JP6874439B2 - High pressure gas tank - Google Patents

Description

The present invention relates to a high pressure gas tank.

The high-pressure gas tank is provided with a fiber-reinforced resin layer on the outer circumference of the liner, and the fiber-reinforced resin layer has a multi-layered structure in which a fiber bundle impregnated with a thermosetting resin is repeatedly wound around the outer circumference of the liner. Since the pressure resistance of the high-pressure gas tank depends on the fiber-reinforced resin layer having a layered structure, a method of acquiring the cut surface of the fiber-reinforced resin layer by X-ray CT or tomography using microwaves and performing a performance inspection is possible. It has been proposed (for example, Patent Document 1). The fiber-reinforced resin layer functions as a reinforcing layer after being formed by a fiber bundle impregnated with a thermosetting resin and then heat-curing the thermosetting resin.

Japanese Unexamined Patent Publication No. 2013-53729

According to tomography by X-ray CT or microwave, the cut surface of the fiber reinforced resin layer can be obtained non-destructively, which is useful in performance inspection. However, since the cured fiber bundles of each layer constituting the fiber-reinforced resin layer are homogeneous, there is a concern that the boundary between the overlapping layers will be blurred in the tomographic image. Therefore, the layer thickness of the fiber-reinforced resin layer must be measured based on the unclear boundary, and there is room for improvement. For these reasons, when acquiring the cut surface of the fiber reinforced resin layer by non-destructive tomography, it has been required to clarify the boundary between the overlapping layers in the fiber reinforced resin layer.

The present invention has been made to solve at least a part of the above-mentioned problems, and can be realized as the following forms. That is, in a high-pressure gas tank provided with a fiber-reinforced resin layer on the outer periphery of the liner, the fiber-reinforced resin layer is a fiber bundle layer in which a fiber bundle impregnated with a thermosetting resin is repeatedly wound around the outer periphery of the liner to cover the outer periphery of the liner. It is a layered structure in which a plurality of layers are stacked, and can be implemented as a form of a high-pressure gas tank in which a metal powder layer made of metal powder is provided between the fiber bundle layers overlapping in the layered structure.

(1) According to one embodiment of the present invention, a high pressure gas tank is provided. This high-pressure gas tank is a high-pressure gas tank provided with a fiber-reinforced resin layer on the outer periphery of the liner, and the fiber-reinforced resin layer is obtained by repeatedly winding a fiber bundle impregnated with a thermosetting resin around the outer periphery of the liner and winding the outer periphery of the liner. It has a layered structure in which a plurality of fiber bundle layers covering the above are laminated, and a metal layer in which a metal is present is provided between the fiber bundle layers overlapping in the layered structure.

In the cut surface obtained by non-destructive tomography of the fiber-reinforced resin layer in this form of high-pressure gas tank, the fiber bundle layers overlap with the metal layer as a boundary. Since the metal layer contains a metal that is a material completely different from the fiber bundle, it is possible to sharpen the boundary between the overlapping layers in the fiber reinforced resin layer.

The present invention can be realized in various aspects. For example, it can be realized in the form of a method for manufacturing a high-pressure gas tank, a form of a manufacturing apparatus, or a method for inspecting a high-pressure gas tank.

It is sectional drawing which shows the schematic structure of the high pressure gas tank of this embodiment together with the enlarged view. It is a process drawing which shows the manufacturing procedure of the high pressure gas tank which concerns on this embodiment. It is explanatory drawing which shows typically the state of formation of the fiber reinforced resin layer together with the state of formation of a metal powder layer. It is explanatory drawing which shows the mode that the fiber reinforced resin layer is formed on a liner in an uncured state. It is explanatory drawing which shows the state of acquisition of the cross-sectional image of a high pressure gas tank schematicly.

