JP5877807B2 - Composite container manufacturing method and composite container manufacturing system - Google Patents

Description

  The present invention relates to a composite container manufacturing method and a composite container manufacturing system.

  Conventionally, as described in Patent Document 1, for example, a manufacturing method for manufacturing a composite container provided with a reinforcing layer is known. In such a manufacturing method, a fiber bundle impregnated with a thermosetting resin is wound around a liner to form a container intermediate, and the container intermediate is heated in a curing furnace to cure the thermosetting resin of the fiber bundle. ing.

JP 2008-304038 A

  By the way, in the prior art as described above, when the container intermediate is heated in the curing furnace, the thermosetting resin self-heats, and an excessive temperature rise phenomenon in which the temperature of the container intermediate temporarily rises may occur. Found. Therefore, before heating the curing furnace temperature as the final curing temperature, a process for holding the curing furnace temperature for a predetermined time at an intermediate curing temperature lower than the final curing temperature is provided, and an excessive temperature rise phenomenon occurs during this process. It is conceivable that the peak of the excessive temperature rise phenomenon is suppressed by.

  In this case, since it is not easy to know in advance at what timing and how the overheating phenomenon occurs, normally, the holding time for holding the curing furnace temperature at the intermediate curing temperature (hereinafter simply referred to as “holding time”) ), A relatively long time is set for safety. For this reason, productivity may be reduced, and as a result, manufacturing cost may be deteriorated.

  This invention is made | formed in view of the said situation, and makes it a subject to provide the manufacturing method of a composite container and the manufacturing system of a composite container which can improve productivity.

  In order to solve the above problems, a manufacturing method of a composite container according to the present invention is a manufacturing method of manufacturing a composite container having a reinforcing layer, and a fiber bundle impregnated with a thermosetting resin is disposed on the outer surface side of the liner. It includes a curing step of curing the thermosetting resin of the fiber bundle by heating the wound container intermediate body in a curing furnace, and the curing step sets the curing furnace temperature of the curing furnace to a predetermined curing temperature The first step to be held, the second step for detecting the start of the overheating phenomenon occurring in the container intermediate based on the temperature of the container intermediate, and the start of the overheating phenomenon in the second step Based on the detected timing, the third step of lowering the curing furnace temperature, the fourth step of detecting the end of the temperature rise due to the excessive temperature rise phenomenon based on the temperature of the container intermediate, and the fourth step At the timing of detecting the end of temperature rise due to temperature rise phenomenon And Zui includes a fifth step of setting a curing oven temperature to a final cure temperature, the.

  The composite container manufacturing system according to the present invention is a manufacturing system for manufacturing a composite container having a reinforcing layer, and is formed by winding a fiber bundle impregnated with a thermosetting resin around the outer surface side of a liner. A curing furnace for heating the container intermediate to cure the thermosetting resin of the fiber bundle, a detection unit for detecting the temperature of the container intermediate, and a controller for controlling the curing furnace temperature of the curing furnace. The controller detects, based on the temperature of the container intermediate, the first process of setting and maintaining the curing furnace temperature of the curing furnace at a predetermined curing temperature, and the start of the excessive temperature rise phenomenon that has occurred in the container intermediate. Based on the second process, the timing at which the start of the excessive temperature rise phenomenon is detected in the second process, the third process for lowering the curing furnace temperature, and the end of the temperature increase due to the excessive temperature increase phenomenon, A fourth process for detecting based on the temperature; Process based on the timing of detecting the end of the temperature rise due to excessive temperature rise phenomenon at executes a fifth process of setting the curing oven temperature to a final cure temperature, the.

  In these inventions, when the container intermediate is heated in the curing furnace, the curing furnace temperature is set to a predetermined curing temperature, while the curing furnace temperature is lowered based on the timing at which the start of the excessive temperature rise phenomenon is detected. As a result, by setting a high temperature as the predetermined curing temperature, the container temperature of the container intermediate can be quickly raised, and when the temperature is rising due to an excessive temperature rise phenomenon, the curing furnace temperature is set. By keeping it low, safety can be ensured. In addition, by setting the curing furnace temperature to the final curing temperature based on the timing at which the end of the temperature increase due to the excessive temperature rise phenomenon is detected, after the risk of damage to the container intermediate due to the excessive temperature increase phenomenon is eliminated, The thermosetting resin can be quickly cured. As a result, productivity can be improved and manufacturing costs can be reduced.

