Manufacturing method of high-pressure storage tank

Abstract

The present invention provides a method for manufacturing a high-pressure storage tank. In the method for manufacturing a high-pressure storage tank (10), in a fiber winding process, a fiber bundle (Ra) impregnated with a thermosetting resin matrix is ​​wound on the outer surface (12a) of an inner liner (12) under an applied tension (T). The fiber winding process includes a crimping process and a cutting process. In the crimping process, the terminal portion (Re) of the fiber bundle (Ra), which serves as the winding end portion, is thermally crimped to the peripheral portion (62) of the fiber bundle (Ra) wound on the inner liner (12). In the cutting process, the remaining portion (Rb) of the fiber bundle (Ra) is cut using a cutting tool (60). Accordingly, the outer peripheral surface of the high-pressure storage tank can be smoothly formed to improve the quality, and the strength of the reinforcing layer can be maintained approximately constant throughout the entire area of ​​the high-pressure storage tank.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a high-pressure storage tank having a fiber bundle wound around the outer peripheral surface of a liner. Background Art

[0002] The high-pressure storage tank is cylindrical in shape. It can be filled with high-pressure gas such as hydrogen. The high-pressure storage tank disclosed in Japanese Patent Publication No. 2021-014019 comprises an inner liner, a reinforcement layer, and a joint. The inner liner has a space for filling with high-pressure gas. The reinforcement layer is reinforced by wrapping a resin-impregnated fiber bundle around the inner liner. The joint is connected to the inner liner and has a flow path for the gas to flow.

[0003] In the case of manufacturing the high-pressure storage tank, a fiber bundle impregnated with a thermosetting resin is wound multiple times on the outer peripheral surface of the inner liner in a state where a specified tension is applied to form a protective layer. And, when the fiber bundle is wound around the outer peripheral surface of the inner liner, the fiber bundle is cut in a cutting process. Then, the end portion of the cut fiber bundle is pasted to the outermost peripheral portion of the fiber bundle already wound on the inner liner. In the bonding process, the end portion of the pasted fiber bundle is heated by an electric heater and bonded to the outermost peripheral portion. Then, in a thermal curing process, the protective layer is formed by thermally curing the thermosetting resin impregnated in the fiber bundle wound on the inner liner. Summary of the Invention

[0004] However, in the above-mentioned method for manufacturing a high-pressure storage tank, after the position of the terminal end of the fiber bundle is cut in the cutting process, the terminal end is heated and bonded to the outermost peripheral portion of the fiber bundle that has been wound around the inner liner. Therefore, in a state where tension is applied near the terminal end of the fiber bundle, the terminal end of the fiber bundle cannot be bonded to the outermost peripheral portion. As a result, when the fiber bundle is thermally cured to form a protective layer, winding disorder caused by relaxation occurs within the entire fiber bundle including the terminal end where tension is not maintained. As a result, the strength of the protective layer (reinforcement layer) decreases, or the outer peripheral surface of the protective layer becomes concave and convex, thereby deteriorating the appearance.

[0005] The technical solution of the present invention is a method for manufacturing a high-pressure storage tank, wherein the high-pressure storage tank has a reinforcement layer on the outer surface of a hollow inner liner.

[0006] It has a winding process and a reinforcement layer forming process, wherein:

[0007] In the winding process, the fiber bundle impregnated with thermosetting resin is wound on the outer surface of the inner liner under tension;

[0008] In the reinforcing layer forming step, the resin contained in the fiber bundle wound on the outer surface is thermally cured to form the reinforcing layer.

[0009] The winding process includes a crimping process and a cutting process, wherein:

[0010] In the crimping step, the terminal portion of the fiber bundle, which is the end of the winding, is thermally crimped to the outer peripheral portion of the fiber bundle wound on the inner liner;

[0011] In the cutting step, a cutting tool is used to cut the remaining portion of the fiber bundle that is close to the terminal end and not wound around the inner liner.

[0012] During the crimping process, the terminal end of the fiber bundle is heat-compressed onto the outer periphery of the fiber bundle already wound around the outer surface of the liner. This prevents the outer periphery of the reinforcing layer, where the fiber bundle is wound multiple times, from becoming uneven. Furthermore, after the terminal end is secured during the crimping process, the remaining portion of the fiber bundle near the terminal end is cut using a cutting tool during the cutting process.

