Manufacturing device for tank

Abstract

A manufacturing apparatus for a tank in which a carbon fiber layer is impregnated with resin comprises a mold and an injector for injecting the resin into the mold, wherein the mold comprises a cavity in which a semi-finished product of the tank before impregnation with the resin is disposed, a runner extending from the injector to the cavity, an extrusion hole branched from the runner in which a coloring agent is disposed, and an extruder slidably disposed within the extrusion hole to push the coloring agent toward the runner.

Description

Technology Field

[0001] The technology disclosed in this specification relates to a tank manufacturing apparatus. Background Technology

[0002] Japanese Patent Publication No. 2021-167653 discloses a manufacturing apparatus for a tank in which a carbon fiber layer is impregnated with resin. The manufacturing apparatus comprises a mold and a first injector for injecting resin into the mold. The problem to be solved

[0003] There is a demand to enhance the aesthetic appeal of tanks by coloring their exterior surfaces. For example, it is envisioned that the exterior of the tank be painted after impregnating a carbon fiber layer with resin. However, painting the exterior surface leads to increased manufacturing costs.

[0004] The present specification provides a technology for ensuring the aesthetic appeal of a tank while suppressing an increase in manufacturing costs. means of solving the problem

[0005] The present specification discloses an apparatus for manufacturing a tank in which a carbon fiber layer is impregnated with resin. The apparatus comprises a mold and an injector for injecting the resin into the mold. The mold comprises a cavity in which a semi-finished product of the tank before impregnation with the resin is placed, a runner extending from the injector to the cavity, an extrusion hole branched from the runner in which a coloring agent is placed, and an extruder slidably disposed within the extrusion hole to push the coloring agent toward the runner.

[0006] According to the above configuration, when injecting resin into the cavity through the runner, a coloring agent can be mixed into the resin flowing from the runner into the extrusion hole. Subsequently, by pushing the resin containing the coloring agent toward the runner, the colored resin is injected into the cavity through the runner. The outer surface of the tank can be colored by impregnating the colored resin into the carbon fiber layer. Furthermore, since the outer surface of the tank can be colored during the process of impregnating the carbon fiber layer with resin, a process of painting the outer surface of the tank is unnecessary. Effects of the invention

[0007] It is possible to ensure the design of the tank while suppressing the increase in manufacturing costs. Brief explanation of the drawing

[0008] The features, advantages, and technical and industrial significance of exemplary embodiments of the present invention are described below with reference to the accompanying drawings, in which similar reference numerals indicate similar elements. Figure 1 is a diagram showing the configuration of a tank manufacturing device. Figure 2 is a top view of the lower mold. Figure 3 is a conceptual diagram of an extrusion hole. Figure 4 is a drawing showing the method of manufacturing a tank. Figure 5 is a drawing showing the method of manufacturing a tank. Specific details for implementing the invention

[0009] Configuration of the manufacturing device (2): FIGS. 1 to 3

[0010] The manufacturing device (2) is a device for manufacturing a tank. The tank is, for example, a high-pressure tank for a fuel cell electric vehicle. The tank has a liner that defines the internal space of the tank and a carbon fiber layer formed on the outer surface of the liner. A resin is impregnated into the carbon fiber layer by the manufacturing device (2).

[0011] The manufacturing device (2) is equipped with a mold (4) on which a semi-finished product (8) in a tank before resin impregnation is placed, and an injector (6) for injecting resin into the mold (4). The mold (4) is composed of a pair of molds (10 and 12) that hold the semi-finished product (8) between them. Specifically, the mold (4) is equipped with an upper mold (10) and a lower mold (12). A cavity (10A) following the upper outer shape of the semi-finished product (8) is formed on the lower surface of the upper mold (10). A cavity (12A) following the lower outer shape of the semi-finished product (8) is formed on the upper surface of the lower mold (12).

[0012] As shown in FIG. 2, a gate (12B), a main runner (12C), and a plurality of sub-runners (12D) are formed on the upper surface of the lower mold (12). In FIG. 2, a symbol is assigned to one of the plurality of sub-runners (12D), and the assignment of symbols to the others is omitted.

[0013] At one end of the gate (12B), a flow path (6A) extending from the injector (6) and penetrating the upper mold (10) is connected. At the other end of the gate (12B), a main runner (12C) extending along the longitudinal direction of the tank is connected. A plurality of sub-runners (12D) branch off from the main runner (12C). The plurality of sub-runners (12D) are connected to the cavity (12A).