FIG. 1 is a cross-sectional view showing a schematic configuration of the high-pressure gas tank 100 of the present embodiment together with an enlarged view. The high-pressure gas tank 100 is provided with a fiber-reinforced resin layer 16 on the outer periphery of the liner 10, and the base 20 and the base 30 are projected from both ends of the liner. The liner 10 is a hollow tank container, and 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. .. After joining the parts, the liner 10 becomes a gas barrier resin hollow container provided with spherical dome portions 12 on both sides of the cylindrical cylinder portion 11. The liner 10 is provided with a base 20 at the top of one dome portion 12 and a base 30 at the top of the other dome portion 12. The base 20 and the base 30 mounted in this way face each other with the liner axis CX as the central axis, and function as a receiver around the rotation axis of the liner 10 when forming the fiber reinforced resin layer 16 and performing various measurements during tank manufacturing. Both the base 20 and the base 30 are made of a lightweight metal such as aluminum or an alloy thereof, and the base 20 is provided with a through hole for a tapered screw having a high pressure seal specification for mounting a valve (not shown). The base 30 is provided with concentric bottomed holes on the outside and inside of the liner.

The fiber-reinforced resin layer 16 covers the outer periphery of the liner 10 in the entire area by repeatedly winding a fiber bundle impregnated with a thermosetting resin around the outer periphery of the liner by a filament winding method (hereinafter, FW method). When winding the fiber bundle, as will be described later, fiber winding by hoop winding and fiber winding by low-angle / high-angle helical winding are used properly. By properly using the winding of the fiber bundle, the fiber reinforced resin layer 16 is formed so as to cover the entire outer surface of the cylinder portion 11 and the dome portion 12 of the liner 10 with a plurality of fiber bundle layers, respectively, and to cover the dome portion 12. The flange portion of the base 20 and the base 30 is covered with the base portion 16c. The fiber-reinforced resin layer 16 of the present embodiment is a fiber of the nth fiber bundle layer 16n (n is the number of layers) of the first fiber bundle layer 161 to the nth layer from the outer peripheral side of the liner 10. It is a layered structure in which a plurality of bundle layers are stacked, and is said to be between the first fiber bundle layer 161 and the second fiber bundle layer 162 and between the second fiber bundle layer 162 and the third fiber bundle layer 163 as shown in the enlarged view. The metal powder layer 17 is interposed between the overlapping fiber bundle layers in the layered structure. The metal powder layer 17 is a thin metal layer formed by spraying liquid water containing a metal powder such as zinc or aluminum, and in which such a metal is present. Then, the metal powder layer 17 adheres the metal powder to the overlapping fiber bundle layers. The formation of the metal powder layer 17 will be described later.

An epoxy resin is generally used as the thermosetting resin for forming the fiber-reinforced resin layer 16, but a thermosetting resin such as a polyester resin or a polyamide resin can be used. Further, as the reinforcing fiber bundle (bundle of sliver fibers) wound around the outer periphery of the liner by the FW method, glass fiber, carbon fiber, aramid fiber and the like are used, and a plurality of types (for example, glass fiber and carbon fiber) of FW are used. By sequentially winding the fiber bundles by the method, the fiber reinforced resin layer 16 can be formed by laminating resin layers made of different fibers.

Next, the manufacturing method of the high-pressure gas tank 100 described above will be described. FIG. 2 is a process diagram showing a manufacturing procedure of the high-pressure gas tank 100 according to the present embodiment. In order to manufacture the high-pressure gas tank 100, first, the first layer of the fiber-reinforced resin layer 16 is formed from the first fiber bundle layer 161 (step S100), and the metal powder layer 17 on the first fiber bundle layer 161 is formed. The formation (step S110) is performed.