[0013] As a result, the outer circumference of the high-pressure storage tank can be smoothly formed, improving its quality. Furthermore, the fiber bundle can be wound and secured to the outer surface of the inner liner while tension is applied throughout the entire area from the start to the end (terminal) of the fiber bundle winding. Consequently, the strength of the reinforcement layer can be maintained approximately constant throughout the entire area of ​​the high-pressure storage tank.

[0014] The above-mentioned objects, features, and advantages can be easily understood by the following description of the embodiments with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic structural diagram including a manufacturing apparatus for manufacturing a high-pressure storage tank according to an embodiment of the present invention.

[0016] Figure 2 yes Figure 1 Ⅱ-Ⅱ cross-sectional view.

[0017] Figure 3 Yes Figure 2 An enlarged cross-sectional view of the crimping mechanism and the vicinity of the terminal end of the fiber bundle.

[0018] Figure 4 yes Figure 3 IV-IV sectional view of FIG.

[0019] Figure 5 This is a cross-sectional view showing the thermal compression bonding step in the manufacturing process of the high-pressure storage tank.

[0020] Figure 6 Yes Figure 5An enlarged cross-sectional view of the crimping mechanism and the vicinity of the terminal end of the fiber bundle.

[0021] Figure 7 Yes Figure 6 An enlarged plan view of the vicinity of the terminal end of a fiber bundle is shown.

[0022] Figure 8 yes Figure 6 Sectional view VIII-VIII of FIG.

[0023] Figure 9 This is a cross-sectional view showing a cutting step in the manufacturing process of a high-pressure storage tank. DETAILED DESCRIPTION

[0024] The high-pressure storage tank 10 is mounted on a fuel cell vehicle, for example, and stores hydrogen gas to be supplied to the fuel cell system. Figure 1 and Figure 2 As shown, the high-pressure storage tank 10 includes an inner liner 12 , a reinforcement layer 14 , a first joint 16 and a second joint 18 .

[0025] The liner 12 is the inner layer. The liner 12 is a hollow body formed of a resin material, for example. It is formed in such a way that a high-pressure gas such as hydrogen can be accommodated inside the liner 12. The liner 12 has a cylindrical main body 20 and a roughly hemispherical plugging portion 22, which blocks both ends of the main body 20. The plugging portion 22 is provided at one axial end and the other axial end of the main body 20 along the axial direction (directions of arrows A and B). Port portions 24 are respectively provided on the two plugging portions 22, and the port portions 24 connect the inside of the liner 12 with the outside. A first joint 16 and a second joint 18 for circulating hydrogen are respectively fixed to the two port portions 24.

[0026] The main body 20 extends linearly along the axial direction (directions of arrows A and B) of the inner container 12. The blocking portion 22 is bent radially inward from one axial end and the other axial end of the main body 20.

[0027] The reinforcing layer 14 is formed of, for example, a fiber-reinforced resin R in which a resin matrix (resin) is impregnated in the fiber. The reinforcing layer 14 is the outer layer of the high-pressure storage tank 10. The reinforcing layer 14 covers the entire outer surface 12a of the main body 20 and the plugging portion 22 of the liner 12, a portion of the first joint 16, and a portion of the second joint 18. In addition, in the fiber winding process performed by the manufacturing device 26 described later, the reinforcing layer 14 winds a plurality of uncured fiber-reinforced resins R as a bundled fiber bundle Ra on the liner 12. Then, the reinforcing layer 14 is formed by curing the fiber bundle Ra (fiber-reinforced resin R) wound on the liner 12 in a thermal curing process (reinforcing layer forming process).

[0028] The first joint 16 and the second joint 18 are respectively connected to one axial end and the other axial end of the inner container 12. Supply and discharge holes (not shown) are formed in each of the first joint 16 and the second joint 18.

[0029] Next, the manufacturing apparatus 26 for manufacturing the high-pressure storage tank 10 will be described.

[0030] like Figure 1 As shown, the manufacturing device 26 includes a rotating mechanism 30, a feeding mechanism 32, a crimping mechanism 34, a detecting mechanism 36, and a cutting mechanism 38 (see Figure 9 ).