  In the third step, heating in the curing furnace may be stopped. This can reliably avoid damage to the container intermediate due to the excessive temperature rise phenomenon.

  In the first step, the final curing temperature may be set as the predetermined curing temperature. As a result, the temperature of the container intermediate can be quickly increased.

  Further, in the second step, when the rate of change in the rate of temperature rise of the container intermediate becomes greater than 1, the start of the excessive temperature rise phenomenon may be detected. In this case, it is possible to suitably detect the start of the excessive temperature rise phenomenon.

  ADVANTAGE OF THE INVENTION According to this invention, it becomes possible to provide the manufacturing method of a composite container which can improve productivity, and the manufacturing system of a composite container.

It is a partial cross section figure which shows the composite container which concerns on one Embodiment. It is a schematic block diagram which shows the manufacturing system of the composite container which concerns on one Embodiment. It is a flowchart which shows the hardening process which concerns on one Embodiment. It is a graph which shows the example of the temperature condition of the hardening furnace which concerns on one Embodiment. It is a graph which shows the relationship between the temperature rise rate of a container intermediate body, and heating time. It is a graph which shows the example of the temperature condition of the conventional hardening furnace. It is a graph which shows the example of the temperature condition of the conventional hardening furnace.

  DESCRIPTION OF EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings. In the following description, the same or corresponding parts are denoted by the same reference numerals, and redundant description is omitted.

  FIG. 1 is a partial cross-sectional view showing a composite container manufactured by a manufacturing method and a manufacturing system according to the present embodiment. As shown in FIG. 1, the composite container 1 is a container for storing fuel gas such as hydrogen or natural gas at a high pressure. The composite container 1 has, for example, a total length of 2 to 4 m and a diameter of about 40 to 60 mm, and can withstand a pressure of about 20 to 90 MPa when used. The use of the composite container 1 is not limited and can be used for various purposes. In addition, the composite container 1 may be used as a stationary type or may be used by being mounted on a moving body.

  The composite container 1 includes a cylindrical liner 2 and a reinforcing layer 3 provided so as to cover the outer surface side of the liner 2. Both end portions 2a of the liner 2 are formed in a dome shape, and a base 4 is attached to the tips of the both end portions 2a.

  The material of the liner 2 is not particularly limited, but resin or metal is selected depending on the application. Examples of the resin liner 2 include a resin obtained by shaping a thermoplastic resin such as high-density polyethylene into a container shape by rotational molding or blow molding and a metal base 4. As the metal liner 2, for example, a pipe shape or plate shape made of an aluminum alloy, steel, or the like is formed into a container shape by spinning or the like, and the shape of the base 4 is formed.

  The reinforcing layer 3 is formed by winding a fiber bundle 10 impregnated with a thermosetting resin around the outer surface side (outer peripheral surface side) of the liner 2 and heating and curing the fiber bundle 10 in a curing furnace. Types of thermosetting resins include phenolic resin, urea resin, unsaturated polyester resin, vinyl ester resin, polyimide resin, bismaleimide resin, polyimide resin, polyurethane resin, diallyl phthalate resin, epoxy resin, melamine resin or allyl resin However, it is not limited to these.

  Further, as the fiber bundle 10, for example, carbon fiber, glass fiber, aramid fiber, boron fiber, polyethylene fiber, steel fiber, Zylon fiber, or vinylon fiber can be used. Lightweight carbon fiber is used. In addition, the number of fibers (filament) of the fiber bundle 10 of the present embodiment is not particularly limited, but is in the range of 1000 to 50000 filaments, preferably 3000 to 30000 filaments, and here, 24,000 filaments. Yes.

  When manufacturing the composite container 1 configured as described above, first, the fiber bundle 10 is wound around the outer surface side of the liner 2, so that a plurality of fiber bundle layers (fiber reinforced plastic layers) are formed on the outer surface side of the liner 2. Forming, thereby obtaining a container intermediate (winding step). A plurality of fiber bundle layers to be formed are wound so as to surround a hoop layer in which the fiber bundle 10 is wound around the liner 2 in the circumferential direction and the fiber bundle 10 in the circumferential direction while being inclined with respect to the liner 2. And a helical layer.

