JP6769348B2 - How to manufacture a high-pressure gas tank - Google Patents

Description

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

The high-pressure gas tank is manufactured by using a liner as a core material and coating the liner with carbon fiber reinforced plastic or glass fiber reinforced plastic (hereinafter, these are collectively referred to as a fiber reinforced resin layer). Usually, the liner is a hollow container made of resin having a gas barrier property from the viewpoint of weight reduction, and the base is a metal molded product. Therefore, a tank manufacturing method for ensuring the gas sealability between the base and the liner in the tank manufacturing process has been proposed (for example, Patent Document 1).

Japanese Unexamined Patent Publication No. 2014-142017

In the manufacturing method proposed in Patent Document 1, prior to the formation of the fiber-reinforced resin layer by the filament winding method (hereinafter referred to as FW method), a sealing member such as a liquid gasket is applied to the boundary portion between the flange of the base and the liner. This sealing member prevents the thermosetting resin from entering between the flange of the mouthpiece and the liner from the fiber bundle impregnated with the thermosetting resin such as epoxy resin. By the way, since the sealing member at the boundary between the flange of the base and the liner is liquid at the time of application, it is necessary to cure the liquid sealing member in order to prevent the resin from entering, and it is necessary to cure the liquid sealing member during the waiting time for curing. The fact is that it takes a considerable amount of time to manufacture the tank. In addition, the liquid sealing material is complicated in its formulation and requires an artificial adjustment treatment of the coating shape, which is one of the causes of the cost increase. For these reasons, there has been a demand for a new tank manufacturing method that can easily and inexpensively suppress the entry of the thermosetting resin from the fiber bundle impregnated with the thermosetting resin without using a liquid sealing member. ..

In order to achieve at least a part of the above-mentioned problems, the present invention can be carried out in the following forms.

(1) According to one embodiment of the present invention, a method for manufacturing a high-pressure gas tank is provided. This method for manufacturing a high-pressure gas tank is a method for manufacturing a high-pressure gas tank having a fiber layer formed by repeatedly winding a fiber bundle around the outer surface of the liner by attaching a base to the tops of dome portions at both ends in the axial direction of the liner. A step of preparing the liner having a bottomed recessed pedestal portion for mounting a base on the top of the dome portion while providing the dome portion so as to have an outer surface following an isotonic curved surface, and a step of preparing the recessed pedestal portion. A step of mounting the mouthpiece having a mouthpiece flange to be inserted and a mouthpiece body protruding from the mouthpiece flange toward the end of the liner onto the top so that the mouthpiece flange enters the recessed pedestal portion, and the recessed pedestal portion. A step of attaching a ring-shaped cap to the boundary portion between the flange outer peripheral edge of the mouthpiece flange and the recessed pedestal portion, and covering the gap of the boundary portion with the cap, and the fiber impregnated with a thermosetting resin. The bundle is repeatedly wound around the outer surface of the liner to which the mouthpiece and the cap are attached to form the fiber layer. Then, in the step of covering the gap of the boundary portion with the cap, the ring-shaped cap has a linear expansion coefficient equivalent to that of the liner, and has a curved surface shape of the outer surface of the dome portion and the outer surface of the base flange. In the step of forming the fiber layer using a cap having an inner surface similar to the above, the dome portion is attached to the base flange by the fiber bundle so that the fiber bundle is hung over the dome portions at both ends in the axial direction. The helical winding layer to be included and wound is formed first.

In the method for manufacturing a high-pressure gas tank of the above embodiment, the cap covering the boundary portion between the outer peripheral edge of the flange of the base flange and the depressed pedestal portion is covered with the fiber bundle of the helical winding layer formed first. Therefore, according to the method for manufacturing a high-pressure gas tank of the above-described embodiment, it is possible to easily suppress the entry of the thermosetting resin from the fiber bundle impregnated with the thermosetting resin into the boundary portion by the cap. Further, according to the method for manufacturing a high-pressure gas tank of the above-described form, it is sufficient to use a ring-shaped cap that can be manufactured at low cost by the existing mold molding method, so that the entry of the thermosetting resin into the boundary portion can be suppressed at low cost. it can. Moreover, since it is not necessary to wait for the sealing material to cure as in the existing method, it is possible to manufacture a high-pressure gas tank in which the entry of the thermosetting resin into the boundary portion is suppressed in a short time.

Further, in the method for manufacturing a high-pressure gas tank of the above embodiment, since the ring-shaped cap covering the gap at the boundary portion has a linear expansion coefficient equivalent to that of the liner, it has already been formed from a fiber bundle impregnated with a thermosetting resin. When the thermosetting resin is heat-cured in the fiber layer of No. 1, it is possible to suppress the breakage of the cap due to the difference in thermal expansion. Therefore, it is possible to suppress the entry of the thermosetting resin from the damaged portion to the boundary portion, which is preferable. In this case, the cap may have the same coefficient of linear expansion as the liner by forming it from the same material as the liner. Originally, the cap and the liner are not limited to the same material, and the coefficient of linear expansion of the cap is within a range in which damage to the cap due to the difference in thermal expansion during heat curing of the thermosetting resin can be suppressed. , It may be equivalent to the liner. In addition, since the cap has an inner surface that follows the curved surface shape of the outer surface of the dome portion and the outer surface of the base flange, the adhesion of the cap to the outer surface of the dome portion and the outer surface of the base flange is increased. It is also possible to suppress the entry of the thermosetting resin from the gap between the two and the boundary portion.

(2) In the method for manufacturing a high-pressure gas tank of the above-described embodiment, in forming the earliest helical winding layer, the winding of the fiber bundle at the time of forming the helical winding layer is performed on the isotonic curved surface at the dome portion. It may be repeated so that the deviation between the theoretical line drawing the above and the center line of the fiber bundle is within half the width of the fiber bundle. In this way, the fiber bundle wound so as to cover the dome portion including the base flange and the cap when forming the helical winding layer is within half the width of the fiber bundle from the theoretical line drawing the isotonic curved surface at the dome portion. By suppressing the displacement of the fiber bundles on the outer surface of the dome portion, the occurrence of wrinkles on the cap is also suppressed. Therefore, it is possible to prevent the thermosetting resin from entering the boundary portion from the wrinkled portion of the cap.

(3) In the step of forming the fiber layer in the method for manufacturing a high-pressure gas tank of the above-described form, the internal pressure of the liner is increased after the formation of the earliest helical winding layer, and the internal pressure is increased. The fiber layer following the earliest helical winding layer may be formed by repeatedly winding the fiber bundle around the outer surface of the liner. By doing so, a high surface pressure can be obtained by applying pressure from the liner side to the cap sandwiched between the fiber layers while covering the gap between the outer peripheral edge of the flange of the base flange and the recessed pedestal portion. The cap can cover the gap of the boundary portion to enhance the sealing property of the cap, that is, the effect of suppressing the entry of the thermosetting resin into the boundary portion.

(4) In the method for manufacturing a high-pressure gas tank of any of the above forms, in the step of covering the gap of the boundary portion with the cap, at least one of the outer surface of the outer surface of the dome portion and the outer surface of the mouthpiece flange is used. The cap may be attached to the boundary portion after applying the elastic adhesive to the dome. By doing so, it is possible to suppress the displacement of the cap after mounting the cap, to stabilize the mounting position of the cap, and to fill the gap that may occur on the inner surface side of the cap due to the manufacturing tolerance of the cap with the elastic adhesive. By closing with, it is possible to prevent the thermosetting resin from entering the boundary portion through this gap.

