Tank and its manufacturing method

Abstract

To provide a tank capable of reducing a fiber bundle amount while maintaining strength.SOLUTION: A tank comprises a tank body part capable of being filled with gas. The tank body part comprises a liner having a hollow cylindrical shape, and a fiber bundle layer covering the outside surface of the liner. The fiber bundle layer has an inner layer, an outer layer, and an intermediate layer arranged between the inner layer and the outer layer. An end part of the intermediate layer is located axially inward with respect to an end part of the fiber bundle layer.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present application relates to a tank and a method of manufacturing the same. [Background technology]

[0002] Among high-pressure gas tanks for storing hydrogen gas and the like, tanks in which a fiber bundle layer is arranged on a hollow cylindrical liner are known. For example, Patent Document 1 discloses a pressure vessel that includes a liner filled with gas, a reinforcing part formed in contact with the outer surface of the liner using a fiber-reinforced resin and covering the liner from the outside, and a predetermined mouthpiece. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2020-112189 Summary of the Invention [Problem to be solved by the invention]

[0004] Typically, the tank body has a hollow cylindrical shape. The tank body includes a trunk portion, a small diameter end portion, and a shoulder portion connecting the two. The tank body may be manufactured using a braiding method in which fiber bundles are woven onto the surface of the liner. In this case, the fiber bundle amount is the same for both the trunk portion and the small diameter end portion. Because the fiber bundle amount is determined based on the strength of the trunk portion, the fiber bundle amount is excessive at the small diameter end portion, which has a small outer diameter.

[0005] Therefore, a main object of the present disclosure is to provide a tank that can reduce the amount of fiber bundles while ensuring strength, and a manufacturing method thereof. [Means for solving the problem]

[0006] As one aspect for solving the above-mentioned problems, the present disclosure provides a tank having a tank main body portion capable of being filled with a gas therein, wherein the tank main body portion comprises a liner having a hollow cylindrical shape and a fiber bundle layer covering the outer surface of the liner, the fiber bundle layer having an inner layer, an outer layer, and an intermediate layer disposed between the inner layer and the outer layer, and the end of the intermediate layer is located axially inward of the end of the fiber bundle layer.

[0007] The tank may include a nozzle disposed at the small-diameter end of the tank body. In this case, the end of the intermediate layer may be located axially inward of the nozzle. The fiber bundle layer may have an adhesive layer inside the intermediate layer and near the end of the intermediate layer.

[0008] As one aspect for solving the above-mentioned problems, the present disclosure provides a method for manufacturing a tank having a tank main body portion capable of being filled with gas, the method comprising: a tank main body manufacturing step of arranging a fiber bundle layer covering the outer surface of a liner having a hollow cylindrical shape, the fiber bundle layer having an inner layer, an outer layer, and an intermediate layer arranged between the inner layer and the outer layer; the tank main body manufacturing step comprising: an inner layer arrangement step of arranging the inner layer on the outer surface of the liner; an intermediate layer arrangement step of arranging the intermediate layer on the outer surface of the inner layer; a cutting step of cutting the intermediate layer so that an end of the intermediate layer is positioned axially inward relative to the end of the fiber bundle layer; and an outer layer arrangement step of arranging the outer layer on the outer surfaces of the inner layer and the intermediate layer.

[0009] The manufacturing method may further include a nozzle arrangement step of arranging a nozzle on the small-diameter end of the tank body after the tank body fabrication step. In this case, the cutting step may include cutting the intermediate layer so that the end of the intermediate layer is positioned axially inward of the nozzle.

