High-pressure tank, manufacturing method for the same and manufacturing device for the same

Abstract

To provide a high-pressure tank that can more reliably increase a breaking strength of a reinforcing layer compared to conventional tanks.SOLUTION: A high-pressure tank 1 of the present invention has a hollow liner 2 and a reinforcing layer 4 formed on an outer surface of the liner 2, the reinforcing layer 4 having a plurality of unit layers 7 laminated on the outer surface of the liner 2, the unit layers 7 being formed by winding the liner 2 so that band-shaped fiber bundles (bands B) containing a curable resin are arranged in parallel in a width direction, and the band-shaped fiber bundles (bands B) is wider in the unit layers 7 laminated on an outer periphery side of the reinforcing layer 4 than in the unit layers 7 on the inner periphery side of the reinforcing layer 4.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a high-pressure tank, a manufacturing method thereof, and an apparatus for manufacturing the same. [Background technology]

[0002] Conventionally, a high-pressure tank is known that has a reinforcing layer formed by winding fibers containing a curable resin around the outside of a substantially cylindrical liner having dome portions at both ends (see, for example, Patent Document 1). The reinforcing layer of this high-pressure tank has a helical layer in which fibers are wound helically, and a hoop layer in which fibers are wound in a hoop shape outside the helical layer. In addition, in the manufacturing method of this high-pressure tank, the tension of the fibers when forming the hoop layer that is the outer layer is set to be greater than the tension of the fibers when forming the helical layer that is the inner layer. With a high-pressure tank manufactured in this manner, even if gas is repeatedly charged and discharged many times in a high-temperature and high-humidity environment, peeling at the interface between the helical layer (inner layer) and the hoop layer (outer layer) can be suppressed. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2022-30873 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the conventional manufacturing method of a high-pressure tank (see, for example, Patent Document 1), the tension of the fibers in the outer layer is greater than that of the fibers in the inner layer, which may loosen the fibers in the inner layer. If the fibers in the inner layer loosen, the breaking strength of the reinforcing layer may decrease.

[0005] An object of the present invention is to provide a high-pressure tank capable of increasing the breaking strength of a reinforcing layer more reliably than in the past, and a manufacturing method and device for the same. [Means for solving the problem]

[0006] The high-pressure tank of the present invention, which achieves the above-mentioned object, comprises a hollow liner and a reinforcing layer formed on the outer surface of the liner, and is characterized in that the reinforcing layer is formed by winding a band-shaped fiber bundle containing a curable resin around the liner, and the band-shaped fiber bundle is wider on the outer periphery side than on the inner periphery side of the reinforcing layer.

[0007] The manufacturing method of the high-pressure tank of the present invention, which achieves the above-mentioned object, is a manufacturing method of a high-pressure tank having a reinforcing layer on the outer surface of a hollow liner, and includes a winding process of winding and laminating a band-shaped fiber bundle containing a curable resin around the outer surface of the liner, and a reinforcing layer formation process of curing the curable resin contained in the fiber bundle wound around the outer surface to form the reinforcing layer, wherein the winding process includes a step of expanding the band-shaped fiber bundle on the outer peripheral side relative to the inner peripheral side of the reinforcing layer.

[0008] The high-pressure tank manufacturing apparatus of the present invention, which achieves the above-mentioned object, is an apparatus for manufacturing a high-pressure tank having a reinforcing layer on the outer surface of a hollow liner, and is equipped with a feed mechanism that feeds out a plurality of fiber bundles containing a curable resin, and a winding mechanism that gathers together the plurality of fiber bundles fed out from the feed mechanism to form a strip-shaped fiber bundle and winds the strip-shaped fiber bundle around the liner, and is characterized in that the winding mechanism is configured to widen the strip-shaped fiber bundles that are stacked on the outer periphery of the reinforcing layer relative to the inner periphery. Effect of the Invention

[0009] According to the method for manufacturing a high-pressure tank of the present invention, the breaking strength of the reinforcing layer can be increased more reliably than in the past. [Brief description of the drawings]