(5) In the method for manufacturing a high-pressure gas tank of any of the above forms, the cap has a cap-side engaging portion including at least one of a convex portion or a concave portion surrounding the boundary portion on the inner peripheral surface of the cap. The liner and the base may have an engaging portion that engages with the cap-side engaging portion of the cap. In this way, even if the thermosetting resin enters through a gap that may occur on the inner surface side of the cap due to the manufacturing tolerance of the cap, specifically, a gap between the cap and the outer surface of the flange, or a gap between the cap and the outer surface of the liner. , The thermosetting resin can be fastened to the cap side engaging portion and the engaging portion of the engaging portion. As a result, the effect of suppressing the entry of the thermosetting resin into the boundary portion can be enhanced. Further, by engaging with the cap-side engaging portion, the cap can be positioned, and the displacement of the cap when winding the fiber bundle can be suppressed.

(6) In the method for manufacturing a high-pressure gas tank of any of the above-described forms, the cap may have a convex portion that enters the boundary gap. By doing so, it is possible to position the cap by inserting the convex portion into the boundary gap, and it is also possible to suppress the displacement of the cap when winding the fiber bundle.

(7) In the method for manufacturing a high-pressure gas tank of the above embodiment, the boundary gap is formed in a tapered shape that widens toward the side of the cap by the inner peripheral wall of the liner and the outer peripheral edge of the flange of the mouthpiece. May have the convex portion as a tapered convex portion that follows the tapered shape of the boundary gap. This has the following advantages: Since the cap receives a pressing force from the fiber bundle wound around the outer surface of the liner, the adhesion between the tapered boundary gap and the tapered convex portion entering the boundary gap is improved. Therefore, the effect of suppressing the entry of the thermosetting resin into the boundary portion can be further enhanced.

(8) In the method for manufacturing a high-pressure gas tank of any of the above-described forms, the cap suppresses the positional deviation of the fiber bundle wound in the formation of the earliest helical winding layer in the fiber bundle width direction. The guide may be provided along the fiber bundle winding path in the helical winding layer. In this way, when the earliest helical winding layer is formed, the fiber bundles can be prevented from being displaced in the width direction, so that the displacement of the cap due to the positional displacement of the fiber bundles can be suppressed.

The present invention can be realized in various forms. For example, a high-pressure gas tank manufacturing apparatus for winding a fiber bundle around the outer surface of a cylindrical liner to form a fiber layer on the liner, or an axial direction of the liner. This can be realized in the form of a high-pressure gas tank or the like in which a base is attached to the tops of the dome portions at both ends to provide a fiber layer.

It is explanatory drawing which shows the structure of the high pressure gas tank obtained by the tank manufacturing method as the embodiment of this invention by the appearance, the sectional view and the enlarged sectional view of the main part. It is explanatory drawing which shows the structure of a liner by a semi-cross-sectional view, a front view and an enlarged view of a main part. It is a process diagram which shows the first half of the manufacturing process of a high pressure gas tank. It is a process diagram which shows the latter half of the manufacturing process of a high pressure gas tank. It is explanatory drawing explaining the state of the preparatory procedure at the time of forming a fiber reinforced resin layer. It is explanatory drawing which shows the state of the helical winding layer formation of the innermost layer schematically. It is explanatory drawing which shows the state of the helical winding layer formation of the innermost layer schematically from the direction of arrow A in FIG. It is explanatory drawing which shows the winding state of the resin impregnated carbon fiber bundle wound first and second by the helical winding of a low angle. It is explanatory drawing which shows the liner using the cap of the 1st modification by a semi-cross-sectional view, a front view, and an enlarged view of a main part. It is explanatory drawing which shows the liner using the cap of the 2nd modification by a semi-cross-sectional view, a front view, and an enlarged view of a main part. It is explanatory drawing which shows the liner using the cap of the 3rd modification by a semi-cross-sectional view, a front view, and an enlarged view of a main part. It is explanatory drawing which shows the liner using the cap of the 4th modification by a semi-cross-sectional view, a front view, and an enlarged view of a main part. It is explanatory drawing which shows the outline of the boundary convex part which a cap has. It is explanatory drawing which shows the liner using the cap of the 5th modification by a semi-cross-sectional view, a front view, and an enlarged view of a main part. It is explanatory drawing which shows the liner using the cap of the 6th modification by the schematic perspective and the front view of the main part. It is explanatory drawing which shows the liner which attached the cap by the cross-sectional view along the 16-16 bending line in FIG.

FIG. 1 is an explanatory view showing the configuration of the high-pressure gas tank 100 obtained by the tank manufacturing method as the embodiment of the present invention with its appearance, a cross-sectional view, and an enlarged cross-sectional view of a main part, and FIG. 2 shows a configuration of a liner 10. It is explanatory drawing which shows the half-cross-sectional view, the front view and the enlarged view of the main part.

As shown in the figure, the high-pressure gas tank 100 is configured by coating the liner 10 with a fiber-reinforced resin layer 102, and the base 16 is projected from both ends. The fiber reinforced resin layer 102 is formed by winding a fiber bundle impregnated with a thermosetting resin around the outer surface of the liner by the FW method described later.

The liner 10 is a hollow tank container, which is a joint product of a pair of liner parts divided into two at the center in the longitudinal direction of the tank. The liner parts divided into two parts are each molded with an appropriate resin such as nylon resin, and the liner 10 is formed by joining the liner parts of the molded product and laser fusion of the jointed portions. .. Through this part joining, the liner 10 is provided with spherical dome portions 14 on both sides of the cylindrical cylinder portion 12. The liner 10 is provided with a bottomed recessed pedestal portion 14r for mounting a base at the top of a dome portion 14 having an outer surface that follows an isotonic curved surface, that is, at both ends in the axial direction along the axis of the liner shaft AX. It has a through hole 14h coaxial with the liner shaft AX in the center.

The base 16 mounted on the tops of the dome portions 14 at both ends in the axial direction along the liner shaft AX is made of metal, and the base flange 16f that enters the recessed pedestal portion 14r and the base body that protrudes from the flange to the liner end side. It is provided with 16b, a convex portion 16t protruding from the base flange 16f toward the inside of the liner, and a valve connection hole 16h. The bases 16 on both sides are common in the basic structure including the outer shape, but one base 16 has a valve connection hole 16h as a through hole, while the other has a valve connection hole 16h as a bottom and is inside the liner. It differs in that it has a bottomed hole 16i coaxial with the valve connection hole 16h. The convex portion 16t is fitted into the through hole 14h of the dome portion 14 and positions the base 16 with respect to the liner 10. The valve connection hole 16h has a taper screw portion having a high-pressure seal specification for connecting pipes on the opening side thereof.

The base flange 16f is formed so that the bottom surface side of the flange is flat and the outer surface is arcuate. Therefore, the outer peripheral edge 16fe of the base flange 16f decreases as the flange thickness goes outward. The base flange 16f forms an opening recess 15 with the recess inner peripheral wall 14rs of the recessed pedestal portion 14r. The opening recess 15 is a wedge-shaped recess that opens wider toward the end of the liner, and is a base flange 16f that has entered the recessed pedestal portion 14r. Specifically, a boundary portion between the outer peripheral edge 16fe of the flange and the recessed pedestal portion 14r. It becomes a gap (boundary gap). In this case, as shown in FIG. 2, the recessed inner peripheral wall 14rs of the dome portion 14 is formed so as to meander in a rectangular wave shape around the axis of the liner 10 and surround the liner shaft AX, and the base flange 16f is the outer peripheral edge thereof. 16fe is meandered in accordance with the meandering shape of the inner peripheral wall 14rs of the recess. Therefore, the opening recess 15 surrounds the liner shaft AX while meandering.

