Cans and their manufacturing methods

Abstract

This invention provides a can that ensures strength and reduces the amount of fiber bundles, and a method for manufacturing the same. In a can having a main body capable of filling the interior with gas, the main body includes a hollow cylindrical liner and a fiber bundle layer covering the outer surface of the liner. The fiber bundle layer has an inner layer, an outer layer, and an intermediate layer disposed between the inner and outer layers, with the end of the intermediate layer located axially inward than the end of the fiber bundle layer.

Description

Technical Field

[0001] This application relates to tanks and methods of manufacturing them. Background Technology

[0002] For high-pressure gas tanks containing hydrogen and the like, it is known that there are tanks with a fiber bundle layer disposed in a hollow cylindrical liner. For example, Patent Document 1 discloses a pressure vessel that includes a liner filled with gas inside, a reinforcing portion formed using fiber-reinforced resin in contact with the outer surface of the liner and covering the liner from the outside, and a specified interface component.

[0003] Patent Document 1: Japanese Patent Application Publication No. 2020-112189

[0004] Typically, the can body is a hollow cylinder. The can body comprises a torso, a narrow-diameter end, and a shoulder connecting them. The can body can be manufactured using a weaving method that stitches fiber bundles into the inner lining surface. In this case, the amount of fiber bundles is the same in both the torso and the narrow-diameter end. The amount of fiber bundles is determined based on the strength of the torso, therefore the narrow-diameter end, with its smaller outer diameter, has an excess of fiber bundles. Summary of the Invention

[0005] Therefore, the main objective of this disclosure is to provide a can that ensures strength and reduces the amount of fiber bundles, and a method for manufacturing the same.

[0006] As one way to solve the above-mentioned problems, this disclosure provides a canister having a canister body capable of filling gas into the interior. The canister body includes: a hollow cylindrical liner; and a fiber bundle layer covering the outer surface of the liner. The fiber bundle layer has an inner layer, an outer layer, and an intermediate layer disposed between the inner layer and the outer layer. The end of the intermediate layer is located axially inward than the end of the fiber bundle layer.

[0007] The aforementioned can may also include an interface component disposed at the small-diameter end of the can body. In this case, the end of the intermediate layer may also be located axially inward than the interface component. The fiber bundle layer may also have an adhesive layer, which is located inside the intermediate layer, near the end of the intermediate layer.

[0008] As one approach to solving the aforementioned problems, this disclosure provides a method for manufacturing a can, wherein the can includes a can body portion capable of filling gas into its interior. The method includes a can body portion manufacturing step comprising a fiber bundle layer disposed on the outer surface of a hollow cylindrical liner, the fiber bundle layer having an inner layer, an outer layer, and an intermediate layer disposed between the inner and outer layers. The can body portion manufacturing step includes: an inner layer placement step, in which an inner layer is disposed on the outer surface of the liner; an intermediate layer placement step, in which an intermediate layer is disposed on the outer surface of the inner layer; a cutting step, in which the intermediate layer is cut such that the end of the intermediate layer is located axially inward of the end of the fiber bundle layer; and an outer layer placement step, in which an outer layer is disposed on the outer surfaces of the inner and intermediate layers.

[0009] The manufacturing method described above may also include an interface component configuration step, which involves configuring an interface component at the small-diameter end of the can body after the can body manufacturing step. In this case, during the cutting step, the intermediate layer may be cut such that the end of the intermediate layer is located axially inward than the interface component.

[0010] The manufacturing process of the can body may also include an adhesive layer preparation step between the intermediate layer preparation step and the cutting step. In this case, during the adhesive layer preparation step, an adhesive layer may be formed inside the intermediate layer, and this adhesive layer is located axially inward of the cutting position of the intermediate layer that is cut in the cutting step, and is located near the cutting position.

[0011] The can disclosed herein ensures strength while reducing the amount of fiber bundles. Furthermore, the manufacturing method of the can disclosed herein allows for the production of cans that ensure strength while reducing the amount of fiber bundles. Attached Figure Description

[0012] Figure 1 This is a simplified cross-sectional view focusing on the end of tank 1000.

[0013] Figure 2 This is a simplified cross-sectional view focusing on the end of the main body 100 of the tank.