  In addition, the container intermediate is intended for the composite container 1 in the manufacturing process, and here, is intended for the state before the thermosetting resin of the fiber bundle 10 is thermoset (hereinafter the same). . Further, the winding method in the winding step is not particularly limited, but for example, an FW (filament winding) method can be adopted. As the FW method, a fiber bundle (tow prepreg) preliminarily impregnated with a thermosetting resin is prepared and wound around the liner 2 (so-called Dry method), or the fiber bundle is impregnated with a thermosetting resin. For example, there is a method (so-called wet method) in which the material is supplied while being wound, and is wound around the liner 2 to be molded.

  And after the said winding process, the thermosetting resin of the fiber bundle 10 is hardened by heating a container intermediate body with a hardening furnace (hardening process). Here, with reference to FIGS. 2-5, the hardening process of this embodiment is explained in full detail.

  FIG. 2 is a schematic configuration diagram illustrating the manufacturing system according to the present embodiment. As shown in FIG. 2, the manufacturing system 100 of this embodiment manufactures the said composite container 1, Comprising: It is used at a hardening process. The manufacturing system 100 includes at least a curing furnace 20, a container temperature detection unit (detection unit) 30, and a controller 40.

  The curing furnace 20 accommodates and heats the container intermediate 1a formed by winding the fiber bundle 10 around the outer surface of the liner 2 (see FIG. 1), and cures the thermosetting resin of the fiber bundle 10. Inside the curing furnace 20, a heater 21 as a heat source of the curing furnace 20 and a curing furnace temperature sensor 22 for detecting the curing furnace temperature (in-furnace temperature) are provided. The heater 21 is connected to the controller 40, whereby the operation of the heater 21 is controlled by the controller 40 and the curing furnace temperature is controlled. The curing furnace temperature sensor 22 is connected to the controller 40 and outputs the detected curing furnace temperature to the controller 40.

  The container temperature detection unit 30 detects the temperature of the container intermediate 1 a (hereinafter referred to as “container temperature”) and is attached to the curing furnace 20. The container temperature detection unit 30 here uses, for example, a non-contact temperature measuring instrument such as thermography or radiation temperature, and detects the surface temperature of the container intermediate 1a as the container temperature. As an example, the non-contact infrared thermometer is used for the container temperature detection part 30, for example, measures the surface temperature of the container intermediate body 1a from the observation window provided in the curing furnace 20. The container temperature detection unit 30 is connected to the controller 40 and outputs the detected container temperature to the controller 40. The heater 21 does not completely cover the reinforcing layer 3, and the number of heaters 21 may be one or plural. Moreover, when there are a plurality of heaters 21, the heaters 21 may be divided and spaced between the heaters 21, and the sizes and shapes of the plurality of heaters 21 may be non-uniform. The container temperature detection unit 30 measures from a place where the container intermediate body 1 a is not obstructed by the heater 21 when looking into the container intermediate body 1 a from the heater 21.

  The controller 40 is for controlling the curing furnace temperature of the curing furnace 20, and is composed of a computer including a CPU (Central Processing Unit), a ROM (Read Only Memory), a RAM (Random Access Memory) and the like. The controller 40 sets the curing furnace temperature based on outputs from the container temperature detection unit 30 and the curing furnace temperature sensor 22 and controls the operation of the heater 21 so as to be the set curing furnace temperature.

  Here, when the container intermediate body 1a is heated in the curing furnace 20, since the thermosetting reaction of the thermosetting resin in the fiber bundle 10 is an exothermic reaction, the thermosetting resin self-heats and its temperature is The occurrence of an excessive temperature rise phenomenon that suddenly rises above the curing furnace temperature is found. Therefore, the controller 40 according to the present embodiment sets the first process in which the curing furnace temperature of the curing furnace 20 is set to a predetermined curing temperature, and the start of the excessive temperature rise phenomenon generated in the container intermediate body 1a. A second process that is detected based on the temperature of the body 1a; a third process that lowers the curing furnace temperature based on the timing at which the start of the excessive temperature increase phenomenon is detected in the second process; and a temperature due to the excessive temperature increase phenomenon Based on the fourth process for detecting the end of the rise based on the temperature of the container intermediate 1a and the timing at which the end of the temperature rise due to the excessive temperature rise phenomenon is detected in the fourth process, the curing furnace temperature is set to the final curing temperature. The fifth process is set (details will be described later).