The cap 18 is a molded product that is molded using the same resin as the liner 10, for example, a nylon resin so as to form a ring shape having a thin leaf cross section having a maximum thickness of 1 mm or less, preferably about 0.3 to 0.5 mm. And has the same coefficient of linear expansion as the liner 10. The cap 18 hangs from the outer peripheral edge 16fe of the base flange 16f to the dome portion 14 to cover the flange outer surface and the dome outer surface. The outer surface of the dome portion 14 (hereinafter referred to as the outer surface of the dome) is a curved surface that follows an isotonic curved surface, and the base 16 is an outer surface of the outer peripheral edge 16fe of the base flange 16f in a range covered by at least the cap 18. Hereinafter referred to as an outer surface of the flange) is an isotonic curved surface continuous with the outer surface of the dome following the isotonic curved surface of the dome portion 14. The cap 18 has an outer surface of the dome of the dome portion 14 that follows the isotonic curved surface and an inner surface that imitates the curved shape of the outer surface of the flange of the base flange 16f that is continuous with the outer surface according to the isotonic curved surface. Therefore, the cap 18 hangs from the outer peripheral edge 16fe of the base flange 16f to the dome portion 14 in a state of covering the opening recess 15 of the meandering locus, and is in close contact with the flange outer surface and the dome outer surface.

In the high-pressure gas tank 100 obtained by the manufacturing method of the present embodiment, the opening recess 15 surrounding the liner shaft AX while meandering as described above is covered with a ring-shaped cap 18, and then the outer surface of the cap 18 is covered. A fiber reinforced resin layer 102 is formed on the outer surface of the liner 10 including the liner 10. In the FW method described later, the fiber reinforced resin layer 102 is formed by properly using fiber winding by hoop winding and fiber winding by low angle / high angle helical winding. An epoxy resin is generally used as the thermosetting resin for forming the fiber-reinforced resin layer 102, but a thermosetting resin such as a polyester resin or a polyamide resin can be used.

Next, a method of manufacturing the high-pressure gas tank 100 as the present embodiment will be described. FIG. 3 is a process diagram showing the first half of the manufacturing process of the high-pressure gas tank 100, and FIG. 4 is a process diagram showing the second half of the manufacturing process of the high-pressure gas tank 100. First, the liner 10 is manufactured and prepared (step S100). In the liner production, a pair of resin-molded liner parts and a base 16 having the above configuration are prepared, and then the base 16 is assembled to the dome portion 14 of the liner parts (step S102). Specifically, the base flange 16f of the base 16 is inserted into the depressed pedestal portion 14r of the dome portion 14 in each liner part, and then the convex portion 16t of the base 16 is fitted into the through hole 14h of the dome portion 14. .. As a result, the base 16 is positioned on the dome portion 14 and attached to the dome portion 14, and a liner part having the base 16 on the top of the dome portion can be obtained. In this liner part, an opening recess 15 is formed between the outer peripheral edge 16fe of the mouthpiece flange 16f of the mounted mouthpiece 16 and the recessed inner peripheral wall 14rs of the recessed pedestal portion 14r.

Next, a pair of liner parts having the base 16 attached to both ends are joined on the side of the cylinder portion 12, and the jointed portion is laser-fused and assembled (step S104). As a result, the liner 10 with the base 16 attached to both ends can be obtained. Next, the cap 18 is attached to the dome portion 14 of the obtained liner 10, specifically, at the boundary portion between the dome portion 14 and the base flange 16f of the base 16 that has entered the depressed pedestal portion 14r (step S106). In mounting the cap, before mounting the cap, a modified silicone-based or urethane resin-based elastic adhesive is applied to the outer surface of the dome of the dome portion 14 around the recessed pedestal portion 14r and the base flange 16f which has entered the depressed pedestal portion 14r. It is applied to at least one of the outer surfaces of the flange on the outer peripheral edge 16fe side, and the cap 18 is attached following the adhesive application. By attaching this cap, the opening recess 15 which is the gap between the dome portion 14 and the base flange 16f of the base 16 which has entered the recessed pedestal portion 14r is covered by the cap 18 around the axis of the liner shaft AX. The applied elastic adhesive cures in about a few minutes to adhere the cap 18. Through the liner manufacturing process up to this point, the manufacturing and preparation of the liner 10 is completed, and the obtained liner 10 is a dome having spherical dome outer surfaces following an isotonic curved surface on both sides of the cylindrical cylinder portion 12. A portion 14 is provided, and a base 16 is attached to the top of each dome portion.

When the liner 10 is obtained in this way, as shown in FIG. 4, a fiber reinforced resin layer 102 is formed on the outer surface of the liner 10 by the FW method (step S200). FIG. 5 is an explanatory diagram illustrating a state of a preparatory procedure for forming the fiber reinforced resin layer 102. In forming the fiber-reinforced resin layer in step S200, first, various jigs are attached to the liner 10 in which the base 16 is already attached to the dome portions 14 at both ends and the cap 18 is also attached. The jigs to be mounted are a long bearing jig 200, a short bearing jig 210, and a rotary bearing jig 230.

The long bearing jig 200 is inserted into the valve connection hole 16h of one base 16 with a sealing property secured, and the tip of the jig is inserted into the bottomed hole 16i in the liner of the other base 16. The bearing short jig 210 is inserted into the valve connection hole 16h on the outer side of the liner of the other base 16 with a sealability secured, and the bearing long jig 200 and the bearing short jig 210 are the liner 10. Is received at both ends and functions as a bearing around the rotation axis of the liner 10. The long bearing jig 200 has a plurality of air discharge ports 201 in a row in a tubular portion located in the liner, and has an air coupler 204 on the outer side of the liner. The air coupler 204 is connected to a compressor (not shown), and the pressurized air pumped by the compressor is passed through an air pipeline (not shown) formed along the axial direction of the bearing short jig 210 to each air discharge port 201. Lead into the liner from. The air coupler 204 is attached to the long bearing jig 200 so as not to interfere with the rotation and the rotary bearing of the long bearing 200 integrated with the liner 10. The supply of pressurized air will be described later.

The rotary bearing jig 230 includes a bearing leg 231, and the bearing leg 231 pivots the long bearing jig 200 and the short bearing 210 on both sides of the liner 10 and rotates by the rotation of a motor (not shown). 10 is rotatably supported around the liner shaft AX. Although the state of the shaft support of the bearing leg 231 is schematically shown in FIG. 5, the bearing leg 231 uses a roller bearing or the like to support the liner 10 without shaft deviation. In this way, the fiber reinforced resin layer 102 is formed on the liner 10 axially supported by various jigs by the following procedure using the FW method.

The fiber reinforced resin layer 102 is formed in the step S200 shown in FIG. 4 in a state where the liner 10 on which the long bearing jig 200 and the short bearing jig 210 are mounted is pivotally supported by the rotary bearing jig 230. It is performed by rotating the liner shaft AX around the axis and repeatedly winding a carbon fiber bundle CF impregnated with an epoxy resin EP (hereinafter referred to as a resin-impregnated carbon fiber bundle ECF) around the outer surface of the rotating liner 10. .. In the method for manufacturing the high-pressure gas tank 100 of the present embodiment, when the fiber-reinforced resin layer 102 is formed, the innermost helical winding layer that is in close contact with the outer surface of the liner 10 is formed first (step S202). When forming the innermost helical winding layer, the bearing length jig 200 guides the pressurized air pumped by the compressor into the rotating liner 10 through the air coupler 204 and the air discharge port 201 to obtain the liner internal pressure. Adjust to an initial internal pressure of 0.1 MPa. FIG. 6 is an explanatory view schematically showing the state of the helical winding layer formation of the innermost layer, and FIG. 7 is an explanatory view schematically showing the state of the helical winding layer formation of the innermost layer from the direction of arrow A in FIG. .. In FIG. 7, a subscript is added to the resin-impregnated carbon fiber bundle ECF in order to indicate the order of the resin-impregnated carbon fiber bundle ECF to be wound.