[0031] A shaft 28 is connected to the rotating mechanism 30. The shaft 28 extends through one axial end and the other axial end of the inner liner 12 and supports the inner liner 12. A feeding mechanism 32 feeds out the fiber bundle Ra wound on the outer surface 12a of the inner liner 12. A crimping mechanism 34 thermally crimps the terminal end Re of the fiber bundle Ra wound on the inner liner 12 to the reinforcing layer 14. A detection mechanism 36 detects the fiber direction (in the direction of arrow D) of the terminal end Re.

[0032] like Figure 9 As shown, the cutting mechanism 38 cuts the remaining portion Rb of the fiber bundle Ra remaining relative to the terminal portion Re, wherein the terminal portion Re is thermally compressed to the outer peripheral portion 62 of the fiber bundle Ra wound on the inner liner 12.

[0033] like Figure 1 As shown, the first end portion 28a provided at one axial end of the shaft 28 has a first connecting member 40 protruding from the interior of the inner liner 12 to one axial direction (direction of arrow A). The first connecting member 40 is fixed to the first joint 16. On the other hand, the second end portion 28b provided at the other axial end of the shaft 28 has a second connecting member 42 protruding from the interior of the inner liner 12 to the other axial direction (direction of arrow B). The second connecting member 42 is fixed to the second joint 18. The first end portion 28a and the second end portion 28b of the shaft 28 are mounted on the rotating mechanism 30. The inner liner 12 is maintained in a state where the axis of the inner liner 12 extends in a substantially horizontal direction (directions of arrows A and B). The rotating mechanism 30 is driven in this state. Accordingly, the inner liner 12 rotates together with the shaft 28.

[0034] The delivery mechanism 32 applies a predetermined tension T to the fiber bundle Ra (fiber reinforced resin R) wound on the rotating inner liner 12. In this state, the delivery mechanism 32 moves the fiber bundle Ra in a direction away from the inner liner 12 ( Figure 1 The machine is sent out in the direction of arrow B).

[0035] like Figures 1 to 8As shown, the crimping mechanism 34 is provided on the outer periphery of the main body 20 of the inner container 12. The crimping mechanism 34 can be moved in the vertical direction (directions of arrows C1 and C2) to approach or leave the inner container 12 by being driven by a cylinder device 48. Figure 2 As shown, the crimping mechanism 34 includes a crimping component 44 and a pressing component 46 .

[0036] The crimping member 44 heat-compresses the terminal portion Re of the fiber bundle Ra, which terminates the winding, to the outer peripheral portion 62 of the fiber bundle Ra already wound around the inner liner 12. The pressing member 46 separates from the crimping member 44 and presses the vicinity of the terminal portion Re toward the inner liner 12. In other words, the crimping member 44 and the pressing member 46 are able to advance and retreat in a direction perpendicular to the axis of the inner liner 12.

[0037] The crimping component 44 has a pressing surface 50 at its tip, which extends from the crimping component 44 toward the inner container 12. The cross-section of the pressing surface 50 is formed into an arc shape that is convex toward the inner container 12. A heater 52, such as an electric heater, is housed within the crimping component 44. When power is supplied to the heater 52, the heater 52 heats the tip of the crimping component 44.

[0038] The pressing member 44 is arranged perpendicular to the outer surface 12a of the inner container 12. The pressing member 44 moves toward or away from the inner container 12 by driving the cylinder device 48.

[0039] like Figures 5 to 8 As shown, when the crimping component 44 moves toward the inner liner 12, the pressing surface 50 of the crimping component 44 abuts against the terminal end portion Re of the fiber bundle Ra. Then, the crimping component 44 presses the terminal end portion Re toward the peripheral portion 62 of the fiber bundle Ra wound on the inner liner 12. In addition, at the same time, the top end portion of the crimping component 44 is heated by the heater 52. Accordingly, the terminal end portion Re is thermally crimped to the peripheral portion 62 of the fiber bundle Ra wound on the inner liner 12 by the crimping component 44. At this time, as shown Figure 2 and Figure 3 As shown, the pressing member 44 is arranged so that the cross section of the pressing surface 50 is arc-shaped when viewed from a direction perpendicular to the fiber direction (arrow D direction) of the fiber bundle Ra.

[0040] And, as Figure 6 As shown, the pressing surface 50 of the distal end portion of the pressing member 44 contacts the terminal end portion Re of the fiber bundle Ra. In this state, the pressing member 44 can swing with the contact portion between the pressing surface 50 and the terminal end portion Re as a fulcrum.