[0014] Figure 3 It is a simplified cross-sectional view of the end of an existing tank.

[0015] Figure 4 (A) is a cross-sectional view of the inner lining 110, in which the inner layer 124 and the intermediate layer 125 are arranged.

[0016] Figure 4 (B) in the middle is composed of Figure 4 Enlarged view of the portion enclosed by the dashed line in (A).

[0017] Figure 4 (C) in the diagram is a cross-sectional view with the outer layer 126 further configured.

[0018] Figure 5 This is a flowchart of one embodiment of the manufacturing method.

[0019] Figure 6 This is a flowchart of process S1, the manufacturing process of the main body of the can.

[0020] Figure 7 This is a simplified diagram of process S1 in the manufacturing of the main body of the can.

[0021] Explanation of reference numerals in the attached figures:

[0022] 100…Can body; 101…Torso; 102…Shoulder; 103…Small diameter end; 110…Inner liner; 111…Inner liner torso; 112…Inner liner shoulder; 113…Inner liner small diameter end; 114…Insertion ring; 120…Fiber bundle layer; 121…Fiber bundle layer torso; 122…Fiber bundle layer shoulder; 123…Fiber bundle layer small diameter end; 124…Inner layer; 125…Intermediate layer; 125a…End; 126…Outer layer; 127…Adhesive layer; 200…Interface component; 300…Manifold. Detailed Implementation

[0023] [Can]

[0024] The can of this disclosure will be described using a can 1000 as one embodiment. Figure 1 The diagram shows a simplified cross-sectional view focusing on the end of tank 1000. Figure 2 The diagram shows a simplified cross-sectional view focusing on the end of the main body 100 of the tank.

[0025] The canister 1000 includes a canister body 100, an interface component 200, and a manifold 300. The canister body 100 is capable of being filled with gas. The interface component 200 is disposed at the small-diameter end 130 of the canister body 100. The manifold 300 is a component that covers the interface component 200 and closes the opening 103a of the canister body 100.

[0026] <Can body 100>

[0027] The main body 100 of the tank can be filled with gas. The type of gas is not particularly limited. For example, hydrogen and natural gas can be used. In addition, the gas is usually filled into the main body 100 of the tank under high pressure.

[0028] like Figure 1As shown, the can body 100 has a hollow cylindrical shape. The can body 100 includes a torso 101, a shoulder 102, and a small-diameter end 103. The torso 101 is the part with the largest outer diameter and extends axially along the can body 100. The small-diameter end 103 has an outer diameter smaller than that of the torso and is the part corresponding to the end of the can body 100. The small-diameter end 103 may be provided only on one side of the can body 100 or on both sides. The small-diameter end 103 has an opening 103a that communicates with the interior of the can body 100. The opening 103a is closed by a manifold 300. The shoulder 102 is the part that connects the torso 101 and the small-diameter end 103, and is formed such that its outer diameter decreases outward in the axial direction.

[0029] Here, axial direction refers to the direction through the central axis of the tank body 100. Figure 1 The axis in the middle is the left-right direction.

[0030] The main body 100 of the tank has a hollow cylindrical inner liner 110 and a fiber bundle layer 120 covering the outer side of the inner liner 110.

[0031] (Liner 110)

[0032] The inner liner 110 is formed of resin materials such as nylon. The inner liner 110 is the innermost layer of the can body and is the basis for the shape of the can body 100. Therefore, the inner liner 110 has portions corresponding to the body 101, shoulder 102, and small diameter end 103 of the can body 100 (inner liner body 111, inner liner shoulder 112, and inner liner small diameter end 113).

[0033] like Figure 2 As shown, the liner 110 has an insertion ring 114 near the small-diameter end 113. The insertion ring 114 is a cylindrical component that serves to prevent the small-diameter end 103 of the can body 100 from deforming (opening) due to the internal pressure of the filled gas, thereby compromising the airtightness. Therefore, the insertion ring 114 is provided at least at the small-diameter end 113 of the liner. Additionally, as... Figure 2 As shown, the insertion ring 114 can also be formed from the end 113 of the inner liner diameter in a manner that extends throughout the shoulder 112. That is, it can also be configured such that one end 114a of the insertion ring 114 is disposed at the end 113 of the inner liner diameter, and the other end 114b is disposed at the shoulder 112 of the inner liner. The position of the other end 114b of the insertion ring 114 is related to the position of the end 122a of the intermediate layer 125, which will be described in detail later.

