JP6146369B2 - Tank manufacturing method - Google Patents

Description

  The present invention relates to a method for manufacturing a tank.

  In manufacturing a tank, a filament may be wound around a liner by a filament winding method (FW method) to form a reinforcing layer. In the FW method, a filament is wound by combining hoop winding and helical winding.

  There is known a method of arranging a plurality of filaments to be wound at the same time along a surface to be wound when performing hoop winding. By arranging along the surface to be wound, the filaments are wound without being stacked, that is, without overlapping (for example, Patent Document 1).

JP 2009-061721 A

  In general, winding is performed mainly on the R portion (end plate) of the tank by helical winding. However, since the surface to be wound around the R portion is not flat, the arrangement of the filaments is likely to be disturbed by using a method in which a plurality of filaments to be wound at the same time are arranged along the surface to be wound as in the prior art. When the arrangement of the filaments is disturbed, there is a risk of causing a decrease in productivity. In addition, simplification of configuration, cost reduction, resource saving, miniaturization, and the like have been desired.

  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.

(1) According to one aspect of the present invention, there is provided a method for manufacturing a tank by using a filament winding method including a hoop winding step and a helical winding step, and winding a plurality of filaments around a liner. . In this manufacturing method, in the case of the hoop winding step, the plurality of filaments are wound in contact with the surface to be wound, and in the helical winding step, the plurality of filaments are laminated on the surface to be wound. According to this embodiment, in the case of hoop winding, since each of the plurality of filaments is wound in contact with the surface to be wound, the area wound at a time is wide and winding is efficient. In the case of helical winding, since it is wound on a surface to be wound, the disorder of the arrangement is suppressed and the layers are arranged in an orderly manner. Note that “winding the filament around the liner” includes further winding the filament on the filament already wound around the surface of the liner.

(2) In the above embodiment, each of the plurality of filaments may be coated with a surface treatment agent. According to this embodiment, the filaments can be prevented from being entangled when the filaments are arranged.

(3) In the above embodiment, the method includes a step of coating a filament with the surface treatment agent; a step of impregnating the coated filament with a resin; and the filament wound may be a filament impregnated with the resin. According to this embodiment, in addition to the coating, the filament can be impregnated with resin.

(4) In the above embodiment, the filament to be coated may be a filament treated with at least one of a sizing agent and a silane coupling agent. According to this form, the structure of the filament is stabilized.

(5) In the above embodiment, in the hoop winding step and the helical winding step, by changing the shape of the eye opening for collecting the plurality of filaments, the winding is brought into contact with the surface to be wound; You may implement | achieve the winding to laminate | stack. According to this form, each winding method is easily realizable.

  The present invention can be realized in various forms other than the above. For example, it can be realized in the form of a program for realizing the above manufacturing method, a non-temporary storage medium storing the program, and the like. It can also be realized as a tank. In addition, the above-described coating method can be realized as a method that does not include winding by the filament winding method, or a coating apparatus for performing this method.

The external view of a tank. The figure which shows a part of hoop layer. The figure which shows a part of helical layer. Tank manufacturing process diagram. Process drawing which shows a coating process. Schematic of the coating apparatus used for a coating process. Schematic of a filament winding apparatus. The enlarged view of a convergence part (in the case of hoop winding). Sectional drawing near a converging part (in the case of hoop winding). Enlarged view of converging part (in the case of helical winding). Sectional view near the converging part (in the case of helical winding). The expanded sectional view of the copper plate of a tank. The expanded sectional view of the R section of a tank. Schematic of the coating apparatus of Embodiment 2. FIG.

  Embodiment 1 will be described. FIG. 1 shows a tank 10. The tank 10 is a pressure vessel for storing high-pressure hydrogen, and is mounted on a fuel cell vehicle. The tank 10 has a structure in which filaments f are wound around the surface of a liner 11 (FIG. 2) manufactured by resin molding as a reinforcing layer. The liner 11 forms an internal space for storing hydrogen as a tank body.

  The reinforcing layer includes a hoop layer formed by hoop winding and a helical layer formed by helical winding. The filament f constituting the reinforcing layer is formed by a bundle of a plurality of single fibers.

  FIG. 2 shows a portion of the hoop layer. As shown in FIG. 2, the hoop layer is a layer in which the filament f is wound in a direction substantially orthogonal to the central axis CX of the liner 11.

  FIG. 3 shows a portion of the helical layer. The helical layer is a layer in which the filament f is wound in various directions with respect to the central axis CX of the liner 11 as shown in FIG.