  FIG. 3 is a flowchart showing the curing process according to the present embodiment, FIG. 4 is a graph showing an example of the temperature condition of the curing furnace according to the present embodiment, and FIG. 5 shows the relationship between the temperature rise rate of the container intermediate and the heating time. It is a graph to show. As shown in FIGS. 3 and 4, in the method for manufacturing the composite container 1 by the manufacturing system 100, the curing furnace temperature is set to a predetermined curing temperature (the final curing temperature T <b> 3 in this embodiment) which is a high temperature, While the temperature rising phenomenon is occurring, the temperature of the curing furnace 20 is lowered, and then the curing furnace temperature is set to the final curing temperature T3 for final curing of the container intermediate 1a.

  Specifically, first, the curing furnace temperature is set and maintained at a predetermined curing temperature (S1, S2). In the present embodiment, the final curing temperature T3 is set as a predetermined curing temperature. Thereby, after container temperature rises, it hold | maintains so that it may become final curing temperature T3, As a result, hardening of the container intermediate body 1a advances.

  The predetermined curing temperature may not be set to the final curing temperature T3, may be equal to or higher than the final curing temperature T3, may be equal to or lower than the final curing temperature T3, and may be set to any temperature. However, from the viewpoint of improving manufacturing efficiency, the predetermined curing temperature is preferably set to be equal to or higher than the maximum intermediate curing temperature T2. The maximum intermediate curing temperature T2 is a temperature at which it is estimated that the peak Tmax of the excessive temperature rise phenomenon that occurs when the resin is cured at that temperature reaches the allowable maximum temperature T4. The allowable maximum temperature T4 is a maximum temperature in a temperature range that does not adversely affect the container performance of the container intermediate 1a, and is a temperature determined according to the heat resistance of the material of the container intermediate 1a. The upper limit of the predetermined curing temperature is not particularly limited, but the predetermined curing temperature may be set to a temperature equal to or lower than the allowable maximum temperature T4. However, since the container temperature of the container intermediate 1a does not immediately exceed the allowable maximum temperature T4 immediately after the start of heating, the predetermined curing temperature may be set higher than the allowable maximum temperature T4.

When the curing furnace temperature is maintained at a predetermined curing temperature (here, the final curing temperature T3), as shown in the determination formula of the following formula (1), the temperature increase rate that is the rate of temperature increase of the container temperature It is determined whether or not the change rate for W is greater than 1 (S3). Thereby, it is possible to detect the start of the overheating phenomenon that has occurred in the container intermediate 1a. Temperature increase rate _{W N} is a pot temperature _{T N} of the N-th measurement time _{t N,} the pot temperature _{T N-1} during measurement _{t N-1} to N-1 th, can be obtained from (the following formulas ( 2)). For example, in the graph shown in FIG. 4, the temperature at which the inclination of the graph of the container temperature increases, and in the graph shown in FIG. 5, the temperature increase rate W is constant by being heated at a predetermined curing temperature. The determination of S3 becomes Yes at the timing when the temperature increase rate W increases due to the start of the overheating phenomenon.

W _N / W _N-1 > 1 (1)
W _N = (T _N −T _N−1 ) / (t _N −t _N−1 ) (2)
N: Any integer.

  Returning to FIG. 3 and FIG. 4, in the case of No in S <b> 3, the curing furnace temperature is continuously maintained at a predetermined curing temperature (final curing temperature T <b> 3), whereas in the case of Yes in S <b> 3, the curing furnace temperature is decreased ( S4). The method for lowering the curing furnace temperature is not particularly limited, but the heating itself in the curing furnace 20 may be stopped by turning off the heater 21 of the curing furnace 20, and the curing furnace temperature is set to a standby temperature lower than at least a predetermined curing temperature. It may be set. The standby temperature is set to a temperature lower than the maximum intermediate curing temperature T2. The standby temperature may be equal to or lower than the lowest intermediate curing temperature T0 that is the lowest temperature at which the thermosetting resin of the fiber bundle 10 can be cured. Note that the process of S4 may be executed immediately after it is determined Yes in S3, may be executed after a predetermined time has elapsed, and there may be a predetermined delay (grace).