[0034] (Fiber bundle layer 120)

[0035] The fiber bundle layer 120 is the outermost layer of the can body and constitutes the external shape of the can body 100. Therefore, the fiber bundle layer 120 has portions corresponding to the body 101, shoulder 102 and small diameter end 103 of the can body 100 (fiber bundle layer body 121, fiber bundle layer shoulder 122 and fiber bundle layer small diameter end 123).

[0036] The fiber bundle layer 120 is formed of fiber-reinforced resin such as carbon fiber. Typically, the fiber bundle layer 120 is formed by weaving a fiber bundle, in which multiple fibers of the reinforcing resin are bundled together, into the outer surface of the liner 110. The number of fibers of the reinforcing resin in the fiber bundle is not particularly limited, but is, for example, 10 or more and 100 or less. The weaving of the fiber bundle is performed multiple times. Therefore, the fiber bundle layer 120 is formed by stacking multiple single layers (fiber bundle monolayers) of the woven fiber bundles.

[0037] Because the fiber bundle layer 120 is formed in this way, its layer structure cannot be distinguished at a glance. However, in this disclosure, the fiber bundle layer 120 is suitably divided into an inner layer 124, an intermediate layer 125, and an outer layer 126 according to its function. Therefore, in this disclosure, the fiber bundle layer 120 includes an inner layer 124, an intermediate layer 125, and an outer layer 126.

[0038] The inner layer 124 is the innermost layer of the fiber bundle layer 120. The inner layer 124 covers the entire outer surface of the liner 110. As described later, the fiber bundle layer 120 may be manufactured by cutting a portion of the intermediate layer 125. In this case, the inner layer 124 serves to protect the liner 110 from the load incurred during the cutting of the intermediate layer 125. The number of fiber bundle monolayers in the inner layer 124 can be appropriately set according to the purpose. For example, the number of fiber bundle monolayers in the inner layer 124 may be more than the number of fiber bundle monolayers in the outer layer 126. Specifically, the number of fiber bundle monolayers in the inner layer 124 may be more than one layer and less than five layers.

[0039] Intermediate layer 125 is a layer disposed between inner layer 124 and outer layer 126. For example... Figure 2As shown, the end 125a of the intermediate layer 125 is located axially inward of the end 120a of the fiber bundle layer 120 (the end 124a of the inner layer 124 and the end 126a of the outer layer 126). That is, the intermediate layer 125 does not cover the entire outer surface of the inner layer 124. The intermediate layer 125 is disposed on the outer surface of the inner layer 124, excluding the end 120a side of the fiber side layer 120. By disposing the intermediate layer 125 in this way, the amount of fiber bundles used in the fiber bundle layer 120 can be reduced. Thus, the intermediate layer 125 has the function of reducing the amount of fiber bundles used in the fiber bundle layer 120. In addition, since the intermediate layer 125 is present in the fiber bundle layer body 121 as in the past, the strength of the can body 100 can be ensured.

[0040] In addition, to ensure the strength of the can body 100, the intermediate layer 125 needs to be disposed at least in the portion corresponding to the torso 101 of the inner layer 124. Therefore, the end 125a of the intermediate layer 125 is located axially inward of the end 120a of the fiber bundle layer 120, and axially outward of the torso 101 (shoulder 102 or small diameter end 103).

[0041] like Figure 2 As shown, the end 125a of the intermediate layer 125 can also be located axially inward of the interface component 200 (specifically, axially inward of the end 200a of the interface component 200). This allows for a reduction in the outer diameter of the small-diameter end 103 of the can body 100. Furthermore, it allows for a reduction in the outer diameter of the interface component 200 and the insertion hole 310 of the manifold 300. Additionally, the end 125a of the intermediate layer 125 can also be positioned within the area overlapping with the insertion ring 114. In other words, the end 125a of the intermediate layer 125 can also be positioned axially inward of one end 114a of the insertion ring 114 and axially outward of the other end 114b. As described later, the fiber bundle layer 120 may be manufactured via a process of cutting a portion of the intermediate layer 125 (cutting process S14). In this case, the insertion ring 114 can protect the liner 110 from the load during the cutting of the intermediate layer 125.