  FIG. 4 is a manufacturing process diagram of the tank 10. First, a sizing process is performed on the filament (process P310). In this embodiment, an epoxy resin is used for the sizing agent. This stabilizes the filament as a bundle of single fibers.

  Next, a coating process is performed to coat the filament (process P320). Step P320 will be described with reference to FIGS. FIG. 5 is a process diagram showing a coating process. FIG. 6 shows a coating apparatus 200 used in the coating process. The coating apparatus 200 is an apparatus that performs extrusion lamination.

  First, the base material is unwound from the bobbin 20 (process P321). This base material is a filament that has been sized in step P310. Next, an adhesive is applied to the substrate by the coater 24 (process P323). The coater 24 applies the adhesive stored in the adhesive tank 22 to the substrate using rotation.

  Subsequently, the adhesive applied to the substrate is dried by the dryer 26 (process P325). Next, the melted polyethylene film is coated on the base material by the extruder 28 (process P327). By the process P327, the entire substrate is physically coated. Finally, the coated filament is wound around the bobbin 29 (process P329).

  Next, the filament with the coating is impregnated with resin (process P330). For the impregnation in this embodiment, a dry method using an epoxy resin is used.

  Subsequently, the impregnated filament is wound around the liner 11 by the FW method (process P340). The liner 11 is previously formed with a base or the like.

  FIG. 7 shows the filament winding apparatus 300 used in the process P340. The filament processed by the process P330 is wound around the bobbins 101 to 104 as the filament f. The FW method of the present embodiment is a technique in which the liner 11 is used as a part of the tank 10 without being removed after the liner 11 is used as a mandrel (mold). As shown in FIG. 7, the X axis direction is defined as a direction parallel to the center axis CX of the liner 11, and the XYZ axes based on the right-hand system are defined. As shown in FIG. 7, the liner 11 is rotatably supported at both ends in the axial direction, and rotates about the central axis CX by driving the motor.

  The filament f wound around the bobbin 101 is referred to as a filament f1. Bobbins 102, 103, and 104 are similarly called filaments f2, f3, and f4.

  The filaments f1 to f4 wound around the bobbins 101 to 104 are fed out by the rotation of the liner 11. The liner 11 is set on the winding part 50 and is rotated by the torque generated by the winding part 50.

  As shown in FIG. 7, the filaments f1 to f4 fed out from the bobbins 101 to 104 are conveyed to the same roller r5 after being conveyed by different rollers r1 to r4, respectively. The filaments f1 to f4 are conveyed after the roller r5 with a predetermined interval in the X-axis direction.

  The tension adjusting unit 30 adjusts the tension of the filaments f1 to f4 by displacing the roller r6 in the Z-axis direction. When the filaments f1 to f4 pass through the roller r6, the filaments f1 to f4 are conveyed to the converging unit 40 via the rollers r7 to r11. When the filaments f1 to f4 are conveyed by the rollers r7 to r11, the filaments f1 to f4 receive a compressive force in the Z-axis direction and widen in the X-axis direction (see FIGS. 9 and 11).

  The converging unit 40 converges the filaments f1 to f4 into one bundle by passing the filaments f1 to f4 through the eye opening formed inside. The converging unit 40 reciprocates by a mechanism such as a linear actuator along the conveyance axis extending in the X-axis direction. The converging part 40 controls how the filaments f1 to f4 are wound by reciprocating in the X-axis direction. By this control, hoop winding and helical winding are realized.

  In the present embodiment, the way of convergence by the converging unit 40 is changed between hoop winding and helical winding. FIG. 8 is a view taken in the direction of arrow A in FIG. 7 and shows a case of hoop winding. FIG. 9 is a sectional view taken along line BB in FIG.

  When performing the hoop winding, as shown in FIGS. 8 and 9, a converging unit 40 a is used as the converging unit 40. As shown in FIGS. 8 and 9, the eye opening 42a provided in the converging part 40a arranges the filaments f1 to f4 in the X-axis direction. As used herein, the term “array” refers to the direction of a row formed by a plurality of filaments f in the ZX plane as a virtual cross section.

  On the other hand, when carrying out helical winding, as shown in FIGS. 10 and 11, a converging unit 40 b is used as the converging unit 40. FIG. 10 is a view taken in the direction of arrow A in FIG. 7 and shows a case of helical winding. FIG. 11 is a sectional view taken along line BB in FIG. As shown in FIGS. 10 and 11, the eye opening 42b provided in the converging unit 40b arranges the filaments f1 to f4 in the Z-axis direction.