After the process of S4, as shown in the determination formula of the following formula (3), it is determined whether or not the temperature of the container intermediate 1a has decreased (S5). Thereby, it is possible to detect the end of the temperature rise due to the excessive temperature rise phenomenon generated in the container intermediate 1a. In the graph shown in FIG. 4, the determination of S5 is made at the timing (timing from P1 to P2 in FIG. 4) past the maximum value (peak Tmax of the excessive temperature rise phenomenon) of the curve portion of the container temperature graph. Yes.

T _N ≦ T _N−1 (3)

  In the case of No in S5, the state where the heater 21 of the curing furnace 20 is turned off again in S4 or the state set to the standby temperature is maintained. On the other hand, in the case of Yes in S5, the end of the temperature rise due to the excessive temperature rise phenomenon is detected, and the curing furnace temperature is set to the final curing temperature T3 and is held at the final curing temperature T3 (S6, S7). . As a result, the container temperature dropped from the peak Tmax of the excessive temperature rise phenomenon immediately rises again and reaches the final curing temperature T3. After the process of S7, it is determined whether or not the container temperature has reached the final curing temperature T3 (S8). In the case of No in S8, the state where the curing furnace temperature is maintained at the final curing temperature T3 is maintained in S7. The final curing temperature T3 may be set to any temperature as long as it is a temperature lower than the allowable maximum temperature T4 and is capable of final curing. In addition, the process of S6 may be performed immediately after it determines with Yes by S5, may be performed after predetermined time passes, and a predetermined | prescribed delay (grace) may exist.

  In the case of Yes in S8, after waiting for a predetermined time in a state where the curing furnace temperature is the final curing temperature T3, the curing furnace 20 is stopped, and the curing furnace temperature is lowered at a constant temperature drop rate. The temperature is lowered at a constant temperature drop rate, thereby completing the curing of the thermosetting resin (S9).

  Next, functions and effects of this embodiment will be described.

  For example, as shown in FIG. 6, when curing is performed with the curing furnace temperature set to the final curing temperature T3 from beginning to end, the container temperature is affected by the temperature rise due to the excessive temperature rise phenomenon, so that the container temperature is the allowable maximum temperature T4. The container performance may be adversely affected with respect to the container intermediate 1a. Here, in order to prevent the container temperature from exceeding the allowable maximum temperature T4, the curing furnace temperature is maintained at the intermediate curing temperature T1 (which is equal to or higher than the minimum intermediate curing temperature T0), and the temperature rises over time. A method of raising the temperature to the final curing temperature when the temperature phenomenon is finished is conventionally known. The holding time for holding the curing furnace temperature at the intermediate curing temperature T1 is determined by an empirical rule or by conducting a curing condition setting test because the overheating phenomenon varies depending on the container size and the type of thermosetting resin. Takes time. Further, conventionally, as shown in FIG. 7, a relatively long time is set for safety as shown in FIG. 7, and as a result, the holding time may continue even after the overheating phenomenon has ended. is there.

  In contrast, in the present embodiment, the curing process is performed while monitoring the container temperature, and when the container intermediate 1a is heated in the curing furnace 20, the curing furnace temperature is set to a predetermined curing temperature, The curing furnace temperature is lowered based on the timing at which the start of the temperature rising phenomenon is detected. Thus, by setting a high temperature as the predetermined curing temperature, the container temperature of the container intermediate 1a can be quickly raised, and when the temperature is rising due to an excessive temperature rise phenomenon, the curing furnace temperature By keeping the value low, safety can be ensured. In addition, after setting the curing furnace temperature to the final curing temperature T3 based on the timing of detecting the end of the temperature rise due to the excessive temperature rise phenomenon, there is no risk of damage to the container intermediate due to the excessive temperature rise phenomenon. The thermosetting resin can be quickly cured. As a result, productivity can be improved and manufacturing costs can be reduced.