[0010] [Figure 1] 1 is a vertical cross-sectional view of a high-pressure tank according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a partially enlarged cross-sectional view of a high-pressure tank according to an embodiment of the present invention. [Diagram 3] 2 is a partially enlarged longitudinal sectional view showing a schematic view of a portion corresponding to part III in FIG. 1. [Figure 4] 1 is a configuration explanatory diagram of a high-pressure tank manufacturing device according to an embodiment of the present invention; [Figure 5A] 5 is an overall perspective view of a first roller constituting a fiber bundle guide mechanism in the manufacturing apparatus of FIG. 4. [Figure 5B] 5 is an overall perspective view of a second roller constituting a guide mechanism for the fiber bundle in the manufacturing apparatus of FIG. 4. FIG. [Figure 6] 5 is a configuration explanatory diagram of a band width adjusting mechanism (alignment width adjusting mechanism) in the manufacturing apparatus of FIG. 4. [Figure 7] FIG. 2 is an explanatory diagram of hoop winding of a fiber bundle performed in a manufacturing method according to an embodiment of the present invention. [Figure 8A] 7 is a flowchart illustrating a procedure executed by a control unit constituting the bandwidth adjusting mechanism (adjusting width adjusting mechanism) of FIG. 6. [Figure 8B] 7 is an explanatory diagram of a table referred to by a control unit constituting the bandwidth adjusting mechanism (adjustment width adjusting mechanism) of FIG. 6. FIG. [Figure 9] FIG. 2 is an explanatory diagram of highly helical winding of a fiber bundle performed in a manufacturing method according to an embodiment of the present invention. [Figure 10] FIG. 2 is an explanatory diagram of low helical winding of a fiber bundle performed in a manufacturing method according to an embodiment of the present invention. [Figure 11] FIG. 11 is an explanatory diagram of a connector winding of a fiber bundle performed in a manufacturing method according to another embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Next, a mode (embodiment) for carrying out the present invention will be described in detail with reference to the drawings as appropriate. First, a high-pressure tank of the present embodiment will be described, and then a manufacturing apparatus and a manufacturing method thereof will be described. <High-pressure tank> Fig. 1 is a vertical cross-sectional view of the high-pressure tank 1. Fig. 2 is a partially enlarged horizontal cross-sectional view of the high-pressure tank 1. The high-pressure tank 1 of this embodiment is assumed to be mounted on, for example, a fuel cell vehicle and store hydrogen gas to be supplied to a fuel cell system. However, the high-pressure tank 1 is not limited to this and may be used for other high-pressure gases.

[0012] As shown in FIG. 1, a high-pressure tank 1 includes a liner 2, a nozzle 3 connected to the liner 2, and a reinforcing layer 4 covering the outside of the liner 2 to the nozzle 3. The base 3 is assumed to be made of a metal material such as an aluminum alloy, etc. The base 3 has a cylindrical base body 3a having an inlet and outlet hole on the inside, and a flange portion 3b formed on one axial end side of the base body 3a.

[0013] The liner 2 is a hollow body made of a thermoplastic resin. Examples of the thermoplastic resin include, but are not limited to, polyamide resin and polyethylene resin. The liner 2 of this embodiment includes a cylindrical body portion 5 and dome portions 6 that are molded integrally with both ends of the body portion 5. As shown in FIG. 1, the dome portion 6 is a flattened bowl-shaped body that gradually decreases in diameter as it moves away from the body portion 5 side toward the outside in the direction of the axis Ax. The radial center of the dome portion 6 is recessed to correspond to the shape of the flange portion 3 b of the base 3 .

[0014] As shown in FIG. 1, the reinforcing layer 4 is formed from the outer surface of the liner 2 to the outer surface of the mouthpiece 3 . As will be described in detail later, this reinforcing layer 4 is formed by curing a curable resin contained in the tow prepreg wound from the liner 2 to the mouthpiece 3. The tow prepreg in this embodiment is composed of fiber bundles (tows) of reinforcing fibers containing a curable resin, and has adhesiveness. The curable resin of the tow prepreg is assumed to be, for example, a thermosetting resin such as an epoxy resin, a phenolic resin, an unsaturated polyester resin, or a polyimide resin, but is not limited to these. Examples of reinforcing fibers include, but are not limited to, carbon fibers, glass fibers, aramid fibers, boron fibers, alumina fibers, and silicon carbide fibers.

[0015] 2, the reinforcing layer 4 is made up of a plurality of unit layers 7 laminated on the outer surface of the liner 2. In this embodiment, the reinforcing layer 4 is assumed to be made up of nine unit layers 7 in the body portion 5 of the liner 2, but the number of unit layers 7 is not limited to this. The unit layer 7 is formed by arranging bands B (see FIG. 4), which are band-shaped fiber bundles fed from a band-feeding head 13b (see FIG. 4) in a manufacturing apparatus 10 (see FIG. 4) described later, in the axial direction (perpendicular to the paper surface of FIG. 2) of the liner 2. The bands B correspond to the "band-shaped fiber bundle" referred to in the claims.

[0016] FIG. 3 is a partially enlarged vertical sectional view showing a schematic view of a portion corresponding to part III in FIG. 3, the reinforcing layer 4 in this embodiment has, in a vertical cross-sectional view along the axial direction of the liner 2, a first unit layer 7a, a second unit layer 7b, a third unit layer 7c, and a fourth unit layer 7d, in that order from the outer circumferential surface side of the body portion 5 of the liner 2. In addition, five more unit layers 7 are laminated on the upper surface of the fourth unit layer 7d, as shown by the virtual line (two-dot chain line).

[0017] In this embodiment, the first unit layer 7a is formed by arranging bands B having a width W1 in parallel in the axial direction of the liner 2 (the left-right direction on the paper surface of FIG. 3). In this embodiment, the second unit layer 7b is formed of a band B having a width W2. The third unit layer 7c is formed of a band B having a width W3. The fourth unit layer 7d is formed of a band B having a width W4.