[0041] The pressing member 46 has an annular retaining portion 54 that is separated from the pressing member 44 in a direction (direction of arrow D) perpendicular to the movement direction of the pressing member 44. Driven by the cylinder device 48, the pressing member 46 approaches or moves away from the inner container 12 in the same manner as the pressing member 44. The pressing member 46 can move independently of the pressing member 44.

[0042] The holding portion 54 is formed into a substantially flat shape perpendicular to the moving direction of the pressing member 46. The holding portion 54 is centered on the pressing member 44 and is spaced apart from the pressing member 44 in a direction perpendicular to the moving direction. The holding portion 54 presses the fiber bundle Ra (fiber reinforced resin R) toward the liner 12.

[0043] like Figure 1 As shown, the detection mechanism 36 is arranged on the outside of the inner liner 12. The detection mechanism 36 is capable of detecting the fiber direction (in the direction of arrow D) of the terminal portion Re. The detection mechanism 36 has an irradiation unit 56 and a detector 58. The irradiation unit 56 irradiates the terminal portion Re of the fiber bundle Ra with light L1. When the light L1 is reflected at the terminal portion Re, reflected light L2 is generated. The detector 58 detects the reflected light L2. Based on the reflected light L2 detected by the detector 58, the fiber direction (in the direction of arrow D) of the terminal portion Re of the fiber bundle Ra spirally wound on the outer surface 12a of the inner liner 12 is determined.

[0044] like Figure 9 As shown, the cutting mechanism 38 is disposed on the outer periphery of the inner liner 12. The cutting mechanism 38 can be moved toward the outer periphery of the inner liner 12 by a moving mechanism (not shown). The cutting mechanism 38 includes a cutting tool 60, such as a cutter. By moving the cutting tool 60 toward the inner liner 12, the remaining portion Rb of the fiber bundle Ra near the terminal end Re is cut.

[0045] The cutting tool 60 of the cutting mechanism 38 moves in a direction perpendicular to the fiber direction based on the fiber direction (the direction of arrow D) of the terminal portion Re detected by the detection mechanism 36 .

[0046] Next, a description will be given of a case where the high-pressure storage tank 10 is manufactured using the above-described manufacturing apparatus 26 .

[0047] First, if Figure 1 As shown, in the high-pressure storage tank 10, the first joint 16 and the second joint 18 are respectively assembled to the two port portions 24 of the inner liner 12. Then, a fiber winding process (winding process) is performed to wind the fiber bundle Ra (fiber-reinforced resin R) onto the outer surface 12a of the inner liner 12. This forms the reinforcement layer 14 on the outer surface 12a of the inner liner 12.

[0048] In this fiber winding process, the shaft 28 is positioned between the first connector 40 and the second connector 42 attached to the first joint 16 and the second joint 18 of the inner liner 12. The inner liner 12 is then mounted on the rotating mechanism 30 with the shaft 28 positioned horizontally. By driving the rotating mechanism 30, the inner liner 12 and the shaft 28 rotate integrally. This allows a fiber bundle Ra, consisting of a plurality of fiber-reinforced resin R impregnated with a resin matrix, to be wound around the outer surface 12a of the inner liner 12.

[0049] The fiber bundle Ra is wound around the outer surface 12a of the rotating inner liner 12 in a spiral shape inclined at a predetermined angle relative to the axis of the inner liner 12 by the delivery mechanism 32. Furthermore, the fiber bundle Ra is wound around the outer surface 12a of the inner liner 12 while a predetermined tension T is applied along the fiber direction (direction indicated by arrow D).

[0050] The fiber bundle Ra is then wound so as to cover the entire body portion 20 and the two plugging portions 22 of the inner container 12. The terminal portion Re of the fiber bundle Ra, which serves as the winding end, is then located. The fiber direction (in the direction of arrow D) of the fiber bundle Ra at the terminal portion Re is detected by the detection mechanism 36 (detection step).

[0051] In this detection process, light L1 is irradiated from the irradiation unit 56 toward the terminal end Re of the fiber bundle Ra. The light L1 is reflected at the terminal end Re to generate reflected light L2. Then, the detector 58 detects the reflected light L2 resulting from the light L1 irradiated onto the terminal end Re. In addition, the fiber direction indicates the extending direction of each fiber-reinforced resin R in the fiber bundle Ra ( Figure 2 and Figure 7 The reflected light L2 is reflected at different angles depending on the fiber direction of the fiber-reinforced resin R in the terminal portion Re. The fiber direction of the fiber-reinforced resin R in the terminal portion Re is detected based on the reflected light L2.

