CN109551778A - 高压罐制造方法 - Google Patents
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- B29C70/28—Shaping operations therefor
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- B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
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- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract
本发明提供了一种高压罐制造方法,其包括预制件制造步骤和成型步骤。在预制件制造步骤中,通过以其中使得具有不同厚度的干燥纤维束(第一纤维束和第二纤维束)彼此相邻的状态将具有不同厚度的干燥纤维束卷绕到衬里上来制造预制件。在成型步骤中,成型包括将在预制件制造步骤中制造的预制件布置于模具中并注入树脂。
Description
技术领域
本公开涉及一种高压罐制造方法。
背景技术
关于高压罐的制造,已知一种方法,其中将浸渍有未固化树脂的纤维束(预浸料)卷绕到衬里上以形成纤维层,然后使树脂固化以形成增强层(例如,参见日本专利申请公开(JP-A)2011-245740号(专利文献1)中的段落0002)。
还有一种方法(树脂传递成型(RTM)),其中通过将未浸渍有树脂的纤维束(干燥纤维束)卷绕到衬里上以形成纤维层来制造预制件,之后将预制件放置在模具中。在这种状态下,使树脂在固化的同时浸渍到纤维层中以形成增强层。在RTM方法中,可以省略制造预浸料的步骤,导致成本降低。
在通过RTM方法制造高压罐时,为了保证强度,需要厚厚地形成预制件的纤维层。然而,如果预制件的纤维层厚,则当以其中预制件已被置于模具中的状态注入树脂时将难以使树脂均匀地浸渍直到纤维层的内层。
作为解决该问题的方法,已考虑通过沿宽度方向在其间以一定间隙卷绕多个纤维束来在纤维层中提供用于树脂的通道。然而,这会降低完工高压罐的纤维体积含量比,造成高压罐强度和品质的下降。
发明内容
本公开考虑到上述情况而设计。本公开的一个目的是提供高压罐制造方法,利用该方法可以低成本制造可靠品质的高压罐。
根据第一方面的高压罐制造方法包括:预制件制造步骤,包括以其中具有不同厚度的干燥纤维束彼此相邻的状态将具有不同厚度的干燥纤维束卷绕到衬里上;和成型步骤,包括将在预制件制造步骤中制造的预制件布置于模具中并注入树脂。
在根据第一方面的高压罐制造方法中,在制造预制件的预制件制造步骤中,将不同厚度的干燥纤维束以使得其彼此相邻的状态卷绕到衬里上。因此,在所制造的预制件的纤维层中,在具有较小厚度的纤维束上方形成间隙。当在成型步骤中注入树脂时,这些间隙将起到树脂通道的作用。因此,树脂更容易浸渍直到树脂层的内层,并可改善树脂浸渍的均匀性。
在根据第二方面的高压罐制造方法中,在根据第一方面的高压罐制造方法中,预制件制造步骤包括在衬里的主体部(trunk portion)上形成至少20层的纤维层。
当如在根据第二方面的压力罐制造方法中那样在预制件制造步骤中形成有至少20层的纤维层时,通常难以使树脂浸渍直到纤维层的内层。然而,在本制造方法中,通过以其中具有不同厚度的纤维束相邻的状态卷绕到衬里上的具有不同厚度的纤维束建立了树脂通道。因此,即使卷绕了至少20层纤维束,树脂也容易浸渍直到纤维层的内层。因此,可制造出具有高强度的高压罐。
在根据第三方面的高压罐制造方法中,在根据第一方面或第二方面的高压罐制造方法中,在预制件制造步骤中,沿宽度方向排列至少三个纤维束并同时卷绕所述纤维束,在所述至少三个纤维束中彼此相邻的两个纤维束的每一组合中,两个纤维束的厚度彼此不同。
在根据第三方面的高压罐制造方法中,沿宽度方向排列并同时卷绕的所述至少三个纤维束中彼此相邻的两个纤维束的每一组合中,两个纤维束的厚度彼此不同。因此,可在预制件的纤维层中有效地形成间隙(树脂通道)。