[0018] Then, in the unit layer 7 forming the reinforcing layer 4, the width of the band B (hereinafter sometimes simply referred to as the "band width") becomes wider as it goes toward the radially outer side of the liner 2. Specifically, as shown in FIG. 3, the band widths of the first unit layer 7a, the second unit layer 7b, the third unit layer 7c, and the fourth unit layer 7d satisfy the relationship of "W1 < W2 < W3 < W4".

[0019] Also, although not shown, in the five unit layers 7 laminated on the upper surface of the fourth unit layer 7d, the band width also becomes wider as it goes toward the radially outer side of the liner 2. Note that the unit layer 7 shown in FIG. 3 assumes that the band B is formed around the liner 2 by hoop winding (see FIG. 7) as described later. However, the configuration in which the band width becomes wider as it goes toward the radially outer side of the liner 2 can also be applied to high helical winding (see FIG. 9), low helical winding (see FIG. 10), etc. as described later. These unit layers 7 are integrated in the reinforcing layer forming step described later in which the curable resin of the tow prepreg is cured.

[0020] ≪Manufacturing Apparatus for High-Pressure Tank≫ Next, the manufacturing apparatus for the high-pressure tank 1 will be described. FIG. 4 is an explanatory diagram of the configuration of the manufacturing apparatus 10. As shown in FIG. 4, the manufacturing apparatus 10 mainly includes a feeding mechanism 11 for the tow prepregs P1, P2, P3, P4, and P5, a guiding mechanism 12 for guiding these tow prepregs P1 to P5 sent out from the feeding mechanism 11 to the winding mechanism 13, a winding mechanism 13 for integrally winding the tow prepregs P1 to P5 guided by the guiding mechanism 12 and press-forming them into a band B having a predetermined width and winding this band B around the liner 2, and a band width adjusting mechanism 14 for adjusting the interval (combined width) between the tow prepregs P1 to P5 in advance so that the band B press-formed by the winding mechanism 13 has a predetermined width. Note that the band width adjusting mechanism 14 corresponds to the "combined width adjusting mechanism" referred to in the claims.

[0021] As shown in Fig. 4, the let-off mechanism 11 includes bobbins 11a1, 11a2, 11a3, 11a4, and 11a5 on which the tow prepregs P1 to P5 are traverse-wound, and a plurality of bobbin motors (not shown) that individually assist the rotation of the bobbins 11a1 to 11a5 so that the tow prepregs P1 to P5 are pulled out from the bobbins 11a1 to 11a5 with a predetermined tension. The let-off mechanism 11 in this embodiment is assumed to include five bobbins 11a1 to 11a5. However, the number of bobbins is not limited to this and can be changed as necessary.

[0022] As shown in FIG. 4, the guide mechanism 12 includes a first roller 12a1 and a second roller 12a2 around which the tow prepregs P1 to P5 are stretched. In this embodiment, the guide mechanism 12 has four first rollers 12a1 and two second rollers 12a2, but the numbers of the first rollers 12a1 and second rollers 12a2 are not limited to this and can be changed appropriately as needed.

[0023] Fig. 5A is an overall perspective view of the first roller 12a1, and Fig. 5B is an overall perspective view of the second roller 12a2. As shown in FIG. 5A, the first roller 12a1 is a substantially cylindrical body that rotates about an axis S. As shown in FIG. 5A, the first roller 12a1 individually guides each of the tow prepregs P1 to P5 (see FIG. 4) fed from the feed mechanism 11 (see FIG. 4). A plurality of (five in this embodiment) circumferential guide grooves G are formed in the circumferential surface Cc of the first roller 12a1 and aligned in the axial direction S. These circumferential guide grooves G have bottom surfaces that are flat in the groove width direction and have a predetermined width. The tow prepregs P1 to P5 travel from the upstream delivery mechanism 11 (see FIG. 4) to the downstream winding mechanism 13 (see FIG. 4) while contacting the bottom surfaces of these circumferential guide grooves G. As a result, the cross-sectional shape of each of the tow prepregs P1 to P5 gradually becomes flattened. Such a first roller 12a1 (see FIG. 5A) may be configured as a divided roller that individually guides each of the tow prepregs P1 to P5 (see FIG. 4).

[0024] As shown in FIG. 5B, the second roller 12a2 is a substantially cylindrical body that rotates about an axis S. On the peripheral surface Cc of the second roller 12a2, peaks M and valleys V extending in the direction of the axis S are formed so as to be alternately arranged in the circumferential direction. The tops of the peaks M, which come into contact with the tow prepregs P1 to P5 (see FIG. 4), are formed as gently curved surfaces in a cross section intersecting the axis S. The number of peaks M aligned in the circumferential direction in this embodiment is set to 12, but can be increased or decreased as necessary. Such a second roller 12a2 (see FIG. 5B) forms each of the tow prepregs P1 to P5 (see FIG. 4) into a plate shape. The second roller 12a2 may be formed of divided rollers that individually correspond to each of the tow prepregs P1 to P5 (see FIG. 4).