[0010] The tank body fabricating step may include an adhesive layer disposing step between the intermediate layer disposing step and the cutting step. In this case, the adhesive layer disposing step may form an adhesive layer inside the intermediate layer, axially inward of and in the vicinity of the cutting position of the intermediate layer that is cut in the cutting step. [Effects of the Invention]

[0011] According to the tank of the present disclosure, it is possible to reduce the amount of fiber bundles while ensuring strength. Furthermore, according to the tank manufacturing method of the present disclosure, it is possible to manufacture a tank that can reduce the amount of fiber bundles while ensuring strength. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a schematic cross-sectional view focusing on an end of the tank 1000. [Figure 2] 1 is a schematic cross-sectional view focusing on an end portion of the tank main body 100. FIG. [Figure 3] FIG. 1 is a schematic cross-sectional view of an end portion of a conventional tank. [Figure 4] (A) A cross-sectional view of the liner 110 with an inner layer 124 and an intermediate layer 125 arranged thereon. (B) An enlarged view of the area enclosed by the dotted line in (A). (C) A cross-sectional view of the liner 110 with an outer layer 126 arranged thereon. [Figure 5] 1 is a flowchart of a manufacturing method according to an embodiment. [Figure 6] 10 is a flowchart of a tank main body manufacturing step S1. [Figure 7] FIG. 10 is a schematic diagram of a tank main body manufacturing step S1. DETAILED DESCRIPTION OF THE INVENTION

[0013] [tank] The tank of the present disclosure will be described using one embodiment, a tank 1000. Fig. 1 shows a schematic cross-sectional view focusing on an end of the tank 1000. Fig. 2 shows a schematic cross-sectional view focusing on an end of the tank main body 100.

[0014] The tank 1000 comprises a tank main body 100, a nozzle 200, and a manifold 300. The tank main body 100 can be filled with gas. The nozzle 200 is disposed at the small diameter end 130 of the tank main body 100. The manifold 300 is a member that covers the nozzle 200 and closes the opening 103a of the tank main body 100.

[0015] <Tank main body 100> The tank main body 100 can be filled with a gas. The type of gas is not particularly limited. Examples include hydrogen and natural gas. The gas is usually filled into the tank main body 100 under high pressure.

[0016] As shown in FIG. 1 , the tank main body 100 has a hollow cylindrical shape. The tank main body 100 includes a body 101, a shoulder 102, and a small diameter end 103. The body 101 is the part with the largest outer diameter and extends in the axial direction of the tank main body 100. The small diameter end 103 has an outer diameter smaller than that of the body and corresponds to an end of the tank main body 100. The small diameter end 103 may be located at only one end of the tank main body 100, or may be located at both ends. The small diameter end 103 includes an opening 103a that communicates with the interior of the tank main body 100. The opening 103a is closed by a manifold 300. The shoulder 102 connects the body 101 and the small diameter end 103 and is formed so that its outer diameter decreases toward the outside in the axial direction.

[0017] Here, the axial direction is the direction passing through the central axis of the tank main body 100. The axial direction in Fig. 1 is the left-right direction.

[0018] The tank main body 100 includes a liner 110 having a hollow cylindrical shape, and a fiber bundle layer 120 covering the outer surface of the liner 110 .

[0019] (Liner 110) The liner 110 is made of a resin material such as nylon. The liner 110 is the innermost layer of the tank body, and is the part that forms the basis of the shape of the tank body 100. Therefore, the liner 110 has parts that correspond to the body 101, shoulder 102, and small diameter end 103 of the tank body 100 (liner body 111, liner shoulder 112, and liner small diameter end 113).

[0020] As shown in FIG. 2, the liner 110 includes an insert ring 114 near the liner small diameter end 113. The insert ring 114 is a cylindrical member and serves to prevent the small diameter end 103 of the tank body 100 from being deformed (opened) by the internal pressure of the filled gas, thereby preventing the tank body 100 from losing its airtightness. Therefore, the insert ring 114 is provided at least at the liner small diameter end 113. Also, as shown in FIG. 2, the insert ring 114 may be formed from the liner small diameter end 113 to the shoulder 112. That is, one end 114a of the insert ring 114 may be located at the liner small diameter end 113, and the other end 114b may be located at the liner shoulder 112. The position of the other end 114b of the insert ring 114 is related to the position of the end 122a of the intermediate layer 125, which will be described later, and will be described in detail later.