The innermost helical winding layer formed in step S202 has a low angle of fiber angle αLH (for example, about 11 to 25 °) formed by the resin-impregnated carbon fiber bundle ECF with respect to the liner shaft AX. It is formed by helical winding. More specifically, in the low angle helical winding for forming the innermost helical winding layer, the region of the outer surface of the dome that follows the isotonic curved surface of the dome portion 14 (see FIG. 5) to which the cap 18 is attached. And the region of the outer surface of the cylinder portion 12 are targeted for winding the fiber bundle, and the liner 10 is rotated around the axis of the liner shaft AX, and the resin extending from the fiber delivery portion 132, which is the supply source of the resin-impregnated carbon fiber bundle ECF. The liner rotation speed and the reciprocating speed of the fiber delivery portion 132 are adjusted so that the impregnated carbon fiber bundle ECF is wound around the liner shaft AX at a low angle fiber angle αLH (about 11 to 25 °). Then, the fiber delivery portion 132 is reciprocated along the liner shaft AX direction, and the resin-impregnated carbon fiber bundle ECF is repeatedly spirally wound around the dome portions 14 at both ends of the cylinder portion 12. In this case, in the dome portions 14 on both sides, the winding direction of the fiber bundle is folded back as the fiber delivery portion 132 switches between the outward path and the return path, and the folded-back position from the liner shaft AX is also adjusted.

By repeating folding back in the winding direction of the dome portion 14 a plurality of times, a resin-impregnated carbon fiber bundle ECF with a low-angle fiber angle αLH is stretched in a mesh shape on the outer surface of the liner 10 and wound around the innermost helical. A winding layer is formed. In this case, in the winding of the resin-impregnated carbon fiber bundle ECF, the outer surface of almost the entire area of the dome portion 14, specifically, the outer surface of the attached cap 18 is wound last from the resin-impregnated carbon fiber bundle ECF1 wound first. The process is repeated until it is covered with each carbon fiber bundle of the resin-impregnated carbon fiber bundle ECFn.

Since the resin-impregnated carbon fiber bundle ECF is helically wound at a low angle in the innermost helical winding layer, the resin-impregnated carbon fiber bundle ECF is hung on the dome portion 14 so as to cover the dome portion 14 including the base flange 16f and the cap 18 of the base 16. It is handed over, wound in sequence, and the cap 18 is pressed against the base flange 16f and the dome portion 14. In the method for manufacturing the high-pressure gas tank 100 of the present embodiment, the resin-impregnated carbon fiber bundle ECF in the innermost helical winding layer is adjusted by adjusting the rotation speed of the liner 10, the reciprocating speed of the fiber delivery portion 132, and the timing of reciprocating switching. The winding of is specified as follows. FIG. 8 is an explanatory view schematically showing the winding state of the resin-impregnated carbon fiber bundles wound first and second by the low-angle helical winding.

In the low-angle helical winding for forming the innermost helical winding layer, each resin-impregnated carbon fiber bundle ECF has a low-angle fiber angle αLH with respect to the liner shaft AX due to the tank manufacturing design with the cap 18 attached. The ECFc, which intersects at (about 11 to 25 °) and is the center line of the resin-impregnated carbon fiber bundle ECF, coincides with the theoretical line PLc that draws an isotonic curved surface formed by imitating the outer surface of the dome portion 14. However, the rotation speed of the liner 10 at the time of winding the fiber bundle, the reciprocating speed of the fiber delivery portion 132, and the reciprocating movement switching timing are matched so that the center line ECFc of the resin-impregnated carbon fiber bundle ECF and the theoretical line PLc drawing the equitension curved surface match. Even if it has been adjusted, the center line ECFc of the resin-impregnated carbon fiber bundle ECF and the theoretical line PLc drawing the iso-tension curved surface deviate from each other due to the influence of the tension related to the resin-impregnated carbon fiber bundle ECF and the resin impregnation amount. Can occur. In FIG. 8, the center line ECFc of the resin-impregnated carbon fiber bundle ECF is shifted to the outside of the liner as shown by the white arrows in the figure.

When the center line ECFc of the resin-impregnated carbon fiber bundle ECF deviates from the theoretical line PLc that draws an iso-tension curved surface and the resin-impregnated carbon fiber bundle ECF is wound, the center line shift Cz (even if the helical winding is at a low angle. (See FIG. 8) allows the resin-impregnated carbon fiber bundle ECF itself to shift to the outside of the liner, for example, as shown in FIG. It is assumed that wrinkles may occur in the cap 18 already attached to the dome portion 14 due to the deviation of the fiber bundle. Therefore, in the method for manufacturing the high-pressure gas tank 100 of the present embodiment, the deviation Cz between the center line ECFc of the resin-impregnated carbon fiber bundle ECF and the theoretical line PLc drawing the isotonic curved surface is the width of the resin-impregnated carbon fiber bundle ECF (fiber bundle width). The rotation speed of the liner 10 at the time of winding the fiber bundle, the reciprocating speed of the fiber delivery unit 132, and the reciprocating movement switching timing are appropriately adjusted so as to be within half of ECFw), and the helical is at a low angle so as to be within this deviation Cz. The winding was repeated a predetermined number of times. As a result, the resin-impregnated carbon fiber bundle ECF1 wound first, the resin-impregnated carbon fiber bundle ECF2 wound second, and the resin-impregnated carbon fiber bundles ECF3 to ECFn wound thereafter (subscripts n are integers). ) Are sequentially wound so that the deviation Cz is within half of the fiber bundle width ECFw to form the innermost helical winding layer. By imaging the resin-impregnated carbon fiber bundle ECF that is sequentially wound with a digital optical camera, the degree of deviation Cz between the center line ECFc of the resin-impregnated carbon fiber bundle ECF and the theoretical line PLc that draws an equal tension curved surface is obtained. It is more preferable to appropriately adjust the rotation speed of the liner 10 at the time of winding the fiber bundle, the reciprocating speed of the fiber delivery unit 132, and the reciprocating motion switching timing according to the degree of the deviation.

Following the formation of the innermost helical winding layer in step S202 described above, low-angle helical winding is continued under the condition that the internal pressure of the liner 10 is increased (step S204), and thereafter, under the condition of further increasing the internal pressure. Hoop winding (step S206) is executed. In step S204, the pressurized air pumped by the compressor into the rotating liner 10 is guided again through the air coupler 204 and the air discharge port 201, and the liner internal pressure is set to the primary internal pressure higher than the initial internal pressure (0.1 MPa). The pressure is adjusted to (0.5 MPa), and under the condition of this pressure adjustment, low-angle helical winding is continued. Then, during the continuation of the low-angle helical winding in step S204, the high-angle helical winding is used together at appropriate intervals. In this high-angle helical winding, the rotation speed and fibers of the liner 10 are set so that the angle formed by the resin-impregnated carbon fiber bundle ECF with respect to the liner shaft AX is a high-angle fiber angle (for example, about 30 to 60 °). The reciprocating speed and reciprocating movement switching timing of the sending unit 132 are appropriately adjusted and executed. By continuing the low-angle helical winding while using the high-angle helical winding together, the internal pressure of the liner 10 including the inside of the dome portion 14 is increased and adjusted to the primary internal pressure (0.5 MPa), and the dome portion 14 The cap 18 of the above is covered with a resin-impregnated carbon fiber bundle ECF.

