the tangent line 44f on the outer surface of the liner dome portion 44 are discontinuous at the boundary 40b between the liner cylindrical portion 42 and the liner dome portion 44. It is molded into. In other words, in the liner 40, the tangent line 42 f on the outer surface of the liner cylindrical portion 42 and the tangent line 44 f on the outer surface of the liner dome portion 44 are not the same at the boundary portion 40 b between the liner cylindrical portion 42 and the liner dome portion 44. It is shaped as follows. In other words, in the liner 40, the tangent line 44 f on the outer surface of the liner dome portion 44 is at the boundary 40 b between the liner cylindrical portion 42 and the liner dome portion 44 with respect to the tangent line 42 f on the outer surface of the liner cylindrical portion 42. It is shaped so as to be inclined at an angle θ.

  Further, as can be seen from FIG. 1A, the boundary portion between the cylindrical portion 20 and the dome portion 30 in the high-pressure tank 10 and the boundary portion 40b between the liner cylindrical portion 42 and the liner dome portion 44 in the liner 40 are the center. The position in the axis AX direction is different.

B. Manufacturing method of high-pressure tank:
Before explaining the manufacturing method of the high-pressure tank 10, a general fiber winding method used when forming the fiber-reinforced plastic layer will be described.

  FIG. 2 is an explanatory view showing various fiber winding methods used when forming a fiber-reinforced plastic layer. In this specification, hoop winding and helical winding will be described. In addition, about helical winding, the low angle helical winding mentioned later and a high angle helical winding are demonstrated.

  Fig.2 (a) is explanatory drawing which shows hoop winding. The state in which the fibers 51 are wound around the liner 40 by hoop winding is shown. “Hoop winding” means winding the fiber 51 so that the winding direction of the fiber 51 is substantially perpendicular to the central axis AX of the liner cylindrical portion 42 and moving the winding position (the position of the reel 15) in the central axis AX direction. Is the method. That is, “hoop winding” is a method of winding so that an angle α (“winding angle α”) formed by the central axis AX and the winding direction of the fiber 51 is substantially perpendicular. Note that “the winding angle of the fiber 51 by the hoop winding is substantially vertical” includes 90 degrees and an angle of about 90 degrees that can be generated by shifting the winding position of the fibers so that the fibers do not overlap each other. A layer formed by this hoop winding is called a “hoop layer”.

  FIG. 2B is an explanatory view showing a low-angle helical winding. The state where the fiber 51 is wound around the liner 40 by the low-angle helical winding is shown. The “low angle helical winding” is a winding method having a relatively small winding angle α in which the winding direction of the fiber 51 is turned back at the liner dome portion 44 before the fiber 51 makes a round of the central axis AX in the liner cylindrical portion 42. is there. A layer formed by this low-angle helical winding is called a “low-angle helical layer”.

  FIG.2 (c) is explanatory drawing which shows a high angle helical winding. The state in which the fiber 51 is wound around the liner 40 by high-angle helical winding is shown. The “high angle helical winding” is a winding method having a relatively large winding angle α in which the winding direction of the fiber 51 is turned back at the liner dome 44 after the fiber 51 has made at least one round of the central axis AX in the liner cylindrical portion 42. is there. A layer formed by this high-angle helical winding is called a “high-angle helical layer”.

  FIG. 3 is an explanatory view showing a part of the manufacturing method of the high-pressure tank 10. FIG. 3 shows a partial cross-sectional view of the high-pressure tank 10. Although illustration of the center axis AX of the liner cylindrical portion 42 is omitted, the horizontal direction in the figure is the direction of the center axis AX of the liner cylindrical portion 42.

  First, a liner 40 (see FIG. 1) having the shape described above was prepared, and as shown in FIG. 3A, only the outer surface of the liner cylindrical portion 42 was impregnated with a thermosetting resin. A first hoop layer 54a is formed by hoop-wrapping a plurality of layers of fibers (in this embodiment, five layers) (first hoop layer forming step). At this time, the first hoop layer 54a is formed so that the thickness of the first hoop layer 54a becomes thinner as the boundary portion 40b between the liner cylindrical portion 42 and the liner dome portion 44 is closer. In the present embodiment, every time the first hoop layer 54a is formed, the folding position of the hoop winding, that is, the end of each layer in the first hoop layer 54a is changed from the boundary 40b side to the central axis AX direction ( It was shifted to the center of the liner cylindrical portion 42).