[0021] (fiber bundle layer 120) The fiber bundle layer 120 is the outermost layer of the tank main body, and is a part that constitutes the external shape of the tank main body 100. Therefore, the fiber bundle layer 120 has parts that correspond to the body 101, shoulder 102, and small diameter end 103 of the tank main body 100 (fiber bundle layer body 121, fiber bundle layer shoulder 122, and fiber bundle layer small diameter end 123).

[0022] The fiber bundle layer 120 is made of fiber reinforced resin such as carbon fiber. Typically, the fiber bundle layer 120 is formed by weaving a fiber bundle formed by combining a plurality of fiber reinforced resin strands into one bundle on the outer surface of the liner 110. The number of fiber reinforced resin strands in the fiber bundle is not particularly limited, but is, for example, 10 to 100. The fiber bundles are woven multiple times. Therefore, the fiber bundle layer 120 is formed by laminating multiple single layers of woven fiber bundles (fiber bundle single layers).

[0023] Since the fiber bundle layer 120 is formed in this manner, its layer configuration cannot be distinguished at a glance. However, in this disclosure, for convenience, the fiber bundle layer 120 will be described by distinguishing it into an inner layer 124, an intermediate layer 125, and an outer layer 126 according to their roles. Therefore, in this disclosure, the fiber bundle layer 120 includes the inner layer 124, the intermediate layer 125, and the outer layer 126.

[0024] 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 will be described later, the fiber bundle layer 120 may be produced through a process of cutting a portion of the intermediate layer 125. In such a case, the inner layer 124 serves to protect the liner 110 from the load applied when the intermediate layer 125 is cut. The number of fiber bundle monolayers in the inner layer 124 can be set appropriately depending on the purpose. For example, the number of fiber bundle monolayers in the inner layer 124 may be greater than the number of fiber bundle monolayers in the outer layer 126. Specifically, the number of fiber bundle monolayers in the inner layer 124 can be set to be 1 or more and 5 or less.

[0025] The intermediate layer 125 is a layer disposed between the inner layer 124 and the outer layer 126. As shown in FIG. 2, the end 125a of the intermediate layer 125 is located axially more inward than 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). In other words, 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 manner, the amount of fiber bundles used in the fiber bundle layer 120 can be reduced. Therefore, the intermediate layer 125 serves to reduce the amount of fiber bundles used in the fiber bundle layer 120. Furthermore, since the intermediate layer 125 is present in the fiber bundle layer trunk portion 121 as in the conventional case, the strength of the tank main body portion 100 can be ensured.

[0026] Furthermore, in order to ensure the strength of the tank main body 100, the intermediate layer 125 needs to be disposed at least in a portion of the inner layer 124 that corresponds to the trunk 101. 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 trunk 101 (the shoulder 102 or the small diameter end 103).

[0027] As shown in FIG. 2 , the end 125a of the intermediate layer 125 may be located axially inward of the nozzle 200 (specifically, axially inward of the end 200a of the nozzle 200). This allows the outer diameter of the small-diameter end 103 of the tank main body 100 to be reduced. Furthermore, the outer diameter of the nozzle 200 and the insertion hole 310 of the manifold 300 can be reduced. Furthermore, the end 125a of the intermediate layer 125 may be located in a range overlapping with the insert ring 114. In other words, the end 125a of the intermediate layer 125 may be located axially inward of one end 114a of the insert ring 114 and axially outward of the other end 114b. The fiber bundle layer 120 may be produced, as described below, through a step of cutting a portion of the intermediate layer 125 (cutting step S14). In such a case, the insert ring 114 can protect the liner 110 from the load generated when the intermediate layer 125 is cut.

[0028] Therefore, the end 125a of the intermediate layer 125 may be located in the axial direction more inward than the mouthpiece 200 and in the axial direction more outward than the other end 114b of the insert ring 114 (W in FIG. 2). This allows the outer diameter of the small diameter end 103 of the tank main body 100 to be reduced, and also allows the liner 110 to be protected from the load when the intermediate layer 125 is cut. Furthermore, the amount of fiber bundles used in the fiber bundle layer 120 can be reduced.