  Since the filaments f1 to f4 receive tension in the negative direction in the Z-axis direction at the eye openings 42a and 42b, they are stably arranged as shown in FIGS. The exchange between the converging unit 40a and the converging unit 40b may be performed manually or may be provided with a mechanism for automatic execution.

  FIG. 12 is an enlarged view of a cross section of the copper plate of the tank 10. The copper plate is a cylindrical portion of the tank 10. In the enlarged view of FIG. 12, only one turn by hoop winding is shown for the filament f.

  In the case of hoop winding, the filaments f1 to f4 are arranged in the X-axis direction by the eye opening 42a as described above. The filaments f1 to f4 are wound in the state of being arranged in this manner, so that they are arranged in the direction of the central axis CX and wound around the liner 11 or the already wound filament f (hereinafter referred to as “winding surface”). . That is, it winds by arranging in the direction along the winding surface. As a result, each of the filaments f1 to f4 comes into contact with the winding surface. The direction along the winding surface is a direction substantially parallel to the generatrix of the body plate of the liner 11. The generatrix here is a straight line or a curve that appears by cutting the winding surface by a virtual surface including the central axis CX. If the winding surface is an outer surface of the body plate of the liner 11, the bus bar is a substantially straight line, and if the winding surface is formed by the filament f, it may be a curve. The direction of the arrangement of the filaments f1 to f4 may be defined as, for example, “the direction of an imaginary line obtained by fitting a representative point (such as the center of gravity) of a cross section perpendicular to the longitudinal direction of the filament f”.

  FIG. 13 is an enlarged view of a section of the R portion of the tank 10. The R part of the tank 10 is provided at both ends of the tank 10 in the direction of the central axis CX, and is also called an end plate. In the enlarged view of FIG. 13, only one turn by helical winding is shown for the filament f. As shown in FIGS. 2 and 3, a reinforcing layer is formed mainly by helical winding in the R portion.

  In the case of helical winding, the filaments f1 to f4 are arranged in the Z-axis direction by the eye opening 42b as described above. With this arrangement, the wound filaments f1 to f4 are stacked on the winding surface. That is, the wound filaments f1 to f4 are arranged in a direction intersecting the winding surface (ideally, a direction substantially orthogonal to the winding surface). As a result, only the filament f4 contacts the winding surface. For example, if the representative point of the cross section orthogonal to the longitudinal direction of the filament f is fitted with a virtual straight line, this virtual straight line intersects the tangential plane at the contact point with the filament f4 (ideally substantially orthogonal) ) ". Here, the tangential plane is a plane that is virtually in contact with the contact point between the filament f4 and the R portion.

  After winding the filament f in this way, the polyethylene coated on the filament f is bonded to the filament f (step P350). This bonding is achieved by heating the filament f to melt the coated polyethylene and then cooling.

According to the first embodiment described above, at least the following effects can be obtained.
(A) The helical layer in the R portion can be formed by orderly arranging the filaments f. As described above, in helical winding, the filaments f1 to f4 are laminated and wound. If wound in this way, there is no gap between the filaments f even if the filaments f are widened. As a result, the disorder of the arrangement is suppressed, and as a result, the above-described effect is exhibited.

(B) Since each filament f is coated with polyethylene, the filaments f1 to f4 are prevented from being entangled when converged by the eye openings 42a and 42b. Thereby, the above arrangement is stably realized.

(C) Hoop winding can be performed efficiently. In the case of hoop winding, the filaments f are spread and arranged on the winding surface, so that the area wound by one winding is wide.

  A second embodiment will be described. In the second embodiment, the coating apparatus used in the process P320 is different from that in the first embodiment. Other methods are the same as those in the first embodiment.

  FIG. 14 shows a coating apparatus 200a according to the second embodiment. The coating apparatus 200a is an apparatus that can be used in place of the coating apparatus 200 of the first embodiment, and is an apparatus that performs dry lamination. Since the bobbin 20, the adhesive tank 22, the coater 24, the dryer 26, and the bobbin 29 are the same as the coating apparatus 200, description thereof is omitted.

  The coating apparatus 200a includes a bobbin 280 for polyethylene film. The base material that has passed through the dryer 26 is bonded to the polyethylene film fed out from the polyethylene film bobbin 280 by an adhesive. Thereby, coating (dry lamination) with polyethylene is realized.