[0042] Therefore, the end 125a of the intermediate layer 125 can also be positioned axially inward of the interface component 200 and axially outward of the other end 114b of the insertion ring 114. Figure 2 (W). As a result, the outer diameter of the small-diameter end 103 of the tank body 100 can be reduced, and the inner liner 110 can be protected from the load when the intermediate layer 125 is cut. Furthermore, the amount of fiber bundles used for the fiber bundle layer 120 can be reduced.

[0043] To illustrate the effects of the aforementioned intermediate layer 125 in detail, a comparison is made with existing tanks. Figure 3The diagram shows a simplified cross-sectional view focusing on the end of an existing tank. (See diagram below.) Figure 3 As shown, in the existing can, the end P of the intermediate layer is positioned at the end of the fiber bundle layer, and the intermediate layer covers the entire surface of the inner layer. Therefore, compared to can 1000, the outer diameter of the small-diameter end of the can body of the existing can is larger, and the amount of fiber bundles used for the fiber bundle layer is also increased. Therefore, the existing can cannot achieve the aforementioned effect.

[0044] The intermediate layer 125 is used to reduce the number of fiber bundle monolayers at the small-diameter end 123 of the fiber bundle layer. Therefore, the number of fiber bundle monolayers in the intermediate layer 125 can be appropriately set according to the purpose. For example, the number of fiber bundle monolayers in the intermediate layer 125 is greater than the number of fiber bundle monolayers in the inner layer 124 and the outer layer 126. Specifically, it can be 3 or more layers and 10 or less.

[0045] The outer layer 126 is located at the outermost layer of the fiber bundle layer 120 and covers the outer surfaces of the intermediate layer 125 and the inner layer 124 (the portion of the inner layer 124 not covered by the intermediate layer 125). The outer layer 126 has the function of suppressing the opening of the ends 125a of the intermediate layer 125, because the opening of the ends 125a is a cause of reduced strength of the can body. The number of fiber bundle monolayers in the outer layer 126 can be appropriately set according to the purpose. For example, the number of fiber bundle monolayers in the outer layer 126 can be less than the number of fiber bundle monolayers in the inner layer 124. Specifically, the number of fiber bundle monolayers in the outer layer 126 can be more than one layer and less than five layers.

[0046] like Figure 2 As shown, the fiber bundle layer 120 may also have an adhesive layer 127 inside the intermediate layer 125 and near the end 125a of the intermediate layer 125. This allows each fiber bundle contained in the intermediate layer 125 to be bonded individually, further suppressing the opening of the end 125a. When the adhesive layer 127 is provided at the end 125a, it becomes difficult to cut the intermediate layer 125 as described later. Therefore, the adhesive layer 127 is positioned at a location other than where the intermediate layer 125 is to be cut. The material constituting the adhesive layer 127 is not particularly limited; any material capable of bonding the intermediate layer 125 to the inner layer 124 is acceptable. For example, a known adhesive can be appropriately used.

[0047] Furthermore, since the adhesive layer 127 is an arbitrary component, the fiber side layer 120 may not have an adhesive layer 127. This is because even without the adhesive layer 127, the outer layer 126 can suppress the opening of the end 125a of the intermediate layer 125.

[0048] (Layered structure)

[0049] In addition, the layered structure of the main body 100 of the tank will be described. Figure 4 A is a cross-sectional view of the inner lining 110, which is provided with an inner layer 124 and an intermediate layer 125. Figure 4 B is from Figure 4 An enlarged view of the area enclosed by the dashed line A. Figure 4 C is a sectional view further configured with the outer layer 126. For example... Figure 4 As shown in Figure A, the end 125a of the intermediate layer 125 is positioned axially inward of the end 124a of the inner layer 124. Here, when the end 125a of the intermediate layer 125 is formed by cutting the intermediate layer 125, as... Figure 4 As shown in Figure B, the ends of the fiber bundle monolayer forming the intermediate layer 125 are exposed, making it prone to budging at the ends 125a. Therefore, as... Figure 4 As shown in Figure C, by further configuring the outer layer 126 and covering the entire intermediate layer 125 with the outer layer 126, the opening of the ends 125a of the intermediate layer 125 is suppressed. Thus, in order to reduce the amount of fiber bundles and suppress opening, the fiber bundle layer consists of three layers. This layer structure can be distinguished, for example, based on cross-sectional CT images.