[0052] The fiber direction (direction of arrow D) of the fiber-reinforced resin R in the terminal portion Re is detected by the detection mechanism 36. The terminal portion Re is then thermocompression-bonded to the outer peripheral portion 62 of the fiber bundle Ra wound on the outer surface 12a of the liner 12 (compression bonding step).

[0053] In this pressing process (thermo-pressing process), the fiber bundle Ra is wound around the outer surface 12a of the inner liner 12 at a predetermined tension T by the feeding mechanism 32. Figure 3 As shown, in this state, first, the crimping member 44 and the pressing member 46 of the crimping mechanism 34 are brought close to the outer peripheral portion 62 of the fiber bundle Ra wound on the outer surface 12a. By energizing the heater 52, the crimping member 44 is heated to a predetermined temperature.

[0054] The pressing member 46 is rotated based on the fiber direction (arrow D direction) of the terminal portion Re so that the extending direction of the holding portion 54 is substantially parallel to the fiber direction (see FIG. Figure 3 and Figure 7 ). At the same time, the crimping member 44 rotates integrally with the pressing member 46. Figure 3 As shown, the pressing surface 50 of the crimping member 44 is arranged along the fiber direction. Figure 3 As shown, the crimping member 44 and the pressing member 46 are moved toward the inner liner 12. Furthermore, the retaining portion 54 of the pressing member 46 contacts the surface of the fiber bundle Ra near the terminal end Re. Specifically, the retaining portion 54 maintains the front-to-back position of the terminal end Re along the fiber direction (direction indicated by arrow D). In this state, the retaining portion 54 of the pressing member 46 presses the terminal end Re of the fiber bundle Ra toward the inner liner 12, thereby maintaining the terminal end Re.

[0055] As a result, the plurality of fiber-reinforced resins R in the fiber bundle Ra are pressed against the inner liner 12, and the plurality of fiber-reinforced resins R adhere closely to each other. Furthermore, the terminal portion Re is retained inside the annular retaining portion 54. In this state, the terminal portion Re is positioned and retained, for example, at an outer peripheral portion 62 approximately near the center of the inner liner 12 in the axial direction.

[0056] Then, the crimping component 44 moves toward the inner container 12, as shown in FIG. Figure 5 and Figure 6 As shown in FIG. 4 , the tip of the crimping member 44 is substantially perpendicular to the terminal end Re of the fiber reinforced resin R located radially inward of the retaining portion 54. Figure 7 As shown, the pressing surface 50 of the crimping member 44 contacts the terminal portion Re in a manner substantially perpendicular to the fiber direction (direction of arrow D) of the terminal portion Re. As a result, the resin base material impregnated in the terminal portion Re is melted by the heat transferred from the pressing surface 50 of the crimping member 44. The molten resin base material flows along the fiber direction of the fiber bundle Ra.

[0057] After the terminal portion Re is pressed and heated by the crimping member 44, the resin base material of the terminal portion Re melts and gradually solidifies through a cross-linking reaction. The terminal portion Re is fixed to a desired location on the outer peripheral portion 62 of the fiber bundle Ra. At this time, the terminal portion Re is fixed while a predetermined tension T is applied in the fiber direction (direction indicated by arrow D) by the feed mechanism 32.

[0058] Then, after the terminal portion Re is fixed to the peripheral portion 62 of the fiber bundle Ra, the cylinder device 48 is driven to move the crimping component 44 in the direction away from the inner liner 12. Accordingly, the crimping component 44 is separated from the terminal portion Re. Next, the pressing component 46 is moved in the direction away from the inner liner 12. Accordingly, the pressing component 46 is separated from the vicinity of the terminal portion Re and the holding state near the terminal portion Re is released. At this time, as shown in FIG. Figure 5 、 Figure 6 and Figure 8 As shown, even if the pressing member 46 is separated from the terminal end portion Re, the terminal end portion Re does not float radially outward from the outer peripheral portion 62 .