  Next, as shown in FIG. 3B, the outer surface of the liner dome portion 44 and the first hoop layer 54a are formed without heating and curing the thermosetting resin contained in the first hoop layer 54a. A low-angle helical layer 54b is formed by winding a fiber impregnated with a thermosetting resin on the entire outer surface of the substrate by low-angle helical winding (helical layer forming step). In this embodiment, the number of low-angle helical layers 54b is one.

  Next, as shown in FIG. 3C, the thermosetting resin contained in the first hoop layer 54a and the thermosetting resin contained in the low-angle helical layer 54b are heated and cured, as shown in FIG. The outer surface of the low-angle helical layer 54b on one hoop layer 54a is hoop-wrapped with a plurality of layers (six layers in this embodiment) impregnated with a thermosetting resin, whereby the second hoop layer 54c. (Second hoop layer forming step). At this time, the second hoop layer 54c is formed so that the thickness of the second hoop layer 54c becomes thinner as the boundary portion 40b between the liner cylindrical portion 42 and the liner dome portion 44 is closer. In this example, as with the first hoop layer 54a, every time the second hoop layer 54c is formed, the folded position of the hoop winding, that is, the end of each layer in the second hoop layer 54c, The boundary portion 40b is shifted in the direction of the central axis AX (in the direction of the central portion of the liner cylindrical portion 42).

  Further, the outermost layer end portion (folding position) of the first hoop layer 54a is disposed closer to the boundary portion 40b than the innermost layer end portion (folding position) of the second hoop layer 54c. The outer surfaces of the low-angle helical layer 54b and the second hoop layer 54c on the liner dome 44 form an isotensive curved surface.

  Next, as shown in FIG. 3D, the outer layer 56 is formed on the outer surface of the inner layer 54 including the first hoop layer 54a, the low-angle helical layer 54b, and the second hoop layer 54c. (Outer layer forming step including second helical layer forming step). In FIG. 3D, the thickness of the outer layer 56 is shown thinly in contrast to the thickness of the inner layer 54 for convenience of illustration. The layer configuration of the outer layer 56 in this embodiment will be described later.

  Then, after the outer layer 56 is formed, the inner layer 54 and the thermosetting resin contained in the outer layer 56 are heat cured (heat curing step). The high-pressure tank 10 is completed by the above manufacturing process.

C. Effects of the embodiment:
The effect of the high-pressure tank 10 of the present embodiment will be described by comparing the high-pressure tank 10 of the present embodiment with the high-pressure tank 10R of the comparative example.

  FIG. 4 is an explanatory diagram showing a schematic configuration of a high-pressure tank 10R as a comparative example. A partial cross-sectional view of the high-pressure tank 10R is shown. FIG. 5 shows the layer configuration of the fiber reinforced plastic layers 50R and 50 in the high-pressure tank 10R of the comparative example and the high-pressure tank 10 of the example, the high-pressure tank 10R of the comparative example, and the high-pressure tank 10 of the example. It is explanatory drawing which shows the evaluation result.

  As shown in FIG. 4, the high-pressure tank 10R of the comparative example includes a fiber-reinforced plastic layer 50R instead of the fiber-reinforced plastic layer 50 in the high-pressure tank 10 of the example. The fiber-reinforced plastic layer 50R is composed of an inner layer 54R and an outer layer 56R instead of the inner layer 54 and the outer layer 56 in the high-pressure tank 10 of the embodiment.

  The inner layer 54 </ b> R is composed of only a hoop layer formed on the outer surface of the liner cylindrical portion 42, and is formed such that the thickness of the hoop layer becomes thinner as the boundary portion 40 b between the liner cylindrical portion 42 and the liner dome portion 44 is closer. Has been. That is, the inner layer 54R in the high-pressure tank 10R of the comparative example has a configuration in which the low-angle helical layer 54b is omitted from the inner layer 54 in the high-pressure tank 10 of the embodiment. In FIG. 4, as in FIG. 3 (d), the thickness of the outer layer 56R is drawn thinly in comparison with the inner layer 54R.

  Further, as shown in FIG. 5, the fiber reinforced plastic layer 50R in the high pressure tank 10R of the comparative example includes 11 hoop layers as the inner layer 54R, and further, one layer of low-angle helical as the outer layer 56R. A layer, four hoop layers, 17 low-angle helical layers, and one hoop layer in this order.