[0025] As shown in Fig. 4, the four first rollers 12a1 in this embodiment guide the tow prepregs P1-P5 fed from the feed mechanism 11 so as to narrow the gap between them. The two second rollers 12a2 in this embodiment further narrow the gap between the tow prepregs P1-P5 fed from the first rollers 12a1 side and guide them to the bandwidth adjustment mechanism 14 (see Fig. 4).

[0026] Next, prior to the band width adjustment mechanism 14 (see FIG. 4), the winding mechanism 13 (see FIG. 4) will be described. As shown in FIG. 4, the winding mechanism 13 includes a drive unit 13a (rotary motor) that rotates the liner 2 around the axis Ax, and a band delivery head 13b that delivers the band B to the rotating liner 2. The band-feeding head 13b arranges and integrates in the width direction the multiple (five) tow prepregs P1 to P5 that have been formed into plate shapes by the guide mechanism 12 (the second roller 12a2), thereby forming a band B, which is a belt-shaped tow prepreg. The band feed head 13b is composed of a pair of pressure rollers 13b1, 13b1 arranged in parallel with a predetermined clearance. The five tow prepregs P1 to P5 arranged side by side on the upstream side of the band feed head 13b are press-molded into a band B by being integrated when passing between the pair of pressure rollers 13b1, 13b1.

[0027] Moreover, the band feeding head 13b is movable in the direction of the axis Ax of the liner 2 while feeding the band B to the rotating liner 2. Specifically, the band feeding head 13b moves in the direction of the axis Ax in response to the rotation of the liner 2 so that the unit layer 7 (see FIG. 2) is formed on the outer periphery of the liner 2. In this embodiment, a linear actuator 13c such as an air cylinder or a linear motor is assumed as a moving means for the band feeding head 13b, but is not limited thereto.

[0028] The band feed head 13b is configured to adjust the tension of the band B supplied to the liner 2. Specifically, the band feed head 13b adjusts the load applied to the tow prepreg P ​​in a direction intersecting the running direction of the tow prepreg P. In this embodiment, the tension adjustment means for the band B is assumed to be a gap adjustment actuator 13d provided between the linear actuator 13c and the band feed head 13b. Examples of the gap adjustment actuator 13d include, but are not limited to, a rack and pinion mechanism driven by a rotary motor and an air cylinder.

[0029] In addition, the gap adjustment actuator 13d in this embodiment is assumed to displace the band feed head 13b so that the detected tension becomes a preset target tension based on the detected tension of the tow prepreg P ​​or the band B. Note that a means for detecting the tension of the tow prepreg P ​​or the band B may be, but is not limited to, a sensor that detects the reaction force that the band feed head 13b receives from the tow prepreg P ​​or the band B. In this embodiment, the tension of the band B supplied to the liner 2 is constant from the start to the end of winding on the liner 2. However, the tension of the band B can be reduced toward the outside in the radial direction of the liner 2.

[0030] Next, the bandwidth adjustment mechanism 14 (see FIG. 4) will be described. As shown in FIG. 4, the band width adjustment mechanism 14 adjusts the spacing between the five plate-shaped tow prepregs P1 to P5 fed from the guide mechanism 12 (second roller 12a2) to the band feed-out head 13b, i.e., the overlapping width of the tow prepregs P1 to P5 described below.

[0031] Fig. 6 is a diagram illustrating the configuration of the bandwidth adjustment mechanism 14 (see Fig. 4). Fig. 6 is a schematic representation of the bandwidth adjustment mechanism 14 shown in Fig. 4 as viewed from above. As shown in FIG. 6, the bandwidth adjustment mechanism 14 is mainly composed of five guide rollers 14a1, 14a2, 14a3, 14a4, and 14a5, an actuator 14b that adjusts the axial spacing between the five guide rollers 14a1 to 14a5, and a control unit 14c that controls the movement of the actuator 14b.

[0032] The guide rollers 14a1 to 14a5 are each configured as an H-shaped guide roller having flanges on both axial ends. The guide rollers 14a1 to 14a5 are arranged from top to bottom (from the front side to the back side of the paper surface of FIG. 6) in the order of guide roller 14a1, guide roller 14a2, guide roller 14a3, guide roller 14a4, and guide roller 14a5.

[0033] The guide roller 14a1 guides the plate-shaped tow prepreg P1 downstream while restricting its widthwise movement. The guide roller 14a2 guides the plate-shaped tow prepreg P2 downstream while restricting its widthwise movement. The guide roller 14a3 guides the plate-shaped tow prepreg P3 downstream while restricting its widthwise movement. The guide roller 14a4 guides the plate-shaped tow prepreg P4 downstream while restricting its widthwise movement. The guide roller 14a5 guides the plate-shaped tow prepreg P5 downstream while restricting its widthwise movement.

[0034] That is, the tow prepregs P1 to P5 are arranged from top to bottom (from the front side to the back side of the paper surface of FIG. 6) in the order of tow prepreg P1, tow prepreg P2, tow prepreg P3, tow prepreg P4, and tow prepreg P5. The tow prepregs P1 to P5 are arranged with a predetermined overlap when viewed from the top-bottom direction.