在根据第四方面的高压罐制造方法中,在根据第一方面或第二方面的高压罐制造方法中,在预制件制造步骤中,沿宽度方向排列至少三个纤维束并同时卷绕所述纤维束;在所述至少三个纤维束中彼此相邻的两个纤维束的每一组合中,两个纤维束的厚度彼此不同;并且在所述预制件制造步骤中卷绕的所述至少三个纤维束中包含的厚度尺寸的类型数目为2。
在根据第四方面的高压罐制造方法中,沿宽度方向排列并同时卷绕的所述至少三个纤维束中彼此相邻的两个纤维束的每一组合中,两个纤维束的厚度彼此不同。另外,由于在预制件制造步骤中卷绕的多个纤维束中存在两种类型的厚度尺寸,因而可在预制件的纤维层中有效地形成间隙(树脂通道),除此之外,可采用小数目的纤维束类型并且可降低成本。
在根据第五方面的高压罐制造方法中,在根据第一方面至第四方面中任一者的高压罐制造方法中,在预制件制造步骤中同时卷绕的多个纤维束的每单位长度的纤维重量彼此相等。
在根据第五方面的高压罐制造方法中,在预制件制造步骤中卷绕的多个纤维束的每单位长度的纤维重量彼此相等。因此,在预制件的纤维层中形成的间隙(树脂通道)更可能在成型步骤中在压缩成型中均匀地填充以纤维。因此,预制件中纤维之间的间隙可在成型步骤之后的制品中更有效地减小。
在根据第六方面的高压罐制造方法中,在根据第一方面至第五方面中任一者的高压罐制造方法中,预制件制造步骤至少包括通过以其中具有不同厚度的干燥纤维束彼此相邻的状态环向卷绕将具有不同厚度的干燥纤维束卷绕到衬里上。
使树脂浸渍到通过环向卷绕形成的纤维层中是特别难的。然而,在根据第六方面的高压罐制造方法中,不同厚度的干燥纤维束以使得彼此相邻的状态卷绕到衬里上。结果,可有效地改善树脂浸渍的均匀性。
在根据第七方面的高压罐制造方法中,在根据第一方面至第六方面中任一者的高压罐制造方法中,成型步骤包括压缩成型,所述压缩成型包括在注入树脂后完全闭合模具。
在根据第七方面的高压罐制造方法的成型步骤中,在将预制件布置于模具内并注入树脂后,完全闭合模具并使纤维增强塑性层压缩成型。因此,预制件中纤维之间的间隙可在成型步骤之后的制品中有效地减小。
如上所述,根据本公开,可以低成本制造可靠品质的高压罐。
附图说明
图1为示出了根据一个示例性实施方案的长丝卷绕装置的总体结构图。
图2A为示出了其中多个纤维束(即四个纤维束)在卷绕到衬里上时沿宽度方向排列的状态的示意图。
图2B为示意性地示出了预制件的纤维层的纤维分层结构的截面图。
图3A为示出了其中在RTM成型步骤中环氧树脂正被注入的状态的截面图。
图3B为示出了其中在RTM成型步骤中模具被完全闭合的状态的截面图。
具体实施方式
首先,使用图1描述根据一个示例性实施方案的长丝卷绕装置10,并描述使用长丝卷绕装置10的预制件制造步骤。
图1示出了长丝卷绕装置10的总体结构。长丝卷绕装置10为用于制造待安装于燃料电池车中的高压罐(高压氢罐)的装置。长丝卷绕装置10用于以高速供应纤维束40并将纤维束40卷绕到衬里80上。
如图1中所示,长丝卷绕装置10配备有退绕部20和抵接部(abutment section)30。
从上游侧开始,退绕部20包括多个(在本示例性实施方案中为4个)线轴21、与线轴21对应设置的多个退绕辊22、捆扎辊23、主动式浮动辊(active dancer)24,以及多个(在本示例性实施方案中为3个)传送辊25、26和27。
纤维束40被卷绕到线轴21上。纤维束40为未浸渍有树脂的“干燥”碳纤维束。
所述多个线轴21从图的左侧开始依次由第一线轴21A、第二线轴21B、第三线轴21C和第四线轴21D构成。第一纤维束40A卷绕到第一线轴21A和第三线轴21C上,第二纤维束40B卷绕到第二线轴21B和第四线轴21D上。第一纤维束40A具有例如9mm的宽度和0.1mm的厚度,第二纤维束40B具有例如6mm的宽度和0.15mm的厚度。第一纤维束40A和第二纤维束40B各自由大约36,000根碳纤维构成。也就是说,第一纤维束40A和第二纤维束40B具有彼此相同的每单位长度的纤维重量,但宽度和厚度彼此不同。
退绕辊22将从线轴21退绕的纤维束40传送到捆扎辊23。捆扎辊23收集从线轴21退绕的纤维束40并使纤维束40退绕到主动式浮动辊24上。主动式浮动辊24通过移动辊24A来调节纤维束40中的张力(参见图1中的箭头)。已调节张力的纤维束40经由多个传送辊25、26和27传送到抵接部30。抵接部30收集多个(4个)纤维束40,施加适当的张力,并组织纤维束40的构型。已由抵接部30组织构型的纤维束40被卷绕到衬里80上。