FIG. 3 is an explanatory diagram schematically showing the state of formation of the fiber reinforced resin layer 16 together with the state of formation of the metal powder layer 17. FIG. 4 is an explanatory view showing how the fiber reinforced resin layer 16 is formed on the liner 10 in an uncured state. In forming the fiber-reinforced resin layer in step S100, first, in the filament winding device (hereinafter referred to as FW device FM) shown in FIG. 3, the liner 10 in which the base 20 and the base 30 are already attached to the dome portion 12 is attached. The rotary bearing jig 230 rotatably supports the liner axis CX. In forming the fiber bundle layers in order from the first fiber bundle layer 161 of the fiber reinforced resin layer 16, the liner 10 pivotally supported by the rotary bearing jig 230 is rotated around the axis of the liner axis CX, and the epoxy resin EP. The resin-containing carbon fiber bundle ECF impregnated with the carbon fiber CF is repeatedly wound around the outer periphery of the liner 10 by the FW device FM. In forming the fiber-reinforced resin layer 16, first, the resin-containing carbon fiber bundle ECF is formed on the first fiber bundle layer 161 at a fiber angle αLH (for example, about 11 to 25 °) at a low angle with respect to the liner axis CX. It is formed as a low-angle helical layer that is cross-wound (step S100). This situation is shown in the upper part of FIG. 4, and in the figure, the outer surface of the liner 10 is exposed, but when the entire outer surface of the liner is covered with the resin-containing carbon fiber bundle ECF of low helical winding, the low angle helical is shown. The first fiber bundle layer 161 of the layer is formed. When the first fiber bundle layer 161 is formed, the liner rotation speed and the reciprocating speed of the fiber delivery portion 132, which is the source of the uncured resin-containing carbon fiber bundle ECF, are adjusted, and then the liner axis CX direction is adjusted. The fiber delivery unit 132 reciprocates along the above. As a result, the resin-containing carbon fiber bundle ECF is repeatedly spirally wound around the dome portions 12 at both ends of the cylinder portion 11. In the dome portions 12 on both sides, the winding direction of the fibers 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 axis CX is also adjusted.

The first fiber bundle layer in which the resin-containing carbon fiber bundle ECF is stretched in a mesh shape on the outer surface of the liner 10 with a low angle fiber angle αLH by repeatedly folding back the dome portion 12 in the winding direction. 161 is formed. In this case, the fiber delivery portion 132 reciprocates until the outer surface of almost the entire area of the dome portion 12 is covered with the resin-containing carbon fiber bundle ECF and at least one low-angle helical layer is formed. In the enlarged view of FIG. 1, the first fiber bundle layer 161 is shown as one low-angle helical layer, but the fiber bundle layer in which a plurality of low-angle helical layers are stacked may be referred to as the first fiber bundle layer 161.

In the step S110 following the formation of the first fiber bundle layer 161 in the step S100, the metal powder layer 17 is formed on the surface of the first fiber bundle layer 161. In forming the metal powder layer 17, after temporarily stopping the reciprocating movement of the fiber delivery portion 132 and the rotation of the liner 10, as shown in FIG. 3, a liquid containing a metal powder such as zinc, aluminum, and stainless steel. A storage tank 250 for storing water and a spray gun 260 for spray-applying the metal powder-containing liquid of the storage tank 250 are used. In the present embodiment, the liquid water stored in the storage tank 250 is pure water containing about 90% by volume of metal powder having a particle size of 0.01 to 0.05 mm. The spray gun 260 reciprocates around the cylinder portion 11 and the dome portions 12 at both ends thereof, and also rotates around the liner axis CX. In the process of such reciprocating movement / rotation, the first first formed on the liner 10. The metal powder-containing liquid is intermittently applied toward the fiber bundle layer 161. By intermittent spray coating of the metal powder-containing liquid from the spray gun 260, the metal powder layer 17 is formed on the first fiber bundle layer 161 with a coating thickness of 0.1 mm or less. The first fiber bundle layer 161 and the metal powder layer 17 are finally formed by heating, which will be described later.

In the step S120 following the formation of the metal powder layer 17 in the step S110, it is determined whether or not the winding of the resin-containing carbon fiber bundle ECF up to the nth fiber bundle layer 16n of the fiber reinforced resin layer 16 is completed, and the winding is not completed. If this is the case, the fiber-reinforced resin layer formation in step S100 and the metal powder layer formation in step S110 are repeated. By repeating this process, a fiber-reinforced resin layer having a layered structure in which a plurality of fiber bundle layers from the first fiber bundle layer 161 to the nth fiber bundle layer 16n in which the epoxy resin EP is uncured is stacked on the outer periphery of the liner 10 16 is formed, and the metal powder layer 17 is interposed between the overlapping fiber bundle layers. When the second fiber bundle layer 162 to the nth fiber bundle layer 16n was formed following the spray coating of the metal powder-containing liquid, the metal powder-containing liquid spray-coated from the spray gun 260 was used as a resin between the overlapping fiber bundle layers. It is held by the contained carbon fiber bundle ECF.