In step S206, which follows the continuation of the low-angle helical winding in step S204, the pressurized air pumped by the compressor into the rotating liner 10 is guided again through the air coupler 204 and the air discharge port 201, and the liner internal pressure is set to 1. The pressure is adjusted to a secondary internal pressure (0.8 MPa) higher than the secondary internal pressure (0.5 MPa), and hoop winding is performed under the condition of this pressure adjustment. Then, in the hoop winding in step S206, the liner 10 is wound so that the resin-impregnated carbon fiber bundle ECF intersects and is wound at a winding angle (fiber angle α0: for example, about 89 °) that is almost perpendicular to the liner shaft AX. The rotation speed, the reciprocating speed of the fiber delivery unit 132, and the reciprocating motion switching timing are appropriately adjusted and executed. If low-angle helical winding is used at appropriate intervals while repeating this hoop winding a predetermined number of times, the cap 18 can be pressed on the dome portion 14 side under the condition that the pressure is adjusted to the secondary internal pressure (0.8 MPa). It will be covered with a resin-impregnated carbon fiber bundle ECF. In the hoop winding in step S206, the low-angle helical winding may be omitted.

The number of turns of the low-angle helical winding fiber bundle combined with the high-angle helical winding in step S204, the number of turns of the hoop-wound fiber bundle in step S206, and the timing of switching to hoop winding are determined by the high-pressure gas tank 100 as a finished product. It is set in consideration of the layer thickness of the fiber reinforced resin layer 102 required for. By winding the resin-impregnated carbon fiber bundle ECF in the above steps S202 to 206, a fiber-reinforced resin layer in which the epoxy resin EP in the resin-impregnated carbon fiber bundle ECF is uncured is formed on the outer surface of the liner 10, and the fiber is reinforced. A semi-finished high-pressure gas tank with an uncured resin layer can be obtained. Although the fiber reinforced resin layer of this semi-finished high-pressure gas tank is uncured, the appearance of the tank is the same as that of the high-pressure gas tank 100.

The obtained semi-finished high-pressure gas tank is conveyed to the curing process of the epoxy resin EP while being pivotally supported by the long bearing jig 200, the short bearing jig 210, and the rotary bearing jig 230, and is heated by the resin. It is processed. By this heat treatment, the epoxy resin EP in the resin-impregnated carbon fiber bundle ECF is cured to form a fiber-reinforced resin layer 102 made of CFRP (Carbon Fiber Reinforced Plastics), and after curing and cooling, the high-pressure gas tank 100 Is completed. In the resin heat treatment, a heating furnace with a built-in heater can be used, or a heating method of induction heating using an induction heating coil that induces high frequency induction heating can be used. In this high frequency induction heating, the temperature of the thermosetting resin can be rapidly raised.

As described above, in the method for manufacturing the high-pressure gas tank 100 of the present embodiment, the base flange 16f of the base 16 that has entered the recessed pedestal portion 14r of the dome portion 14, specifically, the outer peripheral edge 16fe and the dome portion 14 of the flange. A ring-shaped cap 18 covers the opening recess 15 which is a gap at the boundary portion. Then, the cap 18 is covered with the respective resin-impregnated carbon fiber bundles ECF1 to ECFn repeatedly wound by low-angle helical winding so as to form the innermost helical winding layer (see FIGS. 7 and 8). , Press against the outer surface of the dome and the outer surface of the flange. Therefore, according to the method for manufacturing the high-pressure gas tank 100 of the present embodiment, the cap 18 can easily suppress the entry of the epoxy resin EP from the resin-impregnated carbon fiber bundle ECF into the opening recess 15.

In the method for manufacturing the high-pressure gas tank 100 of the present embodiment, it is sufficient to use the ring-shaped cap 18 that can be inexpensively manufactured by the existing mold molding method, and there is no need to wait for the sealing material to harden as in the existing method. is there. Therefore, according to the method for manufacturing the high-pressure gas tank 100 of the present embodiment, it is possible to inexpensively suppress the entry of the epoxy resin EP into the boundary portion, and the high-pressure gas tank 100 in which the entry of the epoxy resin EP into the boundary portion is suppressed is shortened. Can be manufactured in time.

In the method for manufacturing the high-pressure gas tank 100 of the present embodiment, the cap 18 is made of the same nylon resin as the liner 10, has the same linear expansion coefficient as the liner 10, and is a dome of the dome portion 14 that follows an equal tension curved surface. A ring-shaped molded product having a thin leaf cross section having an inner surface following the curved surface shape of the outer surface of the flange of the base flange 16f which is continuous with the outer surface and the outer surface following an equal tension curved surface. Therefore, when the epoxy resin EP is heat-cured in the uncured fiber-reinforced resin layer formed from the resin-impregnated carbon fiber bundle ECF, the cap 18 can be suppressed from being damaged due to the difference in thermal expansion from the liner 10. It is possible to improve the adhesion of the cap 18 to the outer surface of the dome of the dome portion 14 and the outer surface of the flange of the base flange 16f continuous thereto. Therefore, according to the manufacturing method of the high-pressure gas tank 100 of the present embodiment, the damaged portion of the cap 18 and the gap between the cap 18 and the outer surface of the dome and the outer surface of the flange are not yet connected to the opening recess 15 which is the gap of the boundary portion. It is possible to more reliably suppress the entry of the cured epoxy resin EP. By the way, when the epoxy resin EP in the uncured fiber-reinforced resin layer is heat-cured, the high-pressure gas tank 100 is cooled by a method such as outgassing from the tank. Even during this cooling, damage to the cap 18 due to the difference in thermal expansion from the liner 10 can be suppressed, which is preferable.

In the method for manufacturing the high-pressure gas tank 100 of the present embodiment, the innermost helical layer in which the cap 18 is pressed against the outer surface of the dome of the dome portion 14 or the outer surface of the flange of the base flange 16f of the base 16 is formed by the resin-impregnated carbon fiber bundle ECF. The resin-impregnated carbon fiber bundle ECF1 wound first from the resin-impregnated carbon fiber bundle ECF1 wound around the dome portion 14 so as to cover the base flange 16f and the cap 18 of the mouthpiece 16 was transferred to the resin-impregnated carbon fiber bundle ECFn. The resin-impregnated carbon fiber bundle ECF was wound so that the deviation Cz between the center line ECFc and the theoretical line PLc drawing the isotonic curved surface was within half of the fiber bundle width ECFw (see FIG. 8). By defining the deviation in this way, wrinkles that are assumed to occur due to the deviation of the fiber bundle are less likely to occur on the cap 18. Therefore, according to the method for manufacturing the high-pressure gas tank 100 of the present embodiment, the generation of wrinkles in the cap 18 is also suppressed by suppressing the deviation of the wound resin-impregnated carbon fiber bundle ECF on the outer surface of the dome portion 14, and the cap 18 is also suppressed. It is possible to more reliably suppress the entry of the uncured epoxy resin EP into the opening recess 15 which is the gap between the wrinkled portion and the boundary portion.