[0029] To explain the effect of the intermediate layer 125 in more detail, a comparison will be made with a conventional tank. FIG. 3 shows a schematic cross-sectional view focusing on the end of the conventional tank. As shown in FIG. 3, in the conventional tank, the end P of the intermediate layer is located at the end of the fiber bundle layer, and the intermediate layer covers the entire surface of the inner layer. Therefore, compared to the tank 1000, the conventional tank has a larger outer diameter at the small-diameter end of the tank body, and the amount of fiber bundles used in the fiber bundle layer also increases. Therefore, the conventional tank cannot achieve the above-mentioned effect.

[0030] The intermediate layer 125 is intended to reduce the number of fiber bundle monolayers at the fiber bundle layer small diameter end portion 123. Therefore, the number of fiber bundle monolayers in the intermediate layer 125 can be set appropriately depending on the purpose. For example, the number of fiber bundle monolayers in the intermediate layer 125 may be greater than the number of fiber bundle monolayers in the inner layer 124 and the outer layer 126. Specifically, it can be 3 layers or more and 10 layers or less.

[0031] The outer layer 126 is 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 that is not covered by the intermediate layer 125). The outer layer 126 has the role of suppressing fraying of the end 125a of the intermediate layer 125. This is because fraying of the end 125a causes a decrease in the strength of the tank body. The number of fiber bundle monolayers in the outer layer 126 can be set appropriately depending on the purpose. For example, the number of fiber bundle monolayers in the outer layer 126 may 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 may be 1 or more and 5 or less.

[0032] As shown in FIG. 2, the fiber bundle layer 120 may have an adhesive layer 127 inside the intermediate layer 125 near the end 125a of the intermediate layer 125. This bonds the individual fiber bundle monolayers included in the intermediate layer 125 together, further suppressing fraying at the end 125a. If the adhesive layer 127 is provided at the end 125a, it may be difficult to cut the intermediate layer 125, as described below. Therefore, the position of the adhesive layer 127 excludes the cutting position of the intermediate layer 125. There are no particular limitations on the material constituting the adhesive layer 127, and it may be any material that can bond the intermediate layer 125 and the inner layer 124 together. For example, a known adhesive may be used as appropriate.

[0033] The adhesive layer 127 is an optional component, and therefore the fiber-side layer 120 does not have to include the adhesive layer 127. This is because, even if the adhesive layer 127 is not provided, the outer layer 126 can prevent the end 125a of the middle layer 125 from fraying.

[0034] (Laminated structure) The layered structure of the tank body 100 will now be described. FIG. 4A is a cross-sectional view of the liner 110 in which the inner layer 124 and the intermediate layer 125 are disposed. FIG. 4B is an enlarged view of the area surrounded by the dotted line in FIG. 4A. FIG. 4C is a cross-sectional view of the liner 110 in which the outer layer 126 is further disposed. As shown in FIG. 4A, the end 125a of the intermediate layer 125 is disposed axially inward of the end 124a of the inner layer 124. When the end 125a of the intermediate layer 125 is formed by cutting the intermediate layer 125, as shown in FIG. 4B, the end of the single layer of fiber bundles forming the intermediate layer 125 is exposed, and fraying of the end 125a is likely to occur. Therefore, as shown in FIG. 4C, the outer layer 126 is further disposed, and the entire intermediate layer 125 is covered with the outer layer 126, thereby suppressing fraying of the end 125a of the intermediate layer 125. In this way, the fiber bundle layer is composed of three layers to reduce the amount of fiber bundles and suppress fraying. Such layer structures can be distinguished based on cross-sectional CT images, for example.

[0035] <200mm socket> The nozzle 200 is disposed at the small diameter end 103 of the tank body 100, and serves to fix the tank body 100 and the manifold together. The outer surface of the nozzle 200 may have a plurality of grooves for threaded engagement with the manifold 300. A known nozzle 200 can be used as this type of nozzle 200.