  On the other hand, the fiber reinforced plastic layer 50 in the high-pressure tank 10 of the embodiment has, as the inner layer 54, five hoop layers (first hoop layer 54a), one low-angle helical layer 54b, and six hoop layers. (Second hoop layer 54c) in this order, and as the outer layer 56, one low-angle helical layer, four hoop layers, sixteen low-angle helical layers, and one layer A hoop layer is provided in this order.

  In the fiber reinforced plastic layer 50 in the high-pressure tank 10 of the example, the thicknesses per layer of the hoop layer and the helical layer were all equal. Therefore, if the thickness per layer of the hoop layer and the helical layer is t, the sum Ttotal of the thickness Ti of the inner layer 54 and the thickness To of the outer layer 56 on the liner cylindrical portion 42 is Ttotal = Ti + To = 34t. Further, the thickness of the hoop layer in the inner layer 54, that is, the sum Tif of the thickness Tif1 of the first hoop layer 54a and the thickness Tif2 of the second hoop layer 54c is Tif = Tif1 + Tif2 = 11t. That is, Tif / Ttotal = 11t / 34t≈0.323..., Within the range of 33% (%) on the inner layer side of the sum Ttotal of the thickness Ti of the inner layer 54 and the thickness To of the outer layer 56. 100% (%) of the sum Tif of the thickness Tif1 of the first hoop layer 54a and the thickness Tif2 of the second hoop layer 54c is arranged.

  As described above, the high-pressure tank 10R of the comparative example and the high-pressure tank 10 of the example both have the same number of hoop layers and low-angle helical layers, specifically 16 layers, as the fiber reinforced plastic layers 50R and 50. And 18 low-angle helical layers. Nevertheless, a significant difference appeared between the evaluation results of the high-pressure tank 10R of the comparative example and the high-pressure tank 10 of the example. In addition, this time, as evaluation items of the high-pressure tanks 10R and 10, the collapse (the degree of collapse of the fibers 51 at the edge of the hoop layer of the inner layers 54R and 54), pressure resistance (tank burst pressure), fatigue performance (acceleration) Evaluation of durability number in cycle test) was performed.

  Regarding the collapse, in the high-pressure tank 10R of the comparative example, as shown by “Δ” in FIG. 5, the collapse occurred during the formation of the inner layer 54R. As indicated by “◎” in FIG. 5, almost no collapse occurred when the inner layer 54 was formed. Regarding the pressure resistance, when the tank burst pressure of the high pressure tank 10R of the comparative example is 1, the tank burst pressure of the high pressure tank 10 of the embodiment is about 1.1, and the pressure resistance is about 1.1 times as high. Improved. Regarding fatigue performance, when the durability of the high-pressure tank 10R of the comparative example in the accelerated cycle test is 1, the durability of the high-pressure tank 10 of the embodiment is about 2.7, and the fatigue performance is about 2. Improved 7 times.

  As described above, in the manufacturing method of the high-pressure tank 10 of the present embodiment, after the first hoop layer 54a is formed on the outer surface of the liner cylindrical portion 42 in the high-pressure tank 10, the outside of the first hoop layer 54a is formed. A low-angle helical layer 54b is formed so as to cover the entire surface, and a second hoop layer 54c is formed on the outer surface of the low-angle helical layer 54b on the first hoop layer 54a. Therefore, the entire first hoop layer 54a can be pressed by the low-angle helical layer 54b, and the collapse of the fibers 51 at the edge of the first hoop layer 54a can be suppressed. Further, the second hoop layer is fixed after the first hoop layer 54a is fixed by the low angle helical layer 54b by sandwiching the low angle helical layer 54b between the first hoop layer 54a and the second hoop layer 54c. 54c can be formed, so that the first hoop layer 54a and the second hoop layer 54c can be formed continuously without the low-angle helical layer 54b being sandwiched between the first hoop layer 54a and the second hoop layer 54c. The collapse of the fibers 51 at the edge of the second hoop layer 54c can be suppressed. Further, in the high-pressure tank 10 of the present embodiment, the thermosetting contained in each layer between the first hoop layer forming step and the helical layer forming step and between the helical layer forming step and the second hoop layer forming step. The process of heat-curing the property is not included. Therefore, the number of steps in the production of the high-pressure tank can be shortened as compared with the case where the thermosetting resin contained in each layer is heat-cured each time each layer is formed. That is, the manufacturing method of the high-pressure tank 10 of the present embodiment can suppress the collapse of the fibers 51 when forming the fiber-reinforced plastic layer 50 using the filament winding method with a relatively small number of steps.