当从所述多个线轴21退绕的多个纤维束40被卷绕到衬里80上时,纤维束40如图2A中所示沿宽度方向排列。排列顺序与从第一线轴21A到第四线轴21D的顺序相匹配。因此,从图2A的左侧开始,第一纤维束40A、第二纤维束40B、第一纤维束40A和第二纤维束40B沿宽度方向以此顺序排列。因此,沿宽度方向排列的四个纤维束40中两个相邻纤维束40的每一组合(总共3个组合)中,两个相邻纤维束40在厚度上彼此不同。此外,施加控制使得任何两个相邻纤维束40之间沿宽度方向不形成间隙。
在其中所述多个纤维束40沿宽度方向排列的状态下,将多个纤维束40卷绕多圈以完全覆盖衬里80,从而在衬里80上形成树脂层52(参见图2B)。以此方式,制得预制件50。
也就是说,所制造的预制件具有衬里80并且具有由卷绕到衬里80上的纤维束40形成的树脂层52。形成树脂层52的纤维束40的层数不受特别限制,但在衬里80的主体部处为为例如约20至30层。树脂层52的厚度也不受特别限制,但例如为20至30mm。术语“主体部”的含义意在包括衬里80的沿衬里80的轴向方向的中途具有圆筒形状的部分(即,夹在圆顶部之间的部分)。
图2B为示意图,其中放大示出了树脂层52的纤维分层结构54。如图2B中所示,在沿厚度方向(图2B中的垂直方向)叠置的层之间,在作为具有较小厚度的束的第一纤维束40A上方形成间隙56。间隙56起到树脂通道的作用,在下文描述的RMT成型步骤中树脂将沿该通道流动。
现在使用图3A和图3B描述成型步骤,该成型步骤为RTM成型步骤。
首先,将预制件50放置于包括上模64和下模62的模具60中。然后,如图3A中所示,使模具60处于未完全闭合而是稍微打开的状态(例如,相对于底端打开几毫米的状态)。在这种状态下注入环氧树脂(参见图3A中的箭头)。当要注入环氧树脂时,模具60的内部可被抽空。
然后,如图3B中所示,将上模64降到底端并使模具60完全闭合。因此,已向其中注入并充填有环氧树脂的树脂层52沿厚度方向被均匀压缩。因此,模具60内的环氧树脂被加热并固化。如上所述进行注射压缩成型。
–运作效果-
现在描述本示例性实施方案的运作效果。
在本示例性实施方案中,在形成预制件50的预制件制造步骤中,如图2A中所示,作为不同厚度的干燥纤维束的纤维束40以使得彼此相邻的状态卷绕到衬里80上。结果,在如图2B中所示制造的预制件50的树脂层52中,在作为具有较小厚度的纤维束的第一纤维束40A上方形成间隙56。间隙56起到树脂通道56的作用,在作为成型步骤的RTM成型步骤中环氧树脂将通过该通道流动。因此,环氧树脂易于浸渍直到树脂层52的内层,并可改善树脂浸渍的均匀性。
在成型步骤中,在预制件50被布置于模具中并注入树脂后,通过完全闭合模具60进行压缩成型(即,注射压缩成型)。因此,已向其中浸渍环氧树脂的树脂层52可沿厚度方向被均匀压缩,并且预制件50中纤维之间的间隙56可在成型步骤之后的制品中有效减小。
在本示例性实施方案中,沿宽度方向排列并同时卷绕的多个(4个)纤维束40中,树脂层52中任何两个相邻纤维束之间沿宽度方向不形成间隙。因此,与其中在树脂层52中相邻一对纤维束之间沿宽度方向形成间隙的模式相比,制品的纤维体积含量比往往要高。因此,可制造出具有高强度的高压罐。
在本示例性实施方案中,沿宽度方向排列并同时卷绕的四个纤维束中彼此相邻的两个纤维束的每一组合(总共三个组合)中,两个相邻纤维束在厚度上彼此不同。因此,可在预制件50的树脂层52中有效地形成间隙56(树脂通道)。
在本示例性实施方案中,在预制件制造步骤中卷绕的多个纤维束40中包含的厚度尺寸的类型数目为2(第一纤维束40A和第二纤维束40B)。因此,待制备的纤维束40的数目可以比其中采用3个或更多个厚度尺寸类型的纤维束40的模式更少,并且成本更低。
在本示例性实施方案中,在预制件制造步骤中卷绕的多个纤维束40的每单位长度的纤维重量彼此相等。因此,在预制件的纤维层中形成的间隙(树脂通道)在成型步骤中更可能被纤维均匀填充。因此,预制件50中纤维之间的间隙56可以在成型步骤之后的制品中甚至更有效地减小。
-补充说明-
在上面的示例性实施方案中,描述了其中沿宽度方向排列并同时卷绕四个纤维束40的示例(参见图2A),但本公开不限于此。可能有两个或三个束,并且可能有五个或更多个束。