  The present invention is not limited to the above-described embodiments, examples, and modifications, and can be realized with various configurations without departing from the spirit thereof. For example, the technical features in the embodiments, examples, and modifications corresponding to the technical features in each embodiment described in the summary section of the invention are to solve some or all of the above-described problems, or In order to achieve part or all of the above-described effects, replacement or combination can be performed as appropriate. Further, if the technical feature is not described as essential in the present specification, it can be deleted as appropriate. For example, the following can be mentioned.

The main components of the resin of the sizing agent are epoxy-modified polyurethane resin, polyester resin, phenol resin, polyamide resin, polyurethane resin, polycarbonate resin, polyetherimide resin, polyamideimide resin, polyimide resin, bismaleimide resin, urethane-modified epoxy resin, A polyvinyl alcohol resin, a polyvinyl pyrrolidone resin, a polyether sulfone resin, or the like may be used, or two or more thereof may be used in combination.
The resin used for impregnation may also be changed to those listed above.

  You may process using a silane coupling agent instead of a sizing agent. In this case, aminosilane is 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3- (2-aminoethyl) aminopropyltrimethoxysilane, 3- (phenylamino) propyltrimethoxysilane, 3- ( 2-aminoethyl) aminopropylmethyldimethoxysilane or the like may be used. Epoxysilanes include 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, 3-glycidoxypropylmethyldimethoxysilane, 2- (3,4-epoxycyclohexyl) ethyltrimethoxysilane, γ -Methacryloxypropyltrimethoxysilane may be used. The vinylsilane may be vinyltrichlorosilane, vinyltrimethoxysilane, vinyltriethoxysilane, vinyltris (2-methoxyethoxy) silane, vinyltriacetoxysilane, or the like.

The surface treatment agent used in the coating in the process P320 (process P327) may not be polyethylene, but may be other thermoplastic resin such as polypropylene, or may be other.
A wet method may be used for the impregnation treatment of the filament. In this case, the impregnation process may be performed immediately before the filament is wound around the liner.

The change of the shape of the eye mouth may be realized by deformation of the convergence portion. In this way, it is not necessary to replace the converging unit. The deformation of the converging unit may be realized, for example, by providing the converging unit with a mechanism that expands and contracts in the X axis direction.
At least one of the hoop winding and the helical winding may be arranged in two or more rows.
The number of filaments to be converged is not limited to four and may be any number.
The coating process and the impregnation process may not be performed.

The tank may be used not only for a fuel cell vehicle, but also for a fuel cell mounted on other transportation equipment, a stationary fuel cell, or a use other than a fuel cell (for example, a hydrogen rotary engine) For).
The fluid stored in the tank may not be high-pressure hydrogen, but may be any fluid such as LNG.

DESCRIPTION OF SYMBOLS 10 ... Tank 11 ... Liner 20 ... Bobbin 22 ... Adhesive tank 24 ... Coater 26 ... Dryer 28 ... Extruder 29 ... Bobbin 30 ... Tension adjustment part 40 ... Convergence part 40a ... Convergence part 40b ... Convergence part 42a ... Eye opening 42b DESCRIPTION OF SYMBOLS Eye opening 50 ... Winding part 101-104 ... Bobbin 200 ... Coating apparatus 200a ... Coating apparatus 280 ... Bobbin for polyethylene film 300 ... Filament winding apparatus f ... Filament f1-f4 ... Filament r1-r11 ... Roller CX ... Center axis

Claims (4)

A method of manufacturing a tank by using a filament winding method including a hoop winding step and a helical winding step, and winding a plurality of filaments together around a liner,
In the case of the hoop winding step, each of the plurality of filaments is wound in contact with the surface to be wound, and in the case of the helical winding step, the plurality of filaments are stacked on the surface to be wound and wound .
In the hoop winding step and the helical winding step, by changing the shape of the eye opening for collecting the plurality of filaments, winding to be brought into contact with the surface to be wound and winding to be laminated on the surface to be wound Realized,
The width of the eye opening in the hoop winding step is approximately equal to the total width of the plurality of filaments,
The manufacturing method of a tank in which the width of the eye opening in the helical winding step is substantially equal to the width of one filament . The method for manufacturing a tank according to claim 1, wherein each of the plurality of filaments is coated with a surface treatment agent. Coating a filament with the surface treatment agent;
Impregnating the coated filament with resin,
The method for manufacturing a tank according to claim 2, wherein the wound filament is a filament impregnated with the resin. The method for manufacturing a tank according to claim 3, wherein the filament to be coated is a filament treated with at least one of a sizing agent and a silane coupling agent.

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