In the method for manufacturing the high-pressure gas tank 100 of the present embodiment, when the cap 18 is attached so as to cover the opening recess 15 which is the gap between the dome portion 14 and the base flange 16f of the base 16, the cap 18 is elastic before the cap is attached. The adhesive was applied to at least one of the outer surface of the dome of the dome portion 14 and the outer surface of the flange of the base flange 16f, and the cap 18 was attached following the application of the adhesive. Therefore, according to the manufacturing method of the high-pressure gas tank 100 of the present embodiment, it is possible to suppress the displacement of the cap 18 after mounting, and to improve the stability and reproducibility of the cap mounting position. In addition, according to the manufacturing method of the high-pressure gas tank 100 of the present embodiment, the gap that may occur on the inner surface side of the cap due to the manufacturing tolerance of the cap 18 is closed with an elastic adhesive, so that the opening recess is formed from this gap. It is possible to prevent the uncured epoxy resin EP from entering the 15.

In the method for manufacturing the high-pressure gas tank 100 of the present embodiment, the inner pressure of the liner 10 is formed after the helical winding layer of the innermost layer is formed by the resin-impregnated carbon fiber bundles ECF1 to ECFn under the condition of the liner internal pressure of the initial internal pressure (0.1 MPa). Continued helical winding (step S204) under the condition that the pressure was increased from the initial internal pressure (0.1 MPa) to the primary internal pressure (0.5 MPa), and the liner internal pressure was higher than the primary internal pressure (0.5 MPa). Hoop winding (step S206) was performed under a condition where the pressure was increased to the secondary internal pressure (0.8 MPa) to form a fiber layer (helical winding layer, hoop winding layer) following the innermost helical winding layer. Therefore, according to the method for manufacturing the high-pressure gas tank 100 of the present embodiment, the innermost helical winding layer covers the opening recess 15 which is the gap between the dome portion 14 and the base flange 16f of the base 16. By applying a high pressure such as a primary internal pressure (0.5 MPa) or a secondary internal pressure (0.8 MPa) to the sandwiched cap 18 from the side of the liner 10, the opening recess 15 is covered with the cap 18 with a high surface pressure. It is possible to improve the sealing property and further enhance the effect of suppressing the entry of the uncured epoxy resin EP into the opening recess 15.

Next, a modified example cap that can be used in place of the cap 18 in the tank manufacturing method as the above-described embodiment will be described. FIG. 9 is an explanatory view showing a semi-cross-sectional view, a front view, and an enlarged view of a main part of the liner 10 using the cap 18A of the first modification. The cap 18A of this modified example is mounted so as to cover the opening recess 15, and the first cap side convex portion 21 is in contact with the outer surface of the base flange 16f on the inner peripheral surface 19a on the liner side in contact with the outer surface of the dome portion 14. The second cap side convex portion 31 is provided on the inner peripheral surface 19b on the base flange side. The inner peripheral surface 19a on the liner side and the inner peripheral surface 19b on the flange side of the base are both inner peripheral surfaces of the cap, and the cap 18A engages the first cap side convex portion 21 and the second cap side convex portion 31 with the cap side. It has as a joint.

The liner 10 to which the cap 18A is mounted has a first engaging recess 22 that engages with the first cap-side convex portion 21 on the dome portion 14 as an engaging portion that engages with the cap-side engaging portion, and has a base. Reference numeral 16 denotes an engaging portion having a second engaging concave portion 32 that engages with the second cap side convex portion 31 on the base flange 16f as an engaging portion that engages with the cap side engaging portion. The first cap-side convex portion 21 and the first engaging recess 22 are formed in a circular shape on the outside of the opening recess 15, and the first cap in which the first cap-side convex portion 21 is engaged with the first engaging recess 22 is the first cap. The engaging portion 20 surrounds the opening recess 15 on the outside. The second cap side convex portion 31 and the second engaging concave portion 32 are formed in a circular shape inside the opening recess 15, and the second cap side convex portion 31 is engaged with the second engaging concave portion 32. The engaging portion 30 internally surrounds the opening recess 15. Therefore, according to the method for manufacturing the high-pressure gas tank 100 using the cap 18A of the first modification, there are the following advantages.

In the process of forming the fiber-reinforced resin layer 102 using the resin-impregnated carbon fiber bundle ECF, the resin-impregnated carbon fiber is formed through the gap between the outer surface of the cap 18A and the dome portion 14 or the gap between the cap 18A and the outer surface of the base flange 16f. Epoxy resin, which is a thermosetting resin in bundled ECF, may enter. However, according to the method for manufacturing the high-pressure gas tank 100 using the cap 18A of the first modification, the uncured epoxy resin that has entered through the above-mentioned gap is applied to the first cap engaging portion 20 and the second cap engaging portion 30. By retaining the epoxy resin, it is possible to suppress the entry of the epoxy resin into the opening recess 15 with high effectiveness. Further, the cap 18A can be positioned by the first cap engaging portion 20 and the second cap engaging portion 30, and the misalignment of the cap 18A when the resin-impregnated carbon fiber bundle ECF is wound can be suppressed.

FIG. 10 is an explanatory view showing a semi-cross-sectional view, a front view, and an enlarged view of a main part of the liner 10 using the cap 18B of the second modification. The cap 18B of this modified example has a first cap-side recess 23 on the inner peripheral surface 19a on the liner side and a second cap-side recess 33 on the inner peripheral surface 19b on the base flange side. The liner 10 to which the cap 18B is mounted has a first engaging convex portion 24 that engages with the first cap side concave portion 23 on the dome portion 14, and the base 16 is on the second cap side on the base flange 16f. It has a second engaging convex portion 34 that engages with the concave portion 33. The first cap-side concave portion 23 and the first engaging convex portion 24 are formed in a circular shape on the outside of the opening recess 15, and the first cap in which the first engaging convex portion 24 is engaged with the first cap-side concave portion 23. The engaging portion 20 surrounds the opening recess 15 on the outside. The second cap-side concave portion 33 and the second engaging convex portion 34 are formed in a circular shape inside the opening recess 15, and the second cap in which the second engaging convex portion 34 is engaged with the second cap-side concave portion 33. The engaging portion 30 internally surrounds the opening recess 15. Therefore, the manufacturing method of the high-pressure gas tank 100 using the cap 18B of the second modification can also suppress the entry of the epoxy resin into the opening recess 15 with high effectiveness, and also achieve the positioning and the suppression of the displacement of the cap 18B. it can.

FIG. 11 is an explanatory view showing a semi-cross-sectional view, a front view, and an enlarged view of a main part of the liner 10 using the cap 18C of the third modification. The cap 18C of this modified example has the first cap-side convex portion 21 described above on the inner peripheral surface 19a on the liner side, and has the second cap-side concave portion 33 described above on the inner peripheral surface 19b on the base flange side. .. The liner 10 to which the cap 18C is mounted has the above-mentioned first engaging recess 22 that engages with the first cap side convex portion 21 on the dome portion 14, and the base 16 is attached to the base flange 16f. 2 It has the above-mentioned second engaging convex portion 34 that engages with the cap side concave portion 33. The first cap engaging portion 20 in which the first engaging recess 22 is engaged with the first cap side convex portion 21 surrounds the opening recess 15 on the outside, and the second engaging convex is formed on the second cap side concave portion 33. The second cap engaging portion 30 with which the portion 34 is engaged surrounds the opening recess 15 inside. Therefore, the manufacturing method of the high-pressure gas tank 100 using the cap 18C of the third modification can also suppress the entry of the epoxy resin into the opening recess 15 with high effectiveness, and also achieve the positioning and the suppression of the displacement of the cap 18B. it can. In this modification, the first cap engaging portion 20 is composed of the first cap side concave portion 23 and the first engaging convex portion 24 shown in FIG. 10, and the second cap engaging portion 30 is shown in FIG. The second cap side convex portion 31 and the second engaging concave portion 32 shown in the above may be formed.