[0059] In addition, after the pressing surface 50 of the crimping member 44 is brought into contact with the terminal portion Re, Figure 6 As shown by the double-dashed line, the crimping member 44 can be swung along the fiber direction (direction of arrow D) with the contact surface between the pressing surface 50 and the terminal portion Re as a fulcrum. Figure 6 As shown, the terminal portion Re abuts within a predetermined range E along the fiber direction (direction of arrow D) from the location where the tip of the crimping member 44 abuts approximately perpendicularly. Consequently, the pressing surface 50 of the crimping member 44 presses and heats the predetermined range E of the terminal portion Re. Therefore, compared to a case where the crimping member 44 abuts approximately perpendicularly against the terminal portion Re, the terminal portion Re can be fixed to the outer peripheral portion 62 of the fiber bundle Ra within a wider predetermined range E.

[0060] In the above-mentioned crimping process, Figure 5 and Figure 6 As shown, the terminal end Re of the fiber bundle Ra is pressed toward the inner liner 12 by the pressing member 46. The terminal end Re is thermally pressed while being pressed toward the inner liner 12 by the pressing member 44. Therefore, the fixed portion (terminal end Re) of the fiber reinforced resin R does not float radially outward of the inner liner 12, thereby preventing it from forming an uneven shape.

[0061] In addition, the cross section of the pressing surface 50 of the pressing member 44 is formed into an arc shape. Figure 7 As shown, when the terminal portion Re of the fiber bundle Ra is heat-compressed to the peripheral portion 62 of the fiber bundle Ra already wound around the liner 12, the fiber-reinforced resin R at the terminal portion Re is prevented from spreading in a direction perpendicular to the fiber direction (direction indicated by arrow D). Furthermore, when the fiber bundle Ra (fiber-reinforced resin R) is heated by the tip of the crimping member 44, the resin matrix impregnated in the fiber bundle Ra melts and flows in the fiber direction. Therefore, with the fiber-reinforced resins R at the terminal portion Re close to each other, the terminal portion Re is heat-compressed to the peripheral portion 62 of the fiber bundle Ra.

[0062] Next, a portion (remaining portion Rb) closer to the feed mechanism 32 than the terminal end portion Re of the fiber bundle Ra fixed in the crimping step is cut (cutting step).

[0063] like Figure 9 As shown, in this cutting process, after the tension T of the fiber bundle Ra is relaxed by the feed mechanism 32, the inner liner 12 is rotated counterclockwise. Then, between the terminal portion Re and the feed mechanism 32, the pedestal 64 is inserted between the remaining portion Rb and the inner liner 12. The flat surface of the pedestal 64 is arranged to abut against the lower surface of the remaining portion Rb.

[0064] Next, based on the fiber direction (arrow D direction) of the terminal portion Re detected by the detection mechanism 36, the cutting tool 60 rotates in a manner substantially orthogonal to the fiber direction. The cutting tool 60 is arranged at a position above the base 64 across the remaining portion Rb, and then the cutting tool 60 moves toward the remaining portion Rb and the base 64 side (cutting direction). Then, at the boundary position between the remaining portion Rb and the terminal portion Re, which is a predetermined distance away from the terminal portion Re toward the delivery mechanism 32, the remaining portion Rb of the fiber bundle Ra is cut by the cutting tool 60 in a direction substantially orthogonal to the fiber direction of the fiber bundle Ra. Accordingly, the remaining portion Rb of the fiber bundle Ra is cut while the terminal portion Re is fixed to the peripheral portion 62 of the fiber bundle Ra. While the fiber bundle Ra is maintained under tension T, the terminal portion Re is fixed to the peripheral portion 62 of the fiber bundle Ra wound on the inner liner 12.

[0065] Finally, the remaining portion Rb of the fiber-reinforced resin R is cut in the cutting step, and then the fiber-reinforced resin R wound on the outer surface 12a of the liner 12 is thermally cured to form the reinforcement layer 14 (thermal curing step).

[0066] In this heat curing process, the inner liner 12 is removed from the rotating mechanism 30 of the manufacturing device 26 together with the shaft 28. Then, the inner liner 12 wrapped with the fiber bundle Ra is moved into a heating furnace not shown. In the heating furnace, the inner liner 12 is heated to a predetermined temperature to cure the fiber bundle Ra (fiber reinforced resin R). Accordingly, a reinforcing layer 14 is formed by laminating the fiber bundle Ra on the outer surface 12a of the inner liner 12 and forming a smooth surface including the terminal portion Re. Then, the manufacture of the high-pressure storage tank 10 in which the outer periphery of the inner liner 12 is covered with the reinforcing layer 14 is completed.