[0050] <Interface Component 200>

[0051] The interface component 200 is disposed at the small-diameter end 103 of the tank body 100 and serves to fix the manifold to the tank body 100. The outer surface of the interface component 200 may also have multiple grooves for threaded engagement with the manifold 300. Such an interface component 200 can use known interface components.

[0052] <Manifold 300>

[0053] The manifold 300 is a component (cover) used to connect to the interface component 200 and close the opening 103a of the can body 100. By configuring the manifold 300, the gas filling the interior of the can body 100 can be sealed. Figure 1 As shown, the manifold 300 has an insertion hole 310 for inserting the small-diameter end 103 of the tank body 100 and the interface component 200. The side of the insertion hole 310 may also have multiple grooves for threaded engagement with the interface component. This manifold 300 can use known manifolds.

[0054] The can of this disclosure has been described above using one embodiment. The end of the intermediate layer of the can of this disclosure is located axially inward of the end of the fiber bundle layer. Furthermore, the fiber bundle layer in the body is the same as in conventional cans. Therefore, according to the can of this disclosure, strength can be ensured, and the amount of fiber bundles can be reduced.

[0055] [Can manufacturing method]

[0056] The manufacturing method of the can disclosed herein will be described using a manufacturing method of a can 1000 as one embodiment. Figure 5 A flowchart illustrating one embodiment of a manufacturing method is shown. Figure 6 The flowchart shows the manufacturing process S1 of the tank body. Figure 7 The diagram shows a simplified diagram of the manufacturing process S1 for the main body of the tank.

[0057] One embodiment of the manufacturing method is a method for manufacturing a can 1000 having a can body 100 capable of filling gas into its interior. For example... Figure 5 As shown, one embodiment of the manufacturing method includes a tank body manufacturing step S1, an interface component configuration step S2, and a manifold configuration step S3.

[0058] <Can body manufacturing process S1>

[0059] The can body manufacturing process S1 involves configuring a fiber bundle layer 120 that covers the outer surface of the hollow cylindrical liner 110. The can body 100 can be manufactured using this process S1. The can body manufacturing process S1 is primarily performed by weaving fiber bundles into the surface of the liner 110, but includes a step of cutting the intermediate layer 125 along the way. The method of weaving the fiber bundles is not particularly limited, but a weaving method can be used, for example.

[0060] like Figure 6 As shown, the manufacturing process S1 of the can body includes an inner layer configuration process S11, an intermediate layer configuration process S12, an adhesive layer configuration process S13, a cutting process S14, and an outer layer configuration process S15.

[0061] (Inner layer configuration process S11)

[0062] The inner layer configuration process S11 is the process of configuring the inner layer 124 on the outer surface of the inner liner 110. The inner layer 124 is formed integrally on the outer surface of the inner liner 110 by weaving fiber bundles into the outer surface of the inner liner 110.

[0063] (Intermediate layer configuration process S12)

[0064] The intermediate layer configuration process S12 is performed after the inner layer configuration process S11. The intermediate layer configuration process S12 is a process of configuring the intermediate layer 125 on the outer surface of the inner layer 124. The intermediate layer 125 is formed integrally on the outer surface of the inner layer 124 by weaving fiber bundles into the outer surface of the inner layer 124.

[0065] (Adhesive layer preparation process S13)

[0066] The adhesive layer preparation step S13 is optional and may not be performed. When the adhesive layer preparation step S14 is performed, in the can body manufacturing step S1, the adhesive layer preparation step S13 is placed between the intermediate layer preparation step S13 and the cutting step S14. The adhesive layer preparation step S13 is a step in which the adhesive layer 127 is formed inside the intermediate layer 125, axially inward and near the cutting position X of the intermediate layer 125 that is cut in the cutting step S14.