[0035] The actuator 14b moves the other guide rollers 14a1 to 14a4 relative to the guide roller 14a5 in the axial direction. The actuator 14b moves the guide rollers 14a1 to 14a4 individually relative to each other, as indicated by the outlined arrows in FIG. This increases the overlapping width of the tow prepregs P1 to P5 when viewed from the top and bottom as shown in Fig. 6. Although not shown, the actuator 14b can also narrow the overlapping width of the tow prepregs P1 to P5 by relatively moving the guide rollers 14a1 to 14a4 in the direction opposite to the white arrow shown in Fig. 6. The actuator 14b in this embodiment may be, but is not limited to, a rack and pinion mechanism driven by a rotary motor or an air cylinder.

[0036] The control unit 14c can be configured to include a ROM (Read Only Memory) that stores a program for controlling the actuator 14b, a RAM (Random Access Memory) that reads out and expands the program stored in the ROM, and a CPU (Central Processing Unit) that executes the expanded program and outputs commands to the actuator 14b. The control unit 14c, in accordance with a preset program, increases the overlapping width of the tow prepregs P1 to P5 as shown in Fig. 6. The procedure executed by the control unit 14c will be described together with the next method for manufacturing a high-pressure tank.

[0037] <Manufacturing method of high pressure tank> Next, a manufacturing method of the high-pressure tank 1 of this embodiment will be described. The manufacturing method of this embodiment includes a winding process in which a band B (see FIG. 4) made of tow prepregs P1 to P5 (see FIG. 4) is wound around the outer surface of a liner 2 (see FIG. 4), and a reinforcing layer forming process in which the curable resin contained in the band B (tow prepregs P1 to P5) wrapped around the outer surface of the liner 2 is cured to form a reinforcing layer 4 (see FIG. 2). Here, the manufacturing method of this embodiment will be specifically described by taking as an example a method of winding band B (see FIG. 3) around body portion 5 (see FIG. 3) of liner 2 (see FIG. 3) by hoop winding.

[0038] FIG. 7 is an explanatory diagram of the hoop winding of the band B around the liner 2. As shown in Fig. 4, hoop winding involves winding the band B in a hoop shape (ring shape) around the body portion 5 of the liner 2. That is, in hoop winding, the angle θ1 (winding angle) between the axis Ax and the extension direction D of the band B is set to an angle close to 90 degrees so that the band B is parallel to the axis Ax direction. As a result, the band B forms a unit layer 7 (see Fig. 2) on the outer peripheral surface of the body portion 5 of the liner 2, the unit layer 7 having approximately the same thickness as the thickness of the band B.

[0039] In the winding process, as shown in FIG. 3, a plurality of unit layers 7 are formed on the outer peripheral surface of the body portion 5 of the liner 2. As shown in FIG. 4, the formation of this unit layer 7 by hoop winding is performed by reciprocating the band delivery head 13b with respect to the rotating liner 2 at a distance corresponding to the length of the body portion 5 of the liner 2. Specifically, the odd-numbered unit layers 7 (see FIG. 3) are formed in the forward path of the band delivery head 13b, and the even-numbered unit layers 7 (see FIG. 3) are formed in the return path.

[0040] Such a winding process is performed so that the band width widens toward the outer peripheral side of the reinforcing layer 4 (see FIG. 2). Specifically, as shown in FIG. 3, the winding process is performed so that the band widths of the first unit layer 7a, the second unit layer 7b, the third unit layer 7c, and the fourth unit layer 7d satisfy the relationship of "W1 < W2 < W3 < W4". Also, in the five unit layers 7 laminated on the upper surface of the fourth unit layer 7d, the winding process is performed so that the band width becomes wider toward the outer side in the radial direction of the liner 2 as described above.

[0041] The widening of the band B (see FIG. 4) in such a band delivery head 13b (see FIG. 4) is performed by the band width adjustment mechanism 14 widening the above-described alignment width of the tow pre-pregs P1 to P5 sent from the guide mechanism 12 to the band delivery head 13b. Specifically, it is performed by the control unit 14c of the band width adjustment mechanism 14 controlling the actuator 14b according to a predetermined procedure.

[0042] FIG. 8A is a flowchart for explaining the procedure executed by the control unit 14c (see FIG. 6). FIG. 8B is an explanatory diagram of a table referred to when the control unit 14c (see FIG. 6) executes the procedure. As shown in FIG. 8A, the control unit 14c (see FIG. 6) first detects which layer the winding of the band B (see FIG. 3) around the liner 2 is (see step S101). The control unit 14c, for example, counts the number of times the band delivery head 13b reciprocates as described above, stores this in a predetermined memory, and reads the number of times from this memory to detect which layer the winding of the band B (see FIG. 3) is on.