[0067] In the above-described method for manufacturing the high-pressure storage tank 10, a tension T is applied to the fiber bundle Ra wound around the inner liner 12 during the fiber winding step. In this state, during the crimping step, the terminal end Re of the fiber bundle Ra is thermally crimped to the outer peripheral portion 62 of the fiber bundle Ra already wound around the outer surface 12a of the inner liner 12. Therefore, in the high-pressure storage tank 10, the outer peripheral surface of the reinforcing layer 14, around which the plurality of fiber bundles Ra are wound, is smooth, without forming irregularities.

[0068] Furthermore, the terminal portion Re can be fixed to the outer peripheral portion 62 of the fiber bundle Ra while tension T is applied to the terminal portion Re. Therefore, the strength of the reinforcing layer 14 at and near the terminal portion Re can be maintained equal to the strength of the portion other than the terminal portion Re. Consequently, the strength of the reinforcing layer 14 can be maintained substantially constant throughout the entire range of the reinforcing layer 14 wrapped around the liner 12.

[0069] As described above, in this embodiment, in the fiber winding step (winding step), a fiber bundle Ra, which is formed by bundling a fiber-reinforced resin R impregnated with a thermosetting resin matrix, is wound around the outer surface 12a of the hollow liner 12 under an applied tension T. Then, in the thermal curing step, the resin matrix contained in the fiber bundle Ra wound around the outer surface 12a of the liner 12 is thermally cured to form the reinforcement layer 14.

[0070] In the fiber winding step, the terminal portion Re of the fiber bundle Ra, which is the end of the winding, is thermally pressed together with the peripheral portion 62 of the fiber bundle Ra already wound around the outer surface 12a of the liner 12. Therefore, the outer peripheral surface of the reinforcing layer 14 around which the plurality of fiber bundles Ra are wound is not formed into an uneven shape.

[0071] During the fiber winding process, the terminal end portion Re, to which tension T is applied, is secured to the outer peripheral portion 62 of the fiber bundle Ra already wound around the inner liner 12 through a crimping process. Thereafter, the fiber bundle Ra is cut through a cutting process. Thus, the fiber bundle Ra is wound around the inner liner 12 while tension T is applied to the entire region from the start of winding of the fiber bundle Ra around the inner liner 12 to the terminal end portion Re, which serves as the winding end. This ensures that the fiber bundle Ra is securely secured.

[0072] As a result, the outer peripheral surface of the high-pressure storage tank 10 can be smoothly formed, improving its quality. The strength of the reinforcing layer 14 can be maintained substantially constant throughout the entire area of ​​the high-pressure storage tank 10. Therefore, even when the liner 12 expands or contracts with the supply or discharge of high-pressure gas in the high-pressure storage tank 10, it is possible to suppress the peeling of the fiber bundle Ra (fiber-reinforced resin R) based on the terminal end Re.

[0073] During the crimping step, the heated crimping member 44 presses the terminal end Re of the fiber bundle Ra radially inward of the inner liner 12. This allows the fiber bundle Ra, which has been wound around the outer surface 12a of the inner liner 12, to be thermally crimped to the terminal end Re. Consequently, the crimping member 44 effectively thermally crimps and secures the terminal end Re to the outer peripheral portion 62 of the fiber bundle Ra.

[0074] The fiber winding process includes a detection step for detecting the fiber direction (direction of arrow D) of each fiber-reinforced resin R in the terminal portion Re of the fiber bundle Ra. Based on the fiber direction detected in this detection step, the pressing direction of the pressing surface 50 of the crimping component 44 pressing the fiber bundle Ra in the crimping process and the cutting direction of the cutting tool 60 cutting the fiber bundle Ra in the cutting process are changed. Accordingly, in the crimping process, the crimping component 44 is brought into contact with the terminal portion Re in a manner substantially perpendicular to the fiber direction (direction of arrow D) of the terminal portion Re, thereby reliably thermally crimping the terminal portion Re. In addition, in the cutting process, the cutting tool 60 is arranged orthogonally to the fiber direction of the terminal portion Re, thereby reliably cutting the remaining portion Rb of the fiber bundle Ra near the terminal portion Re in a direction orthogonal to the fiber direction.