[0067] The method for forming the adhesive layer 127 is not particularly limited. For example, such as... Figure 7 As shown, the adhesive layer 127 is formed by dripping adhesive A, which constitutes the adhesive layer 127, onto the outer surface of the intermediate layer 125, thereby allowing adhesive A to permeate into the interior of the intermediate layer 125. By forming the adhesive layer 127 inside the intermediate layer 125, each fiber bundle of the intermediate layer 125 is bonded in a single layer, and the opening of the ends 125a is further suppressed.

[0068] (Cutting process S14)

[0069] The cutting step S14 is performed after the intermediate layer configuration step S12 or the adhesive layer configuration step S13. The cutting step S14 is a process of cutting the intermediate layer 125 such that the end 125a of the intermediate layer 125 is located axially inwards from the end 120a of the fiber bundle layer 120. The cutting is performed circumferentially throughout the intermediate layer 125. The method for cutting the intermediate layer 125 is not particularly limited, but a method using a disc-shaped cutter can be cited as an example.

[0070] like Figure 7 As shown, the cutting process S14 can cut the intermediate layer 125 such that the end 125a of the intermediate layer 125 is located axially inward of the interface member 200. This reduces the outer diameter of the small-diameter end 103 of the tank body 100, thereby reducing the outer diameter of the interface member 200. In other words, the interface member 200 can be miniaturized. Furthermore, the intermediate layer 125 can be cut such that the end 125a of the intermediate layer 125 overlaps with the insertion ring 114. This protects the liner 110 from the load during cutting via the insertion ring 114.

[0071] (Outer layer configuration process S15)

[0072] The outer layer configuration process S15 is performed after the cutting process S14. The outer layer configuration process S15 is a process of configuring the outer layer 126 on the outer surface of the intermediate layer 125 and the inner layer 124 (the portion of the inner layer 124 not covered by the intermediate layer 125). The outer layer 126 is formed integrally on the outer surface of these layers by weaving fiber bundles into the outer surface of the intermediate layer 125 and the inner layer 124.

[0073] <Interface component configuration process S2>

[0074] The interface component configuration step S2 is performed after the tank body manufacturing step S1. The interface component configuration step S2 is the process of configuring the interface component 200 at the small-diameter end 103 of the tank body 100. The method of configuring the interface component 200 at the small-diameter end 103 of the tank body 100 is known.

[0075] <Manifold Process S3>

[0076] The manifold process S3 is performed after the interface component configuration process S2. The manifold process S3 is a process of configuring the manifold 300, which is threadedly engaged with the interface component 200 to close the opening 103a of the tank body 100. The method for configuring the manifold 300 is known.

[0077] The manufacturing method of the can of this disclosure has been described above using one embodiment. According to the manufacturing method of the can of this disclosure, a can that ensures strength and reduces the amount of fiber bundles can be manufactured.

Claims

1. A method for manufacturing a can, the can comprising a can body portion capable of filling the interior with gas, in, The method for manufacturing the can includes a step of manufacturing a can body with a fiber bundle layer covering the outer surface of the can having a hollow cylindrical liner. The fiber bundle layer has an inner layer, an outer layer, and an intermediate layer disposed between the inner layer and the outer layer. The manufacturing process of the main body of the tank includes: In the inner layer configuration process, the inner layer is configured on the outer surface of the inner liner; The intermediate layer configuration process involves configuring the intermediate layer on the outer surface of the inner layer; A cutting process, wherein the intermediate layer is cut such that its end is positioned axially inward from the end of the fiber bundle layer; and The outer layer configuration process involves configuring the outer layer on the outer surface of the inner layer and the intermediate layer.

2. The method for manufacturing a can according to claim 1, wherein, The process includes an interface component configuration step, whereby, after the manufacturing step of the tank body, an interface component is configured at the small-diameter end of the tank body. In the cutting process, the intermediate layer is cut such that the end of the intermediate layer is located axially inward than the interface component.

3. The method for manufacturing a can according to claim 1 or 2, wherein, The manufacturing process of the main body of the tank includes an adhesive layer preparation step between the intermediate layer preparation step and the cutting step. In the adhesive layer configuration step, an adhesive layer is formed inside the intermediate layer, the adhesive layer being located axially inward of the cut position of the intermediate layer that is cut in the cutting step, and near the cut position.

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