  Further, when the curing furnace temperature is lowered in S4, the heating in the curing furnace 20 may be stopped. Thereby, damage to the container intermediate body 1a due to an excessive temperature rise phenomenon can be surely avoided. In particular, when the final curing temperature T3 is set as the predetermined curing temperature in S1, and when the control for stopping the heater 21 of the curing furnace 20 is performed in S4, simple control by simply turning the heater 21 on and off is performed. Productivity can be improved.

  In S1, the final curing temperature T3 may be set as the predetermined curing temperature. Thereby, the temperature of the container intermediate body 1a can be quickly raised.

  Further, in S3, when the rate of change in the temperature rise rate of the container intermediate is greater than 1, the start of the excessive temperature rise phenomenon may be detected. In this case, it is possible to suitably detect the start of the excessive temperature rise phenomenon.

  The preferred embodiments of the present invention have been described above. However, the present invention is not limited to the above-described embodiments. The present invention is modified without departing from the scope described in the claims or applied to others. It may be.

  For example, in the above embodiment, the start of the excessive temperature rise phenomenon is detected by determining that the rate of change of the temperature increase rate W of the container temperature is greater than 1, and the excessive increase is determined by determining the decrease in the container temperature. Although the end of the temperature rise due to the temperature phenomenon is detected, the detection method is not limited, and each detection may be performed by various methods. In the above, S1 and S2 correspond to the first step, S3 corresponds to the second step, S4 corresponds to the third step, S5 corresponds to the fourth step, and S6 corresponds to the fifth step. .

  DESCRIPTION OF SYMBOLS 1 ... Composite container, 1a ... Container intermediate body, 2 ... Liner, 3 ... Reinforcement layer, 10 ... Fiber bundle, 20 ... Curing furnace, 30 ... Container temperature detection part (detection part), 40 ... Controller, 100 ... Manufacturing system.

Claims (5)

A manufacturing method for manufacturing a composite container having a reinforcing layer,
A curing step of curing the thermosetting resin of the fiber bundle by heating a container intermediate formed by winding the fiber bundle impregnated with the thermosetting resin around the outer surface of the liner in a curing furnace;
The curing step includes
A first step of setting and holding a curing furnace temperature of the curing furnace at a predetermined curing temperature;
A second step of detecting the start of an overheating phenomenon occurring in the container intermediate based on the temperature of the container intermediate;
A third step of lowering the curing furnace temperature based on the timing at which the start of the overheating phenomenon is detected in the second step;
A fourth step of detecting the end of the temperature rise due to the overheating phenomenon based on the temperature of the container intermediate;
And a fifth step of setting the curing furnace temperature to a final curing temperature based on the timing at which the end of the temperature rise due to the excessive temperature rise phenomenon is detected in the fourth step.   The method for manufacturing a composite container according to claim 1, wherein in the third step, heating in the curing furnace is stopped.   The method for manufacturing a composite container according to claim 1 or 2, wherein, in the first step, the final curing temperature is set as the predetermined curing temperature.   The composite container according to any one of claims 1 to 3, wherein in the second step, when the rate of change in the temperature increase rate of the container intermediate becomes greater than 1, the start of an overheating phenomenon is detected. Manufacturing method. A manufacturing system for manufacturing a composite container having a reinforcing layer,
A curing furnace for heating a container intermediate formed by winding a fiber bundle impregnated with a thermosetting resin around the outer surface of the liner, and curing the thermosetting resin of the fiber bundle;
A detection unit for detecting the temperature of the container intermediate;
A controller for controlling the curing furnace temperature of the curing furnace,
The controller is
A first process of setting and holding a curing furnace temperature of the curing furnace at a predetermined curing temperature;
A second process for detecting the start of an overheating phenomenon occurring in the container intermediate based on the temperature of the container intermediate;
A third process for lowering the curing furnace temperature based on the timing at which the start of the overheating phenomenon is detected in the second process;
A fourth process for detecting the end of the temperature rise due to the excessive temperature rise phenomenon based on the temperature of the container intermediate;
A composite container manufacturing system that executes a fifth process of setting the curing furnace temperature to a final curing temperature based on a timing at which the end of the temperature increase due to the excessive temperature rise phenomenon is detected in the fourth process.

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