[0014] The resin injected from the injector (6) passes through the flow path (6A) and gate (12B) and flows into the main runner (12C). The resin flowing into the main runner (12C) flows into each sub-runner (12D) and flows into the cavity (12A) from each sub-runner (12D).

[0015] An extrusion hole (12E) is formed at the connection point between the main runner (12C) and each sub-runner (12D). The extrusion hole (12E) branches off from the sub-runner (12D) along the depth direction of the cavity (12A). As shown in FIG. 2, the lower die (12) has an equal number of extrusion holes (12E) as the sub-runner (12D). Additionally, an extruder (12F) is slidably disposed inside each extrusion hole (12E). A piston is formed by the extrusion hole (12E) and the extruder (12F). The extruder (12F) is operated by an actuator such as a hydraulic actuator or a motor. Furthermore, the number of extrusion holes (12E) shown in FIG. 2 is merely an example. In the lower die (12), fewer extrusion holes (12E) than the sub-runner (12D) may be formed, or more extrusion holes (12E) than the sub-runner (12D) may be formed. Also, in FIG. 2, one of the plurality of extrusion holes (12E) and one of the plurality of extruders (12F) are assigned a symbol, and the assignment of symbols to the rest is omitted.

[0016] A coloring agent (16) (see FIG. 4) is disposed within the extrusion hole (12E). The extrusion hole (12E) is configured so that the coloring agent (16) is mixed with the resin flowing in from the sub-runner (12D). Specifically, as shown in FIG. 3, a plurality of ribs (12G) are formed on the inner wall of the extrusion hole (12E) to promote mixing of the resin and the coloring agent (16). Each rib (12G) extends in the axial direction of the extrusion hole (12E). Additionally, a pressure sensor (12H) for measuring the pressure of the resin flowing through the extrusion hole (12E) is disposed on the inner wall of the extrusion hole (12E). Here, the pressure sensor (12H) may be disposed in at least one of the plurality of extrusion holes (12E). In addition, in a modified example, the pressure sensor (12H) may be disposed on the inner surface of either of the cavities (10A and 12A). This is because the cavities (10A and 12A) are connected to the extrusion hole (12E) through the sub-runner (12D).

[0017] Additionally, the extruder (12F) has a plurality of grooves formed corresponding to a plurality of ribs (12G). By pushing the extruder (12F) toward the sub-runner (12D), the coloring agent (16) inside the extrusion hole (12E) is mixed with the resin. Additionally, by pushing the extruder (12F) toward the sub-runner (12D), pressure can be applied to the resin flowing through the sub-runner (12D).

[0018] As shown in FIG. 1, the manufacturing device (2) additionally includes a control device (20). The control device (20) is configured to control the operation of the injector (6) and each extruder (12F). For example, the control device (20) controls the operation of the extruder (12F) based on the pressure measured by the pressure sensor (12H) in the extrusion hole (12E).

[0019] Method of manufacturing the tank: Figs. 4, 5

[0020] Referring to FIGS. 4 and 5, a manufacturing method for manufacturing a tank in which a carbon fiber layer is impregnated with resin is described. The manufacturing method is realized by controlling a manufacturing device (2). In addition, FIGS. 4 and 5 use a cross-sectional view of the manufacturing device (2) cut along line IV-IV of FIG. 2.

[0021] FIG. 4 illustrates a batch process S1 and an injection process S2. In batch process S1, the mold (4) is opened, and a semi-finished product (8) is placed in the cavity (12A) of the lower mold (12). In batch process S1, the extruder (12F) is positioned at the furthest starting position from the sub-runner (12D). In batch process S1, a coloring agent (16) is placed in each of the multiple extrusion holes (12E). Once the coloring agent (16) is placed in the extrusion holes (12E), mold fastening is performed by pushing the upper mold (10) against the lower mold (12). Afterward, degassing is performed to bring the cavities (10A and 12A) of the mold (4) close to a vacuum. Also, in each drawing, the device for performing degassing is omitted.

[0022] After the batch process S1, the injection process S2 is executed. In the injection process S2, the control device (20) transmits a command to the injector (6) to start injecting resin into the mold (4). By this, the injector (6) starts injecting resin. The resin is injected into the cavities (10A and 12A) through the flow path (6A), gate (12B), main runner (12C), and sub-runner (12D). Additionally, in the injection process S2, a portion of the resin flowing through the main runner (12C) and sub-runner (12D) is introduced into each extrusion hole (12E).