In the present embodiment, the odd-numbered fiber bundle layer including the first fiber bundle layer 161 is used as the helical layer, and the even-numbered fiber bundle layer including the second fiber bundle layer 162 is used as the hoop layer overlapping the formed helical layer. This situation is shown in the lower part of FIG. 4, and when the even-numbered fiber bundle layer, for example, the second fiber bundle layer 162 is formed, the hoop winding is repeated at both ends of the cylinder portion in the cylinder portion 11. This forms a hoop layer. That is, by rotating the liner 10 again around the liner axis CX and reciprocating the fiber delivery portion 132 along the liner axis CX at a predetermined speed, it overlaps with the first fiber bundle layer 161 of the already formed helical layer. The hoop layer is formed by the resin-containing carbon fiber bundle ECF. In this hoop winding, the resin-containing carbon fiber bundle ECF from the fiber delivery portion 132 intersects and winds at a winding angle (fiber angle α0: for example, about 89 °) that is almost perpendicular to the liner axis CX of the cylinder portion 11. The liner rotation speed and the reciprocating speed of the fiber delivery unit 132 are adjusted so as to be attached. Then, the fiber delivery portion 132 is reciprocated along the liner axis CX direction, and the resin-containing carbon fiber bundle ECF is repeatedly wound in the range of the cylinder portion 11.

By repeating the folding back in the winding direction in the cylinder portion 11 many times, the already formed odd-th helical layer fiber bundle layer, for example, the first fiber bundle layer 161 is provided with resin-containing carbon having a high angle fiber angle αLH. The second fiber bundle layer 162 of the hoop layer in which the fiber bundle ECF is stretched in a mesh pattern is formed with the metal powder layer 17 interposed therebetween. In this case, the fiber delivery unit 132 reciprocates until at least one hoop layer is formed after the resin-containing carbon fiber bundle ECF is repeatedly wound around the entire area of the cylinder unit 11. In the enlarged view of FIG. 1, the second fiber bundle layer 162 is shown as one hoop layer, but the fiber bundle layer in which a plurality of hoop layers are stacked may be referred to as the second fiber bundle layer 162.

The change from the helical winding for forming the helical layer to the hoop winding for forming the hoop layer is made by adjusting the rotation speed of the liner 10 and the reciprocating speed of the fiber delivery portion 132. When changing from the low-angle helical winding to the hoop winding described above, the resin-containing carbon fiber bundle ECF is wound at a high angle with respect to the liner axis CX (for example, about 30 to 60 °). Helical winding can also be incorporated.

In this way, the hoop winding and the helical winding of the uncured resin-containing carbon fiber bundle ECF are properly used, so that the outer periphery of the liner 10 has the first fiber bundle layer 161 of the low-angle helical layer and the second fiber bundle of the hoop layer. The layers 162 are overlapped with the metal powder layer 17 interposed therebetween. Further, the fiber-reinforced resin layer up to the nth fiber bundle layer 16n in which the odd-numbered fiber bundle layer of the low-angle helical layer and the even-numbered fiber bundle layer of the hoop layer are alternately layered with the metal powder layer 17 interposed therebetween. 16 is formed by the FW method in a state where the epoxy resin EP is uncured.