[0036] <Manifold 300> The manifold 300 is connected to the nozzle 200 and is a member (lid) for closing the opening 103a of the tank main body 100. By disposing the manifold 300, the gas filled inside the tank main body 100 can be sealed. As shown in FIG. 1, the manifold 300 has an insertion hole 310 for inserting the small diameter end 103 of the tank main body 100 and the nozzle 200. The side of the insertion hole 310 may have multiple grooves for screwing onto the nozzle. A known manifold 300 can be used as this type of manifold 300.

[0037] The tank of the present disclosure has been described above using one embodiment. In the tank of the present disclosure, the end of the intermediate layer is located axially inward of the end of the fiber bundle layer. Furthermore, the fiber bundle layer in the body portion is similar to that of a conventional tank. Therefore, the tank of the present disclosure can reduce the amount of fiber bundles while ensuring strength.

[0038] [Tank manufacturing method] The manufacturing method of the tank of the present disclosure will be described using a manufacturing method of the tank 1000 as one embodiment. Fig. 5 shows a flowchart of the manufacturing method according to one embodiment. Fig. 6 shows a flowchart of the tank main body manufacturing step S1. Fig. 7 shows a schematic diagram of the tank main body manufacturing step S1.

[0039] The manufacturing method of one embodiment is a manufacturing method for a tank 1000 having a tank main body 100 that can be filled with a gas. As shown in Fig. 5, the manufacturing method of one embodiment includes a tank main body manufacturing step S1, a nozzle arrangement step S2, and a manifold arrangement step S3.

[0040] <Tank body manufacturing process S1> The tank body fabrication process S1 is a process of arranging a fiber bundle layer 120 that covers the outer surface of a hollow cylindrical liner 110. The tank body fabrication process S1 makes it possible to fabricate the tank body 100. The tank body fabrication process S1 is mainly carried out by weaving fiber bundles onto the surface of the liner 110, and includes a process of cutting the intermediate layer 125 during this process. There are no particular limitations on the method for weaving the fiber bundles, and for example, a braiding method can be used.

[0041] As shown in FIG. 6, the tank body manufacturing process S1 includes an inner layer arranging process S11, a middle layer arranging process S12, an adhesive layer arranging process S13, a cutting process S14, and an outer layer arranging process S15.

[0042] (Inner layer arrangement step S11) The inner layer disposing step S11 is a step of disposing the inner layer 124 on the outer surface of the liner 110. By weaving fiber bundles on the outer surface of the liner 110, the inner layer 124 is formed on the entire outer surface of the liner 110.

[0043] (Middle layer arrangement step S12) The intermediate layer arranging step S12 is performed after the inner layer arranging step S11. The intermediate layer arranging step S12 is a step of arranging the intermediate layer 125 on the outer surface of the inner layer 124. By knitting the fiber bundles on the outer surface of the inner layer 124, the intermediate layer 125 is formed on the entire outer surface of the inner layer 124.

[0044] (Adhesive layer placement step S13) The adhesive layer disposing step S13 is an optional step and does not necessarily have to be performed. When the adhesive layer disposing step S14 is performed, the tank main body fabricating step S1 includes the adhesive layer disposing step S13 between the intermediate layer disposing step S13 and the cutting step S14. The adhesive layer disposing step S13 is a step of forming an adhesive layer 127 inside the intermediate layer 125, axially inward of and in the vicinity of the cutting position X of the intermediate layer 125 cut in the cutting step S14.

[0045] There is no particular limitation on the method for forming adhesive layer 127. For example, as shown in Fig. 7, adhesive layer 127 can be formed by dropping adhesive A that constitutes adhesive layer 127 onto the outer surface of intermediate layer 125 and allowing it to penetrate into the interior. By forming adhesive layer 127 inside intermediate layer 125, each fiber bundle monolayer of intermediate layer 125 is bonded, and fraying of end portions 125a is further suppressed.