FIG. 12 is an explanatory view showing a semi-cross-sectional view, a front view, and an enlarged view of a main part of the liner 10 using the cap 18D of the fourth modification. FIG. 13 is an explanatory view showing an outline of the boundary convex portion 40 included in the cap 18D. The liner 10 to which the cap 18D of this modification is mounted has an opening recess 15 as a circular shape surrounding the base 16, and the cap 18D has a boundary convex portion 40 that enters the opening recess 15 that is a boundary gap. The boundary convex portion 40 is a thin annular body protruding from the inner peripheral surface of the cap, which is the lower surface of the cap 18D, and enters the opening recess 15 over the entire area of the opening recess 15. Also by the method of manufacturing the high-pressure gas tank 100 using the cap 18D of the fourth modification, the positioning of the cap 18D and the suppression of the misalignment can be achieved by inserting the opening recess 15 into the boundary convex portion 40. Further, as shown in FIG. 13, if the boundary convex portion 40 is provided with the convex shape 41, the convex shape 41 can prevent the cap 18D from rotating around the liner shaft AX. If the opening recess 15 is a recess that surrounds the liner shaft by repeating the rectangular wave shape as in the above-described embodiment, the boundary convex portion 40 is curved so as to enter a part of the rectangular wave shape. It may be a plate-shaped body.

FIG. 14 is an explanatory view showing a semi-cross-sectional view, a front view, and an enlarged view of a main part of the liner 10 using the cap 18E of the fifth modification. The liner 10 and the base 16 to which the cap 18E of this modified example is mounted form the opening recess 15 which is a boundary gap in a tapered shape which widens toward the side of the cap 18E with the recess inner peripheral wall 14rs and the outer peripheral edge 16fe. The cap 18E has a boundary convex portion 40A as a tapered convex portion that follows the tapered shape of the opening recess 15. Since the cap 18E of this modified example receives a pressing force from the resin-impregnated carbon fiber bundle ECF wound around the outer surface of the liner 10 as shown by the white arrow in the figure, the boundary convex portion 40A has a tapered shape with high adhesion. Press against the opening recess 15. Therefore, according to the method for manufacturing the high-pressure gas tank 100 using the cap 18E of the fifth modification, it is possible to suppress the entry of the epoxy resin into the opening recess 15 with higher effectiveness. If the opening recess 15 is a recess that surrounds the liner shaft by repeating the rectangular wave shape as in the above-described embodiment, the opening recess 15 is tapered in a part of the rectangular wave shape. The boundary convex portion 40A may be inserted into the opening recess 15 of a part of the portion.

FIG. 15 is an explanatory view showing a liner 10 using the cap 18F of the sixth modification with a schematic perspective view and a front view of a main part. FIG. 16 is an explanatory view showing the liner 10 to which the cap 18F is attached by cross-sectional view along the 16-16 bending line in FIG. The cap 18F of this modification is impregnated with a resin that is first helically wound at a low angle fiber angle αLH (eg, about 11-25 °) to form the innermost helical winding layer described with reference to FIG. It has a concave guide 50 into which the carbon fiber bundle ECF1 enters. The concave guide 50 functions to suppress the positional deviation of the resin-impregnated carbon fiber bundle ECF1 in the fiber bundle width direction due to the entry of the resin-impregnated carbon fiber bundle ECF1, and the resin-impregnated carbon fiber bundle ECF1 that is first helically wound. It is formed along the fiber bundle winding path of the above, and its depth is set to about 0.1 mm so that the resin-impregnated carbon fiber bundle ECF1 fits. The resin-impregnated carbon fiber bundle ECF1 that is initially helically wound is spirally wound at a low angle while being housed in the concave guide 50, so that the base flange 16f and the cap 18F of the base 16 are included to cover the dome portion 14. Is hung on the dome portion 14, and the cap 18F is pressed against the base flange 16f and the dome portion 14 as shown by the white arrows in FIG. The component force of this pressing force may act on the side where the resin-impregnated carbon fiber bundle ECF1 is deviated from the theoretical line PLc (see FIG. 8) drawing the iso-tension curved surface of the dome portion 14 in the fiber bundle width direction. Since the bundle ECF1 is housed in the concave guide 50 in the winding path, the misalignment of the fiber bundle is avoided. Therefore, according to the method for manufacturing the high-pressure gas tank 100 using the cap 18F of the sixth modification, the displacement of the cap 18F due to the positional displacement of the resin-impregnated carbon fiber bundle ECF1 can be suppressed.

The present invention is not limited to the above-described embodiment, and can be realized with various configurations without departing from the spirit of the present invention. For example, the technical features of the embodiments corresponding to the technical features in each embodiment described in the column of the outline of the invention may be used to solve some or all of the above-mentioned problems, or a part of the above-mentioned effects. Or, in order to achieve all of them, it is possible to replace or combine them as appropriate. Further, if the technical feature is not described as essential in the present specification, it can be appropriately deleted.

In the above embodiment, the opening recess 15 is surrounded by the liner shaft by repeating the rectangular wave shape, but the liner shaft AX is surrounded by repeating the shape such as a sine wave or a triangular wave, or a deformed shape is formed in a part of the region. The opening recess 15 may be formed so as to have the liner shaft AX. Further, the opening recess 15 may be circularly surrounding the liner shaft AX, or the opening recess 15 may be arcuate to partially surround the liner shaft AX.

In the above embodiment, the cap 18 has the same coefficient of linear expansion as the liner 10 by molding the cap 18 into a ring shape using the same nylon resin as the liner 10, but the cap 18 is referred to as the liner 10. Ring-shaped molding may be performed using different resin materials, and in this case, the linear expansion coefficient of the obtained cap 18 may be as follows. If the coefficient of linear expansion of the cap 18 is not significantly different from that of the liner 10, the possibility of the cap being damaged due to the difference in thermal expansion during heat curing of the epoxy resin EP forming the fiber reinforced resin layer 102 is suppressed. it can. Therefore, the cap forming material may be selected so that the linear expansion coefficient of the cap 18 is equivalent to that of the liner 10 within the range in which the cap breakage due to the difference in thermal expansion can be suppressed. Alternatively, even if the linear expansion coefficient of the cap 18 is different from that of the liner 10, the strength of the cap 18 may be increased so that the cap breakage due to the difference in thermal expansion can be suppressed.

In the above embodiment, when the cap 18 is attached, the elastic adhesive is applied to at least one of the outer surface of the dome of the dome portion 14 and the outer surface of the flange of the base flange 16f, but the elastic adhesive is applied to the inner surface of the cap 18. A cap 18 that has been coated and coated with an adhesive may be attached. The application of the elastic adhesive before attaching the cap may be omitted.

In the above embodiment, the reinforcing fiber bundle wound around the outer surface of the liner by the FW method is a resin-impregnated carbon fiber bundle ECF. However, an epoxy resin-containing glass fiber bundle, an aramid fiber bundle, or the like can be used, and a plurality of fibers can be used. A fiber bundle in which various types of sliver fibers are bundled, for example, a fiber bundle in which glass fibers and carbon fibers are mixed is repeatedly wound by the FW method to form a fiber reinforced resin layer 102.

In the above embodiment, the liner 10 is divided into two parts, but it may be a three-part product divided into a cylinder portion 12 and dome portions 14 on both sides thereof.

In the first modification to the third modification described above, the first cap engaging portion 20 and the second cap engaging portion 30 surrounding the opening recess 15 are provided on the outside and the inside of the opening recess 15, but the first modification is provided. The cap engaging portion of either the 1 cap engaging portion 20 or the second cap engaging portion 30 may be provided.