  Moreover, in the manufacturing method of the high-pressure tank 10 of the present embodiment, since the low-angle helical winding is used in the helical layer forming step, the collapse of the fibers 51 at the edge of the first hoop layer 54a is suppressed, and the liner 40 The strength in the direction of the central axis AX can be improved. Further, in the low angle helical winding, in order to obtain the same strength with respect to the strength in the central axis AX direction of the liner 40, the number of windings, in other words, the use amount of the fiber 51 may be reduced as compared with the high angle helical winding. As a result, the high-pressure tank can be reduced in size, weight, and cost.

  Further, according to the manufacturing method of the high-pressure tank 10 of the present embodiment, as shown in FIG. 3A, in the first hoop layer forming step, the edge of the first hoop layer 54a is slanted, It is possible to prevent the fibers 51 from collapsing at the edge of one hoop layer 54a. Further, by forming the edge of the first hoop layer 54a into a slant shape, the fiber meandering when forming the low-angle helical layer 54b (see FIG. 3B), that is, the displacement of the winding position of the fiber 51 is prevented. The effect of suppressing and improving the strength of the low-angle helical layer 54b in the central axis AX direction of the liner 40 can be effectively used.

  Further, according to the manufacturing method of the high-pressure tank 10 of the present embodiment, as shown in FIG. 3C, in the second hoop layer forming step, the edge of the second hoop layer 54c is slanted, The collapse of the fibers 51 at the edge of the second hoop layer 54c can be prevented. Further, by forming the edge portion of the second hoop layer 54c into a slant shape, as shown in FIG. 3D, in the second helical layer forming step, the low level in the outer layer 56 is formed on the second hoop layer 54c. The effect of suppressing the meandering of the fibers when forming the angle helical layer, that is, the displacement of the winding position of the fibers 51, and improving the strength of the low angle helical layer 54b in the direction of the central axis AX of the liner 40 is effectively used. You can also.

  Further, according to the manufacturing method of the high-pressure tank 10 of the present embodiment, as shown in FIG. 3C, these edges are formed in a slant shape from the first hoop layer 54a to the second hoop layer 54c. Therefore, it is possible to prevent the fibers 51 from collapsing at the edges of the first hoop layer 54a and the second hoop layer 54c.

  The high-pressure tank 10 of the present embodiment is a high-pressure tank particularly when the ratio (L / D ratio) between the length L of the liner 40 in the central axis AX direction and the diameter D of the cylindrical portion of the liner 40 is small. The effect of weight reduction is great.

  Further, the hoop winding has a greater effect of improving the circumferential strength of the liner 40 than the helical winding. In the fiber reinforced plastic layer 50 formed on the outer surface of the liner cylindrical portion 42 when the high pressure tank 10 is filled with high pressure gas, the stress acting in the circumferential direction of the liner 40 is as much as the inner layer side (inner side). Increased (thick cylinder theory). In the method of manufacturing the high-pressure tank 10 according to the present embodiment, as shown in FIG. 5, on the liner cylindrical portion 42, the sum of the thickness of the inner layer 54 and the thickness of the outer layer 56 is within 33% of the inner layer side. In this range, 100% (%) of the sum of the thickness of the first hoop layer 54a and the thickness of the second hoop layer 54c is disposed. That is, the hoop winding (hoop layer) having a large effect of improving the circumferential strength of the liner 40 is collected and laminated on the inner layer side where the stress acting in the circumferential direction of the liner 40 is relatively large. The strength in the direction can be effectively improved.

  Moreover, in the manufacturing method of the high pressure tank 10 of a present Example, since the effect which improves the intensity | strength of the high pressure tank 10 of each layer in the fiber reinforced plastic layer 50 can be used more effectively than before, the high pressure tank equivalent to the past is used. In order to obtain the performance (pressure resistance performance and durability performance), the total number of layers constituting the fiber reinforced plastic layer 50 can be reduced. Therefore, the high-pressure tank can be reduced in size, weight, and cost. Moreover, in order to obtain the performance of a high-pressure tank equivalent to the conventional one, if low-grade fibers are used for strength and rigidity, the cost of the high-pressure tank can be reduced. In addition, when the number of the fiber reinforced plastic layers 50 is the same as the conventional one, the strength of the high-pressure tank can be improved. Further, when the outer diameter shape of the high-pressure tank is the same as the conventional one, the volume of the liner can be increased. Therefore, when this high-pressure tank is filled with fuel gas and mounted on a vehicle, for example, the cruising distance of this vehicle can be extended.