[0043] Next, the control unit 14c (see FIG. 6) refers to the table shown in FIG. 8B to determine the target width of the band B, that is, the target band width (see step S102). As shown in FIG. 8, the table prescribes in advance the band widths W1, W2, W3, W4 (W1 < W2 < W3 < W4) shown in FIG. 3 and the band widths in each of the plurality of unit layers 7 that are laminated on the upper surface of the fourth unit layer 7d (not shown in FIG. 3) and become wider toward the outer diameter side of the liner 2. Then, when the control unit 14c (see FIG. 6) detects that the winding is on the third layer, for example, it sets the width W3 of the band B corresponding to the third unit layer 7c whose stacking layer order in the table shown in FIG. 8 is the third layer as the target band width.

[0044] Next, as shown in FIG. 8, the control unit 14c (see FIG. 6) outputs a drive command to the actuator 14b (see FIG. 6) so that the width of the band B (see FIG. 4) becomes the determined target width (target band width) (see step S103). Thereby, the subroutine in which the control unit 14c (see FIG. 6) controls the actuator 14b (see FIG. 6) ends.

[0045] Then, as shown in FIG. 6, based on the drive command from the control unit 14c, the actuator 14b adjusts the combined width of the prepregs P1 to P5 fed from the guide mechanism 12 (see FIG. 4) to the band delivery head 13b (see FIG. 4) to the target band width. As shown in FIG. 4, the band delivery head 13b presses the fed prepregs P1 to P5 as described above to send out the band B with the target band width to the liner 2 side.

[0046] Meanwhile, the band delivery head 13b reciprocates over a distance corresponding to the length of the body portion 5 of the liner 2, thereby stacking a plurality of unit layers 7 on the body portion 5 of the liner 2 as shown in FIG. The band width forming the unit layer 7 increases as it approaches the radial outside of the liner 2 .

[0047] The manufacturing method of this embodiment assumes a configuration in which, as shown in FIG. 7, band B is hoop-wound only around the body portion 5 of the liner 2, and then band B is further wound using high helical winding and low helical winding.

[0048] Fig. 9 is an explanatory diagram of the high helical winding of band B (see Fig. 4), and Fig. 10 is an explanatory diagram of the low helical winding of band B (see Fig. 4). 9, the high helical winding is set so that the angle θ2 (winding angle) of the band B (see FIG. 4) between the axis Ax and the extending direction D of the band B is approximately 75 degrees. As a result, the band B is wound around the body portion 5 of the liner 2 that has been hoop wound and the periphery of the dome portion 6 adjacent to the body portion 5. As shown in Fig. 10, the low helical winding is set so that the angle θ3 (winding angle) of the band B (see Fig. 4) between the axis Ax and the extending direction D of the band B is approximately 10 degrees. As a result, the band B is wound from the body portion 5 to the dome portion 6 of the liner 2, which has been subjected to the hoop winding and high helical winding.

[0049] In the manufacturing method of this embodiment, the band width of the high helical winding and the band width of the low helical winding are set to be the same as the band width of the hoop winding of the outermost layer. However, the band width of the high helical winding and the band width of the low helical winding may be configured to be wider toward the outer periphery of the reinforcing layer 4 (see FIG. 1).

[0050] In the reinforcing layer forming process, the liner 2 (see FIG. 4) that has completed the winding process is removed from the winding mechanism 13 (see FIG. 4) and heated to a predetermined temperature in a heating furnace (not shown). This hardens the hardening resin contained in band B (see FIG. 4) wrapped around liner 2. In the process of hardening the hardening resin, the stacked unit layers 7 (see FIG. 5) become integrated and adhere to the outer surface of liner 2. This forms reinforcing layer 4 (see FIG. 1), completing the series of manufacturing processes for high-pressure tank 1.

[0051] <Action and effect> Next, the effects of the high-pressure tank 1 according to this embodiment, its manufacturing method, and its manufacturing apparatus 10 will be described. In the high-pressure tank 1 of this embodiment, the band B (band-shaped fiber bundle) is wider on the outer periphery side of the reinforcing layer 4 than on the inner periphery side. According to this high-pressure tank 1, the outer band B is made wider than the inner band B, thereby reducing the surface pressure (pressure per unit area of ​​band B) that the outer band B exerts on the inner band B. Unlike conventional high-pressure tanks (see, for example, Patent Document 1), this high-pressure tank 1 prevents the fibers of the inner band B from loosening. This makes it possible for the high-pressure tank 1 to more reliably increase the breaking strength of the reinforcing layer 4 compared to the prior art.

[0052] In the high-pressure tank 1, the reinforcing layer 4 includes a plurality of unit layers 7 laminated on the outer surface of the liner 2. The unit layers 7 are formed by winding the liner 2 so that the bands B (strip-shaped fiber bundles) are arranged in parallel in the width direction. The bands B are wider in width than the unit layers 7 laminated on the inner periphery of the reinforcing layer 4 toward the outer periphery. According to this high-pressure tank 1, since the band B is increased in width for each stacked unit layer 7, the breaking strength of the reinforcing layer 4 can be increased more reliably.

[0053] In such a high-pressure tank 1, the liner 2 is configured to have a cylindrical body portion 5 and dome portions 6 on both ends of the body portion 5. The multiple unit layers 7 are formed only on the body portion 5 of the liner 2. According to this high-pressure tank 1, by focusing on wrapping band B around the body portion 5 rather than the dome portion 6, which has a relatively high strength against the internal pressure of the high-pressure tank 1, the reinforcing layer 4 of the high-pressure tank 1 as a whole can be strengthened more efficiently.