[0023] FIG. 5 illustrates an extrusion process S3 executed after an injection process S2. The control device (20) executes the extrusion process S3 when the pressure measured by the pressure sensor (12H) exceeds a predetermined value. The extrusion process S3 includes a first extrusion process and a second extrusion process. In the first extrusion process, the control device (20) moves the extruder (12F) toward the sub-runner (12D) from a starting position to a predetermined intermediate position. By doing so, the coloring agent (16) placed in the extrusion hole (12E) in the batching process S1 and the resin introduced into the extrusion hole (12E) by the injection process S2 are mixed. In particular, the mixing of the coloring agent (16) and the resin is promoted by the rib (12G). Additionally, when the control device (20) moves the extruder (12F) to the intermediate position, it temporarily stops the extruder (12F) at the intermediate position. For example, until the coloring agent (16) is sufficiently diffused within the resin, the extruder (12F) is stopped at an intermediate position.

[0024] In the second extrusion process, the control device (20) moves the extruder (12F) toward the sub-runner (12D) from the intermediate position to the end position after a predetermined time has elapsed since the extruder (12F) moved to the intermediate position. By doing so, the resin colored by the coloring agent (16) is injected into the cavities (10A and 12A) through the sub-runner (12D). Additionally, additional pressure is applied to the resin injected into the cavities (10A and 12A) by the extruder (12F).

[0025] Effects of this embodiment

[0026] According to the configuration of the present embodiment, when resin is injected into the cavities (10A and 12A) through the sub-runner (12D), a coloring agent (16) can be mixed into the resin flowing from the sub-runner (12D) into the extrusion hole (12E). Then, by pushing the resin containing the coloring agent (16) toward the sub-runner (12D), the colored resin is injected into the cavities (10A and 12A) through the sub-runner (12D). The outer surface of the tank can be colored by impregnating the colored resin into the carbon fiber layer. Furthermore, since the outer surface of the tank can be colored during the process of impregnating the resin into the carbon fiber layer, a process of painting the outer surface of the tank is unnecessary. The aesthetic appeal of the tank can be secured while suppressing the increase in manufacturing costs. Additionally, tanks with various colors can be manufactured simply by changing the color of the coloring agent (16) placed in the extrusion hole (12E).

[0027] Corresponding relationship

[0028] The manufacturing device (2), mold (4), and injector (6) are examples of the “manufacturing device,” “mold,” and “injector,” respectively. The semi-finished product (8) and control device (20) are examples of the “semi-finished product” and “control device,” respectively. The cavities (10A and 12A) are examples of the “cavities.” The sub-runner (12D), extrusion hole (12E), and extruder (12F) are examples of the “runner,” “extrusion hole,” and “extruder,” respectively. The rib (12G) and pressure sensor (12H) are examples of the “rib” and “pressure sensor,” respectively.

[0029] Hereinafter, points regarding the technology shown in the examples are described. The number of ribs (12G) is not limited to the four shown in FIG. 3, but may be one, two, three, five or more. Also, the ribs (12G) in FIG. 3 are merely an example of a configuration that promotes the mixing of the coloring agent (16) and the resin. Additionally, ribs (12G) do not need to be formed in the extrusion hole (12E).

Claims

Claim 1 A manufacturing apparatus for a tank in which a carbon fiber layer is impregnated with resin, comprising a mold and an injector for injecting the resin into the mold, wherein the mold comprises a cavity in which a semi-finished product of the tank before impregnation with the resin is placed, a runner extending from the injector to the cavity, an extrusion hole branched from the runner in which a coloring agent is placed, and an extruder slidably disposed within the extrusion hole to push the coloring agent toward the runner. Claim 2 A manufacturing apparatus according to claim 1, wherein the extrusion hole is configured to mix the coloring agent with the resin flowing in from the runner. Claim 3 A manufacturing apparatus according to paragraph 2, wherein ribs are formed on the inner wall of the extrusion hole to promote mixing of the resin and the coloring agent. Claim 4 A manufacturing apparatus in which, in paragraph 3, a plurality of ribs extending in the axial direction of the extrusion hole are formed on the inner wall. Claim 5 A manufacturing apparatus according to any one of claims 1 to 4, wherein the manufacturing apparatus further comprises a pressure sensor for measuring the pressure of the resin flowing through the extrusion hole and a control device for controlling the operation of the extruder based on the pressure measured by the pressure sensor, and wherein the control device is configured to perform a process of moving the extruder toward the runner from a starting position to a predetermined intermediate position when the pressure measured by the pressure sensor exceeds a predetermined value after the injection of the resin by the injector begins, and a process of temporarily stopping the extruder at the intermediate position and then moving the extruder toward the runner from the intermediate position to a terminal position.

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