  Further, in the manufacturing method of the high-pressure tank 10 of the present embodiment, the outer surfaces of the low-angle helical layer 54b and the second hoop layer 54c on the liner dome portion 44 form an isotonic curved surface, so that they are formed on the outer surface of the inner layer 54. The low-angle helical layer in the outer layer 56 can be formed with an equal tension and can be effectively used to improve the strength of the high-pressure tank 10.

D. Variation:
As mentioned above, although several embodiment of this invention was described, this invention is not limited to such embodiment at all, and implementation in various aspects is possible within the range which does not deviate from the summary. It is. For example, the following modifications are possible.

D1. Modification 1:
In the said Example, although the low angle helical layer 54b was used in the inner layer 54 of the fiber reinforced plastic layer 50, this invention is not limited to this. A high angle helical layer may be used instead of the low angle helical layer 54b.

D2. Modification 2:
In the above embodiment, as shown in FIG. 5, the first hoop is within a range of 33 (%) on the inner layer side of the sum of the thickness of the inner layer 54 and the thickness of the outer layer 56 on the liner cylindrical portion 42. Although 100 (%) of the sum of the thickness of the layer 54a and the thickness of the second hoop layer 54c is arranged, the present invention is not limited to this. On the liner cylindrical portion 42, the thickness of the first hoop layer 54a and the thickness of the second hoop layer 54c are within a range of 75% on the inner layer side of the sum of the thickness of the inner layer 54 and the thickness of the outer layer 56. 90% or more of the sum may be arranged.

D3. Modification 3:
In the above embodiment, in the inner layer 54 of the fiber reinforced plastic layer 50, the first hoop layer 54a has five layers, the low-angle helical layer 54b has one layer, and the second hoop layer 54c has six layers. The number of layers can be arbitrarily set according to the strength required for the high-pressure tank 10. The same applies to the layer configuration of the outer layer 56 of the fiber reinforced plastic layer 50.

D4. Modification 4:
In the above embodiment, the thermosetting resin and the fibers constituting the fiber reinforced plastic layer 50 are all of the same type, but at least some of them are of different types. Also good.

DESCRIPTION OF SYMBOLS 10,10R ... High pressure tank 14 ... Cap part 14a ... Opening part 15 ... Reel 20 ... Cylindrical part 25 ... Space part 30 ... Dome part 40 ... Liner 40b ... Boundary part 42 ... Liner cylindrical part 42f ... Tangent 44 ... Liner dome part 44f ... tangential line 50, 50R ... fiber reinforced plastic layer 51 ... fiber 54, 54R ... inner layer 54a ... first hoop layer 54b ... low angle helical layer 54c ... second hoop layer 56, 56R ... outer layer AX ... central axis

Claims (7)