[0054] The manufacturing method of the high-pressure tank 1 of this embodiment includes a winding process of wrapping and laminating a band B (a strip-shaped fiber bundle containing a curable resin) around the outer surface of the liner 2, and a reinforcing layer formation process of curing the curable resin contained in the band B wrapped around the outer surface to form a reinforcing layer 4, and the winding process includes a step of widening the band B on the outer peripheral side relative to the inner peripheral side of the reinforcing layer 4. According to such a manufacturing method for the high-pressure tank 1, it is possible to manufacture a high-pressure tank 1 having a reinforcing layer 4 with improved breaking strength more reliably than in the past.

[0055] In such a manufacturing method, the winding step is performed by hoop-winding the band B (a band-shaped fiber bundle) around the body portion 5 of the liner 2. According to this manufacturing method, the band B is wound around the body portion 5 of the liner 2 so as to be substantially perpendicular to the axis Ax of the liner 2, so that the band B can contribute more effectively to improving the breaking strength of the reinforcing layer 4.

[0056] The manufacturing apparatus 10 for the high-pressure tank 1 of this embodiment includes a feed-out mechanism 11 that feeds out tow prepregs P1-P5 (a plurality of fiber bundles containing a curable resin), and a winding mechanism 13 that gathers the tow prepregs P1-P5 fed out from the feed-out mechanism 11 together to form a band B (a strip-shaped fiber bundle) and winds the band B around the liner 2. The winding mechanism 13 is configured so that the width of the band B laminated on the outer periphery side of the reinforcing layer 4 is increased from the inner periphery side to the outer periphery side. According to this manufacturing apparatus, it is possible to manufacture a high-pressure tank 1 having a reinforcing layer 4 with improved breaking strength more reliably than in the past.

[0057] Such a manufacturing apparatus 10 further includes a guide mechanism 12 that guides the tow prepregs P1-P5 (multiple fiber bundles containing a curable resin) from the feed mechanism 11 to the winding mechanism 13 while flattening the cross-sectional shape of the tow prepregs P1-P5 into a plate-like shape, and a band width adjustment mechanism 14 (lamination width adjustment mechanism) that sets the lamination width of the flattened tow prepregs P1-P5 to the width of a band B (strip-shaped fiber bundle) that the winding mechanism 13 winds around the liner 2. According to this manufacturing apparatus 10, the winding mechanism 13 can more accurately widen the band B that is laminated on the outer periphery side of the reinforcing layer 4 from the inner periphery side.

[0058] Although the embodiment of the present invention has been described above, the present invention is not limited to the above embodiment and can be embodied in various forms. In the manufacturing method according to the above embodiment, the process of performing the high helical winding and the low helical winding after the hoop winding of the band B around the liner 2 has been described. However, the order of the hoop winding, high helical winding and low helical winding of the band B around the liner 2 can be interchanged.

[0059] In addition, the widening of band B in the above embodiment is assumed to be applied only to the hoop winding applied to the body portion 5 of the liner 2, but the widening of band B may be such that at least a portion of band B in any of the hoop winding, high helical winding, and low helical winding has a wider band width than the band B wound around its inner circumference.

[0060] In addition, the winding process of the manufacturing method of the above embodiment combines hoop winding and helical winding in the thickness direction of the reinforcing layer 4, changing the winding angles θ1, θ2, θ3 (see Figures 7, 9 and 10) of the band B (strip-shaped fiber bundle) relative to the liner 2. Furthermore, assuming a method of manufacturing a high-pressure tank 1 in which the order of hoop winding, high helical winding, and low helical winding, which are the methods of winding band B around liner 2, is interchanged, the winding angle of band B changes from θ1 to θ2 or θ3, from θ2 to θ1 or θ3, or from θ3 to θ1 or θ2. In such a manufacturing method, prior to changing the winding angle of band B, a connector winding can be interposed in which band B is wound around liner 2 at a winding angle between the winding angles to be changed.

[0061] Figure 11 is an explanatory diagram of the connector winding of band B. In Figure 11, for convenience of drawing, the body 5 of the liner 2 is drawn to be longer in the axis Ax direction than the actual one. Here, the connector winding of band B will be explained using the example of changing from low helical winding (see Figure 10) to hoop winding (see Figure 7). 11, the symbol Lh indicates the end position of the low helical winding (see FIG. 10) on the liner 2. The symbol hh indicates the start position of the hoop winding (see FIG. 7) on the liner 2.