As shown in FIG. 2, following the completion of winding of the fiber bundle determined in step S120, heating / curing of the fiber reinforced resin layer 16 (step S130) and a cross-sectional image of the fiber reinforced resin layer 16 by an X-ray CT image. The acquisition (step S140) and the thickness determination of the first fiber bundle layer 161 to the nth fiber bundle layer 16n in the fiber reinforced resin layer 16 (step S150) are sequentially executed. In the formation of the fiber reinforced resin layer 16 in step S130, the liner 10 in which the uncured fiber reinforced resin layer 16 has been formed on the outer periphery is pivotally supported in a state of being rotatable around the liner axis CX and carried into the heating furnace. .. Then, the epoxy resin of the fiber reinforced resin layer 16 is heated to 150 ° C. and thermally cured by microwave heating or hot air heating in the furnace. The liner 10 is heated while rotating around the liner axis CX, undergoes cooling curing after thermosetting the epoxy resin, and is conveyed to an X-ray imaging section in which step S140 is performed.

In step S140, cross-sectional images of a plurality of circumferential and cylindrical cross sections of the liner 10 on which the fiber reinforced resin layer 16 has been formed, that is, the high-pressure gas tank 100, are acquired non-destructively. FIG. 5 is an explanatory view schematically showing a state of acquisition of a cross-sectional image of the high-pressure gas tank 100. In acquiring the cross-sectional image of the high-pressure gas tank 100 in the circumferential direction, the high-pressure gas tank 100 is rotated around the liner axis CX, and the X-ray CT imaging device 300 is used to obtain a cross-sectional view of a plurality of locations in the cylinder portion 11 in the circumferential direction. Acquire a cross-sectional image. In acquiring the cross-sectional image of the high-pressure gas tank 100 in the cylindrical direction, the cylinder portion 11 is held horizontally while the X-ray CT imaging device 300 and the high-pressure gas tank 100 are relatively moved along the liner axis CX. A cross-sectional image in the cylindrical direction extending from the dome portion 12 on one end side to the dome portion 12 on the other end side is acquired. Next, the high-pressure gas tank 100 is rotated around the liner axis CX by a predetermined angle, and acquisition of a cross-sectional image in the cylindrical direction is repeated. The acquired cross-sectional image shows the overlapping fiber bundles such as between the first fiber bundle layer 161 and the second fiber bundle layer 162 and between the second fiber bundle layer 162 and the third fiber bundle layer 163 as shown in FIG. The image is such that the metal powder layer 17 is reflected between the layers, and the fiber bundle layers are overlapped with the metal powder layer 17 as a boundary.

In the thickness determination in step S150, the thickness of each fiber bundle layer of the first fiber bundle layer 161 to the nth fiber bundle layer 16n that overlaps with the metal powder layer 17 as a boundary is calculated from the acquired cross-sectional image, and the calculated layer thickness is calculated. Is determined to be within the specified value (specified thickness). Then, if the calculated layer thickness matches the specified value, the high-pressure gas tank 100 is sent to the next process, and the manufacturing procedure in the present embodiment is completed. On the other hand, if the calculated layer thickness is less than the specified value, the high-pressure gas tank 100 is subjected to non-rated measures (step S160), and then the high-pressure gas tank 100 is sent to the next process, and the manufacturing procedure in the present embodiment is performed. finish. As a countermeasure against this out-of-rating, resin-containing carbon fiber bundle ECF is additionally wound in the region where the calculated layer thickness is insufficient, or it is effectively used as a high-pressure gas tank with a low pressure resistance standard although the calculated layer thickness is insufficient. In order to achieve this, some discriminant measure, for example, a measure of attaching a sticker such as "for low pressure resistant standard products" can be exemplified.

In the high-pressure gas tank 100 of the present embodiment manufactured by the procedure described above, the cross-sectional images of the fiber-reinforced resin layer 16 obtained in a non-destructive manner in the circumferential direction and the cylindrical direction are taken with the metal powder layer 17 as a boundary of the first fiber bundle. It is possible to provide an image in which the layer 161 and the second fiber bundle layer 162, the second fiber bundle layer 162 and the third fiber bundle layer 163, and the like are overlapped. Since the metal powder layer 17 contains a metal powder such as zinc which is completely different from the resin-containing carbon fiber bundle ECF forming each fiber bundle layer, the obtained cross section is obtained according to the high-pressure gas tank 100 of the present embodiment. The boundary between the fiber bundle layer and the fiber bundle layer overlapping in the fiber reinforced resin layer 16 in the image can be made clear by the metal powder layer 17.