A method for manufacturing a high-pressure tank for storing fluid, comprising:
Preparing a liner having a cylindrical portion having a cylindrical shape, and a dome portion having a dome shape and provided at both ends of the cylindrical portion;
A fiber reinforced plastic layer forming step of forming a fiber reinforced plastic layer on the outer surface of the liner using a filament winding method;
With
The fiber reinforced plastic layer forming step includes:
A first hoop layer forming step of forming a first hoop layer by winding a plurality of layers of fibers impregnated with a thermosetting resin only on the outer surface of the cylindrical portion;
The thermosetting resin is impregnated on at least a part of the outer surface of the dome portion and the outer surface of the first hoop layer without heat-curing the thermosetting resin contained in the first hoop layer. A helical layer forming step of forming a helical layer by helically winding the formed fibers;
On the outer surface of the helical layer on the first hoop layer without heat curing the thermosetting resin contained in the first hoop layer and the thermosetting resin contained in the helical layer, A second hoop layer forming step of forming a second hoop layer by winding a plurality of layers of the fiber impregnated with the curable resin with a hoop;
A heat-curing step of heat-curing the thermosetting resin contained in the first hoop layer, the thermosetting resin contained in the helical layer, and the thermosetting resin contained in the second hoop layer; ,
Only including,
In the first hoop layer forming step, the cylindrical portion and the dome portion are formed on the cylindrical portion.
The first hoop layer is reduced so that the thickness of the first hoop layer becomes thinner as the boundary is closer.
Including the step of forming,
The first hoop layer forming step and the second hoop layer forming step are performed in the axial direction of the cylindrical portion.
The end of the outermost layer of the first hoop layer is the end of the innermost layer of the second hoop layer.
The first hoop layer and the second hoop so as to be disposed closer to the boundary side than
A method for manufacturing a high-pressure tank, including a step of forming a layer . A method for producing a high-pressure tank according to claim 1,
In the second hoop layer forming step, the second hoop layer is formed such that the thickness of the second hoop layer is reduced on the cylindrical portion as it is closer to the boundary portion between the cylindrical portion and the dome portion. Forming a layer,
Manufacturing method of high-pressure tank. A method for manufacturing a high-pressure tank for storing fluid, comprising:
Preparing a liner having a cylindrical portion having a cylindrical shape, and a dome portion having a dome shape and provided at both ends of the cylindrical portion;
A fiber reinforced plastic layer forming step of forming a fiber reinforced plastic layer on the outer surface of the liner using a filament winding method;
With
The fiber reinforced plastic layer forming step includes:
A first hoop layer forming step of forming a first hoop layer by winding a plurality of layers of fibers impregnated with a thermosetting resin only on the outer surface of the cylindrical portion;
The thermosetting resin is impregnated on at least a part of the outer surface of the dome portion and the outer surface of the first hoop layer without heat-curing the thermosetting resin contained in the first hoop layer. A helical layer forming step of forming a helical layer by helically winding the formed fibers;
On the outer surface of the helical layer on the first hoop layer without heat curing the thermosetting resin contained in the first hoop layer and the thermosetting resin contained in the helical layer, A second hoop layer forming step of forming a second hoop layer by winding a plurality of layers of the fiber impregnated with the curable resin with a hoop;
A heat-curing step of heat-curing the thermosetting resin contained in the first hoop layer, the thermosetting resin contained in the helical layer, and the thermosetting resin contained in the second hoop layer; ,
Only including,
In the second hoop layer forming step, the cylindrical portion and the dome portion are formed on the cylindrical portion.
The second hoop layer is arranged so that the thickness of the second hoop layer becomes thinner as the boundary is closer.
Including the step of forming,
The first hoop layer forming step and the second hoop layer forming step are performed in the axial direction of the cylindrical portion.
The end of the outermost layer of the first hoop layer is the end of the innermost layer of the second hoop layer.
The first hoop layer and the second hoop so as to be disposed closer to the boundary side than
A method for manufacturing a high-pressure tank, including a step of forming a layer . A method for producing a high-pressure tank according to any one of claims 1 to 3 ,
The helical winding in the helical layer forming step is performed by winding the fibers on the outer surface of the first hoop layer before the fibers constituting the helical layer make a round of the central axis of the liner. Helical winding whose direction is folded,
Manufacturing method of high-pressure tank. A method of manufacturing a high-pressure tank according to any one of claims 1 to 4,
In the fiber reinforced plastic layer forming step, a fiber impregnated with a thermosetting resin is further wound around an outer surface of an inner layer composed of the first hoop layer, the helical layer, and the second hoop layer. Including an outer layer forming step of forming an outer layer,
The first hoop layer forming step, the helical layer forming step, the second hoop layer forming step, and the outer layer forming step are the sum of the thickness of the inner layer and the thickness of the outer layer on the cylindrical portion. 90% or more of the sum of the thickness of the first hoop layer and the thickness of the second hoop layer is disposed within a range of 75% on the inner layer side of the inner layer and Forming the outer layer,
Manufacturing method of high-pressure tank. A method for producing a high-pressure tank according to any one of claims 1 to 4 ,
The fiber reinforced plastic layer forming step includes the first hoop layer, the helical layer,
A second helical layer forming step of forming a second helical layer by helically winding a fiber containing a thermosetting resin on the outer surface of the inner layer composed of the second hoop layer;
The liner has a discontinuous shape at the boundary between the cylindrical portion and the dome portion,
In the first hoop layer forming step, the helical layer forming step, and the second hoop layer forming step, the outer surface of the helical layer on the dome portion and the second hoop layer are curved with constant tension. Forming the first hoop layer, the helical layer, and the second hoop layer so as to form
Manufacturing method of high-pressure tank. High-pressure tank produced by the production method according to any one of claims 1 to 6.

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