[0062] As shown in Figure 11, when the winding method of the connector-wound band B changes from low helical winding with a winding angle θ3 (see Figure 10) to hoop winding with a winding angle θ1 (see Figure 7), the band B is wound around the liner 2 in a round trip from the end position Lh of the low helical winding (see Figure 10) set on one end of the axis Ax of the liner 2 to the start position hh of the hoop winding (see Figure 7) set on the end of the body 5 at the other end. Then, the connector-wound band B is wound around the liner 2 so that during one round trip, the winding angle gradually changes from the winding angle θ3 to the winding angle θ1, that is, at a winding angle between the changed winding angle θ3 (see Figure 10) and the winding angle θ1 (see Figure 7), that is, at a winding angle that exceeds θ3 and is less than θ1. Such connector winding (see FIG. 11) can prevent the band B from slipping due to changes in the winding angle.

[0063] In addition, in the manufacturing method of this embodiment in which such a connector winding (see FIG. 11) is interposed, the band B of the connector winding can be configured to be wider than the band B on the inner periphery side.

[0064] That is, the winding process of this manufacturing method combines hoop winding and helical winding in the layer thickness direction of the reinforcing layer 4, and is performed so as to change the winding angle of the band B (strip-shaped fiber bundle) relative to the outer surface of the liner 2, and prior to changing the winding angle, a connector wind is interposed around which the band B (strip-shaped fiber bundle) is wound at a winding angle between the winding angles to be changed, and the connector-wound band B (strip-shaped fiber bundle) is wider than the band B (strip-shaped fiber bundle) on the inner side of the connector-wound band B (strip-shaped fiber bundle).

[0065] According to this manufacturing method, even if the reinforcing layer 4 is formed using a winding method in which the winding angle of the band B changes, slippage of the band B is suppressed, making it possible to manufacture a high-pressure tank 1 with an even higher breaking strength of the reinforcing layer 4. [Explanation of symbols]

[0066] 1. High pressure tank 2 Liner 4 Reinforcement layer 5. Torso 6 Dome section 7 Unit Layer 11 Delivery mechanism 12 Guide mechanism 13 Wrapping mechanism 14 Band width adjustment mechanism (adjustment width mechanism) B Band (band-shaped fiber bundle) P1~P5 Tow prepreg (multiple fiber bundles)

Claims

1. A hollow liner; a reinforcing layer formed on an outer surface of the liner; having The reinforcing layer is formed by winding a band-shaped fiber bundle containing a curable resin around the liner, 2. A high-pressure tank comprising: a reinforcing layer having a width greater than that of an inner periphery of the reinforcing layer on an outer periphery of the reinforcing layer;

2. The reinforcing layer includes a plurality of unit layers laminated on an outer surface of the liner, The unit layer is formed by winding the liner so that the belt-like fiber bundles are arranged in parallel in the width direction, 2. The high-pressure tank according to claim 1, wherein the width of the band-shaped fiber bundle is increased from the inner periphery of the reinforcing layer to the outer periphery of the unit layer.

3. The liner has a cylindrical body and dome portions at both ends of the body, 3. The high-pressure tank according to claim 2, wherein the plurality of unit layers are formed only in the body portion of the liner.

4. A method for manufacturing a high-pressure tank having a reinforcing layer on an outer surface of a hollow liner, comprising the steps of: a winding step of winding and laminating a band-shaped fiber bundle containing a curable resin around the outer surface of the liner; a reinforcing layer forming step of forming the reinforcing layer by curing the curable resin contained in the fiber bundle wrapped around the outer surface; having The method for manufacturing a high-pressure tank, wherein the winding step includes a step of widening the band-shaped fiber bundle on an outer periphery side of the reinforcing layer relative to an inner periphery side.

5. 5. The method for manufacturing a high-pressure tank according to claim 4, wherein the winding step is performed by hoop-winding the belt-shaped fiber bundle around the body portion of the liner.

6. the winding step is performed by combining hoop winding and helical winding in a layer thickness direction of the reinforcing layer so that a winding angle of the belt-shaped fiber bundle with respect to the outer surface of the liner changes; Prior to changing the winding angle, a connector winding is interposed around which the belt-like fiber bundle is wound at an angle between the winding angles to be changed; The method for manufacturing a high-pressure tank according to claim 4, characterized in that the band-shaped fiber bundle of the connector winding is wider than the band-shaped fiber bundle on the inner circumferential side of the band-shaped fiber bundle of the connector winding.

7. A manufacturing apparatus for a high-pressure tank having a reinforcing layer on an outer surface of a hollow liner, comprising: a delivery mechanism for delivering a plurality of fiber bundles containing a curable resin; a winding mechanism that gathers the plurality of fiber bundles sent out from the delivery mechanism into a strip-shaped fiber bundle and winds the strip-shaped fiber bundle around the liner; Equipped with A high-pressure tank manufacturing apparatus, characterized in that the winding mechanism is configured to widen the band-shaped fiber bundles stacked on the outer periphery side of the reinforcing layer more than on the inner periphery side.

8. The high-pressure tank manufacturing apparatus according to claim 7, further comprising: a guide mechanism that flattens a cross-sectional shape of the fiber bundle into a plate shape while guiding the plurality of fiber bundles from the delivery mechanism to the winding mechanism; and a matching width adjustment mechanism that sets a matching width of the flattened plurality of fiber bundles to a width of the band-shaped fiber bundle that is wound around the liner by the winding mechanism.

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