In the embodiment, since the liquid water containing a metal powder such as zinc or aluminum is intermittently spray-coated, the first fiber bundle layer 161 and the second fiber bundle layers 162 and the second are overlapped in the region where the liquid water is not applied. The fiber bundle layer 162, the third fiber bundle layer 163, and the like are made continuous with an uncured epoxy resin. Therefore, according to the high-pressure gas tank 100 of the present embodiment, it is possible to ensure the integration of the overlapping fiber bundle layers that have undergone heat curing of the uncured epoxy resin so as not to hinder the adhesion of the overlapping fiber bundle layers.

In obtaining the high-pressure gas tank 100 of the present embodiment, a metal is used in the existing manufacturing procedure in which the fiber bundle layer is sequentially formed from the first fiber bundle layer 161 to the nth fiber bundle layer 16n by winding the resin-containing carbon fiber bundle ECF. It is only necessary to incorporate a liquid water application containing powder. Therefore, according to the tank manufacturing method of the present embodiment, the high-pressure gas tank 100 in which the boundary between the overlapping fiber bundle layer and the fiber bundle layer in the fiber reinforced resin layer 16 is made clear by the metal powder layer 17 can be easily manufactured.

The present invention is not limited to the above-described embodiments, examples, and modifications, and can be realized with various configurations within a range not deviating from the gist thereof. For example, the technical features in the embodiments, examples, and modifications 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. , It is possible to replace or combine as appropriate to achieve some or all of the above effects. Further, if the technical feature is not described as essential in the present specification, it can be deleted as appropriate.

In the above-described embodiment, in forming the metal powder layer 17, liquid water containing a metal powder such as zinc or aluminum is spray-applied intermittently, but may be continuously applied. Further, liquid water containing a metal powder other than zinc or aluminum may be applied.

In the above-described embodiment, the metal powder-containing liquid water is spray-coated to form the metal powder layer 17, but the metal powder-containing liquid water is applied to the surface of the formed fiber bundle layer using a brush or the like. You may. The liquid water containing the metal powder may be applied to almost the entire surface of the formed fiber bundle layer, or the liquid water containing the metal powder may be applied in a band shape along the liner axis CX. In addition, instead of applying liquid water containing metal powder, a metal thin film having a thickness of about 0.01 to 0.05 mm may be attached to the surface of the fiber bundle layer in a strip shape along the liner axis CX. When the liquid water containing metal powder is applied in a band shape or a band-shaped metal thin film is attached to a part of the region in this way, the overlapping fiber bundle layer and the fiber in the band-shaped application region and the band-shaped metal thin film application region. The boundary of the bundle layer can be made clear. In addition, the strip-shaped coating of the liquid water containing the metal powder and the sticking of the strip-shaped metal thin film may be performed over a plurality of streaks around the axis of the liner axis CX.

10 ... Liner 11 ... Cylinder part 12 ... Dome part 16 ... Fiber reinforced resin layer 161 to 16n ... 1st fiber bundle layer to nth fiber bundle layer 16c ... Base side part 17 ... Metal powder layer 20 ... Base 30 ... Base 100 ... High-pressure gas tank 132 ... Fiber delivery part 230 ... Rotating bearing jig 250 ... Storage tank 260 ... Spray gun 300 ... X-ray CT imaging equipment CF ... Carbon fiber ECF ... Resin-containing carbon fiber bundle EP ... Epoxy resin FM ... FW device CX ... Liner Axis line LH ... Fiber angle α

Claims (1)

A high-pressure gas tank provided with a fiber-reinforced resin layer on the outer circumference of the liner.
The fiber-reinforced resin layer has a layered structure in which a plurality of fiber bundle layers covering the outer periphery of the liner are repeatedly wound around the outer periphery of the liner with a fiber bundle impregnated with a thermosetting resin.
A high-pressure gas tank in which a metal powder layer made of metal powder is provided between the fiber bundle layers that overlap in the layered structure.

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