此外,在上面的示例性实施方案中,描述了其中相邻的纤维束(第一纤维束40A和第二纤维束40B)在厚度和宽度上都不同的示例,但本公开不限于此。例如,具有不同厚度的相邻束可具有相同的宽度。
在上面的示例性实施方案中,描述了其中虽然相邻的纤维束(第一纤维束40A和第二纤维束40B)在厚度上不同但它们具有相同的每单位长度的纤维重量的示例。然而,本公开不限于此。
在图2B中,示意性地示出了其中卷绕到衬里80上的卷绕角度沿分层方向在叠置的相邻层之间彼此相差很大的情况,但本公开不限于此。即便卷绕角度之间的差异小而不是大,也可形成间隙56。
在上面的示例性实施方案中,描述了其中在相邻的纤维束40之间沿宽度方向不形成间隙的示例(参见图2A和2B),但本公开不限于此。在一定程度上形成间隙(即,宽度方向上的间隙)是可接受的。
在上面的示例性实施方案中,描述了其中沿宽度方向排列并同时卷绕的四个纤维束中彼此相邻的两个纤维束的每一组合(总共三个组合)中两个相邻的纤维束在厚度上彼此不同的示例,但本公开不限于此。例如,沿宽度方向排列并同时卷绕的所述四个纤维束40中,一个束可为具有较小厚度的第二纤维束40B,而另外三个束可为具有较大厚度的第一纤维束40A。
在上面的示例性实施方案中,描述了其中纤维束为碳纤维束的示例,但纤维束可为例如玻璃纤维束。此外,在上面的示例性实施方案中,描述了其中树脂为环氧树脂的示例,但树脂的类型不限于此。
在上面的示例性实施方案中,描述了其中通过在注入树脂后完全闭合模具60来进行压缩成型的示例,但本公开不限于此。可以在其中模具被完全闭合的状态下注入树脂。
向通过衬里80的主体部的环向卷绕(即,基本垂直于衬里80的中心轴进行卷绕)形成的纤维层中浸渍树脂是特别困难的。因此,在衬里80的主体部的环向卷绕中使用具有不同厚度的纤维是优选的。
Claims (7)
1.一种高压罐制造方法,包括:
预制件制造步骤,包括以其中具有不同厚度的干燥纤维束彼此相邻的状态将所述具有不同厚度的干燥纤维束卷绕到衬里上;和
成型步骤,包括将在所述预制件制造步骤中制造的所述预制件布置于模具中并注入树脂。
2.根据权利要求1所述的高压罐制造方法,其中所述预制件制造步骤包括在所述衬里的主体部上形成至少20层的纤维层。
3.根据权利要求1或权利要求2所述的高压罐制造方法,其中:
在所述预制件制造步骤中,沿宽度方向排列至少三个纤维束并同时卷绕所述纤维束,
在所述至少三个纤维束中彼此相邻的两个纤维束的每一组合中,所述两个纤维束的厚度彼此不同。
4.根据权利要求1或权利要求2所述的高压罐制造方法,其中:
在所述预制件制造步骤中,沿宽度方向排列至少三个纤维束并同时卷绕所述纤维束,
在所述至少三个纤维束中彼此相邻的两个纤维束的每一组合中,所述两个纤维束的厚度彼此不同,和
在所述预制件制造步骤中卷绕的所述至少三个纤维束中包含的厚度尺寸的类型数目为2。
5.根据权利要求1至4中任一项所述的高压罐制造方法,其中在所述预制件制造步骤中同时卷绕的多个所述纤维束的每单位长度的纤维重量是彼此相等的。
6.根据权利要求1至5中任一项所述的高压罐制造方法,其中所述预制件制造步骤至少包括以其中所述具有不同厚度的干燥纤维束彼此相邻的状态通过环向卷绕将所述具有不同厚度的干燥纤维束卷绕到所述衬里上。
7.根据权利要求1至6中任一项所述的高压罐制造方法,其中所述成型步骤包括压缩成型,所述压缩成型包括在注入所述树脂后完全闭合所述模具。
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JP6801620B2 (ja) | 2020-12-16 |
CN109551778B (zh) | 2021-07-06 |
JP2019059176A (ja) | 2019-04-18 |
US20190091919A1 (en) | 2019-03-28 |
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US10889051B2 (en) | 2021-01-12 |
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