[0046] (Cutting process S14) The cutting step S14 is performed after the intermediate layer arranging step S12 or the adhesive layer arranging step S13. The cutting step S14 is a step of cutting the intermediate layer 125 so that the end 125a of the intermediate layer 125 is positioned axially more inward than the end 120a of the fiber bundle layer 120. The cutting is performed over the entire circumferential direction of the intermediate layer 125. The method for cutting the intermediate layer 125 is not particularly limited, but examples include a method using a disc-shaped cutter.

[0047] 7, in the cutting step S14, the intermediate layer 125 may be cut so that the end 125a of the intermediate layer 125 is located axially inward of the nozzle 200. This allows the outer diameter of the small-diameter end 103 of the tank main body 100 to be reduced, and therefore the outer diameter of the nozzle 200 to be reduced. In other words, the nozzle 200 can be made smaller. Furthermore, the intermediate layer 125 may be cut so that the end 125a of the intermediate layer 125 overlaps with the insert ring 114. This allows the insert ring 114 to protect the liner 110 from the load during cutting.

[0048] (Outer layer arrangement step S15) The outer layer arranging step S15 is performed after the cutting step S14. The outer layer arranging step S15 is a step of arranging the outer layer 126 on the outer surfaces of the intermediate layer 125 and the inner layer 124 (portions of the inner layer 124 that are not covered by the intermediate layer 125). The outer layer 126 is formed on the entire outer surfaces of these layers by weaving fiber bundles into the outer surfaces of the intermediate layer 125 and the inner layer 124.

[0049] <Case placement process S2> The nozzle arrangement step S2 is performed after the tank main body fabrication step S1. The nozzle arrangement step S2 is a step of arranging the nozzle 200 on the small diameter end 103 of the tank main body 100. The method of arranging the nozzle 200 on the small diameter end 103 of the tank main body 100 is well known.

[0050] <Manifold process S3> The manifold step S3 is performed after the nozzle placement step S2. The manifold step S3 is a step of placing a manifold 300 that screws into the nozzle 200 and closes the opening 103a of the tank main body 100. The method of placing the manifold 300 is well known.

[0051] The method for manufacturing a tank according to the present disclosure has been described above using one embodiment. According to the method for manufacturing a tank according to the present disclosure, it is possible to manufacture a tank that can reduce the amount of fiber bundles while ensuring strength. [Explanation of symbols]

[0052] 100 Tank body 101 Torso 102 Shoulder 103 Small diameter end 110 Liner 111 Liner body 112 Liner shoulder 113 Small diameter end of liner 114 Insert ring 120 fiber bundle layer 121 Fiber bundle layer body 122 Fiber bundle layer shoulder 123 Fiber bundle layer small diameter end 124 Inner layer 125 Middle Class 125a end 126 Outer layer 127 Adhesive layer 200 cap 300 manifold

Claims

1. A method for manufacturing a tank having a tank main body portion capable of being filled with gas, comprising: a tank main body fabrication step of arranging a fiber bundle layer covering an outer surface of a liner having a hollow cylindrical shape, 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 tank main body manufacturing process includes: an inner layer disposing step of disposing the inner layer on an outer surface of the liner; an intermediate layer disposing step of disposing the intermediate layer on an outer surface of the inner layer; a cutting step of cutting the intermediate layer so that an end portion of the intermediate layer is positioned axially more inward than an end portion of the fiber bundle layer; and an outer layer arranging step of arranging the outer layer on outer surfaces of the inner layer and the intermediate layer. Tank manufacturing method.

2. a nozzle arrangement step of arranging a nozzle on a small diameter end of the tank main body after the tank main body fabrication step, In the cutting step, the intermediate layer is cut so that an end portion of the intermediate layer is positioned axially inward of the mouthpiece. The method of claim 1.

3. the tank body manufacturing step includes an adhesive layer arranging step between the intermediate layer arranging step and the cutting step, The adhesive layer disposing step forms an adhesive layer inside the intermediate layer, axially inward of a cutting position of the intermediate layer cut in the cutting step, and in the vicinity of the cutting position. The method according to claim 1 or 2.

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