In the sixth modification described above, the cap 18F is provided with the concave guide 50 into which the resin-impregnated carbon fiber bundle ECF1 to be wound first helically enters, but as shown in FIG. 7, the resin-impregnated carbon fiber bundle to be wound second is provided. A plurality of concave guides 50 may be provided so that the ECF2 and the resin-impregnated carbon fiber bundle ECF3 wound in the third position can enter.

Further, in the sixth modification described above, the concave guide 50 is used to suppress the positional deviation of the resin-impregnated carbon fiber bundle ECF1 that is first helically wound in the fiber bundle width direction, but the present invention is not limited to this. For example, on the outer surface of the cap 18F, a plurality of small protrusions are provided on both sides of the fiber bundle in the width direction so as to suppress the positional deviation of the resin-impregnated carbon fiber bundle ECF1 that is initially helically wound in the fiber bundle width direction. Alternatively, two small protrusions may be provided on both sides in the width direction of the fiber bundle.

In the above-mentioned first modification to sixth modification, the application of the elastic adhesive at the time of attaching the cap may be omitted.

10 ... Liner 12 ... Cylinder part 14 ... Dome part 14h ... Through hole 14r ... Depressed pedestal part 14rs ... Recessed inner peripheral wall 15 ... Opening recess 16 ... Base 16b ... Base body 16f ... Base flange 16fe ... Outer peripheral edge 16h ... Valve connection hole 16i ... Bottom hole 16t ... Convex portion 18, 18A-18F ... Cap 19a ... Liner side inner peripheral surface 19b ... Base flange side inner peripheral surface 20 ... First cap engaging portion 21 ... First cap side convex portion 22 ... No. 1 Engagement recess 23 ... 1st cap side recess 24 ... 1st engagement convex 30 ... 2nd cap engagement part 31 ... 2nd cap side convex 32 ... 2nd engagement recess 33 ... 2nd cap side recess 34 ... Second engaging convex parts 40, 40A ... Boundary convex parts 41 ... Convex 50 ... Concave guide 100 ... High pressure gas tank 102 ... Fiber reinforced resin layer 132 ... Fiber delivery part 200 ... Bearing long jig 201 ... Air outlet 204 ... Air coupler 210 ... Bearing short jig 230 ... Rotary bearing jig 231 ... Bearing leg AX ... Liner shaft CF ... Carbon fiber bundle Cz ... Misalignment EP ... Epoxy resin ECF, ECF1 to ECFn ... Resin impregnated carbon fiber bundle ECFw ... Fiber Bundle width ECFc ... Center line PLc ... Theoretical line αLH ... Fiber angle

Claims (8)

A method for manufacturing a high-pressure gas tank having a fiber layer formed by repeatedly winding a fiber bundle around the outer surface of the liner by attaching a mouthpiece to the top of the dome portion at both ends in the axial direction of the liner.
A step of preparing the liner having the outer surface of the dome portion following an isotonic curved surface and having a bottomed depressed pedestal portion for mounting a base on the top of the dome portion.
A step of mounting the base having a base flange that enters the recessed pedestal portion and a base body that protrudes from the base flange toward the liner end side onto the top so that the base flange enters the recessed pedestal portion. ,
A step of attaching a ring-shaped cap to the boundary portion between the outer peripheral edge of the flange of the mouthpiece flange and the inner peripheral wall of the depressed pedestal portion that has entered the recessed pedestal portion, and covering the boundary gap of the boundary portion with the cap.
The fiber bundle impregnated with a thermosetting resin is repeatedly wound around the outer surface of the liner to which the mouthpiece and the cap are attached to form the fiber layer.
In the step of covering the boundary gap with the cap,
The ring-shaped cap has a linear expansion coefficient equivalent to that of the liner, and has an inner surface that follows the curved surface shape of the outer surface of the dome portion and the outer surface of the mouthpiece flange, and is the inner circumference of the cap. Use a cap having a cap-side engaging portion on the surface that includes at least one of a convex or concave portion surrounding the boundary portion.
As the liner and the mouthpiece, a liner and a mouthpiece having an engaging portion that engages with the cap-side engaging portion of the cap are used.
In the step of forming the fiber layer,
A helical winding layer in which the dome portion is wound around the dome portion including the base flange is first formed by the fiber bundle so that the fiber bundle is hung around the dome portions at both ends in the axial direction.
Manufacturing method of high pressure gas tank. A method for manufacturing a high-pressure gas tank having a fiber layer formed by repeatedly winding a fiber bundle around the outer surface of the liner by attaching a base to the top of the dome portion at both ends in the axial direction of the liner.
A step of preparing the liner having the outer surface of the dome portion following an isotonic curved surface and having a bottomed depressed pedestal portion for mounting a base on the top of the dome portion.
A step of mounting the mouthpiece having a mouthpiece flange that enters the recessed pedestal portion and a mouthpiece body that protrudes from the mouthpiece flange toward the liner end side onto the top so that the mouthpiece flange enters the recessed pedestal portion. ,
A step of attaching a ring-shaped cap to the boundary portion between the outer peripheral edge of the flange of the mouthpiece flange and the inner peripheral wall of the depressed pedestal portion that has entered the recessed pedestal portion, and covering the boundary gap of the boundary portion with the cap.
The fiber bundle impregnated with a thermosetting resin is repeatedly wound around the outer surface of the liner to which the mouthpiece and the cap are attached to form the fiber layer.
In the step of covering the boundary gap with the cap,
As the ring-shaped cap, a cap made of the same material as the liner and having an inner surface that follows the curved surface shape of the outer surface of the dome portion and the outer surface of the mouthpiece flange is used.
In the step of forming the fiber layer,
A helical winding layer in which the dome portion is wound around the dome portion including the base flange is first formed by the fiber bundle so that the fiber bundle is hung around the dome portions at both ends in the axial direction.
Manufacturing method of high pressure gas tank. In the step of forming the fiber layer, in forming the earliest helical winding layer, the winding of the fiber bundle at the time of forming the helical winding layer is defined as a theoretical line for drawing the isotonic curved surface in the dome portion. wherein like deviation of the center line of the fiber bundle will be within half the width of the fiber bundle is repeated, a manufacturing method of a high-pressure gas tank mounting serial to claim 1 or claim 2. In the step of forming the fiber layer, the internal pressure of the liner is increased after the formation of the earliest helical winding layer, and under the pressure increasing state of the internal pressure, the fiber layer following the earliest helical winding layer is formed. The method for manufacturing a high-pressure gas tank according to any one of claims 1 to 3 , which is formed by repeatedly winding the fiber bundle around the outer surface of the liner. In the step of covering the boundary gap with the cap, the cap is attached after applying an elastic adhesive to at least one outer surface of the outer surface of the dome portion and the outer surface of the mouthpiece flange. The method for manufacturing a high-pressure gas tank according to any one of claims 4 . The method for manufacturing a high-pressure gas tank according to claim 2 , wherein the cap has a convex portion that enters the boundary gap. The method for manufacturing a high-pressure gas tank according to claim 6 .
The boundary gap is formed in a tapered shape that widens toward the side of the cap by the inner peripheral wall of the liner and the outer peripheral edge of the flange of the mouthpiece.
A method for manufacturing a high-pressure gas tank, wherein the cap has the convex portion as a tapered convex portion that follows the tapered shape of the boundary gap. The cap has a guide for suppressing a positional deviation of the fiber bundle in the fiber bundle width direction, which is wound during the formation of the earliest helical winding layer, along the fiber bundle winding path in the helical winding layer. The method for manufacturing a high-pressure gas tank according to any one of claims 1 to 7 .

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