[0075] The top end of the crimping component 44 has a pressing surface 50 with an arc-shaped cross section, and the pressing surface 50 presses the terminal portion Re in a state arranged along the fiber direction (arrow D direction) of the fiber bundle Ra. In addition, the pressing surface 50 is brought into contact with the terminal portion Re, and the crimping component 44 is made to press the terminal portion Re in a manner that swings along the fiber direction. Accordingly, in the terminal portion Re, it is possible to suppress the terminal portion Re from expanding in a direction that is roughly perpendicular to the fiber direction of each fiber-reinforced resin R. In addition, in the terminal portion Re, the resin base material impregnated in the fiber bundle Ra melts and flows along the fiber direction (arrow D direction). Therefore, it is possible to suppress the separation of each fiber-reinforced resin R in the terminal portion Re, so that the terminal portion Re can be reliably hot-pressed to the peripheral portion 62 of the fiber bundle Ra.

[0076] In contrast, when the fiber bundle Ra is thermally compressed using a compression member 44 having a flat tip, for example, the fiber bundle Ra expands in a direction substantially perpendicular to the fiber direction (direction indicated by arrow D), creating gaps between the fiber-reinforced resins R. Furthermore, the resin matrix impregnated in the fiber bundle Ra melts and flows in a direction perpendicular to the fiber direction. Consequently, the fiber-reinforced resins R are more likely to separate from each other at the thermally compressed portion. Consequently, the strength of the reinforcing layer 14 near the terminal end Re is reduced.

[0077] During the crimping process, the area near the terminal portion Re is pressed against the inner liner 12 by the pressing member 46 of the crimping mechanism 34. This allows the pressing member 46 to reliably bring the area near the terminal portion Re into close contact with the peripheral portion 62. Furthermore, the fibers R near the terminal portion Re can be brought into close proximity with one another. Therefore, when the crimping member 44 is thermally crimping the terminal portion Re, separation of the fibers R at the terminal portion Re can be suppressed, allowing the terminal portion Re to be reliably thermally crimped to the peripheral portion 62 of the fiber bundle Ra.

[0078] In addition, the present invention is not limited to the above-described embodiment, and various structures can be adopted without departing from the gist of the present invention.

Claims

1. A method for manufacturing a high-pressure storage tank (10), wherein the high-pressure storage tank (10) has a reinforcement layer (14) on the outer surface (12a) of a hollow inner liner (12), characterized in that: It has a winding process and a reinforcement layer forming process, wherein: In the winding step, a fiber bundle (Ra) impregnated with a thermosetting resin is wound around the outer surface of the inner liner under tension; In the reinforcing layer forming step, the resin contained in the fiber bundle wound around the outer surface is thermally cured to form the reinforcing layer. The winding process includes a crimping process and a cutting process, wherein: In the crimping step, a terminal portion (Re) of the fiber bundle as a winding end portion is thermally crimped to an outer peripheral portion of the fiber bundle wound on the inner liner by a crimping component (44) while tension is applied to the fiber bundle. In the cutting process, the remaining portion (Rb) of the fiber bundle close to the terminal portion and not wound around the inner container is cut by a cutting tool (60). In the crimping step, the terminal portion is thermally crimped to the outer peripheral portion of the fiber bundle while the portion of the fiber bundle pressed by the crimping member is compressed by a pressing member on both sides along the fiber direction of the fiber bundle.

2. The method for manufacturing a high-pressure storage tank according to claim 1, wherein: In the crimping step, the terminal portion is pressed from the outside of the inner liner toward the inner liner by the crimping component (44), thereby thermally crimping the terminal portion to the outer peripheral portion of the fiber bundle.

3. The method for manufacturing a high-pressure storage tank according to claim 1 or 2, characterized in that: The winding step includes a detection step, wherein in the detection step, the fiber direction of the fiber bundle at the terminal portion is detected. Based on the fiber direction detected by the detection step, at least one of the orientation of the pressing surface (50) of the crimping member and the cutting direction of the fiber bundle is changed.

4. The method for manufacturing a high-pressure storage tank according to claim 3, wherein: The pressing surface is formed to have an arcuate cross-section convex toward the fiber bundle, and presses the fiber bundle while being along the fiber direction of the fiber bundle.

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