WO2020251001A1 - 燃料タンク - Google Patents
燃料タンク Download PDFInfo
- Publication number
- WO2020251001A1 WO2020251001A1 PCT/JP2020/023141 JP2020023141W WO2020251001A1 WO 2020251001 A1 WO2020251001 A1 WO 2020251001A1 JP 2020023141 W JP2020023141 W JP 2020023141W WO 2020251001 A1 WO2020251001 A1 WO 2020251001A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fuel tank
- support column
- steel
- upper panel
- panel
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
- B60K15/03—Fuel tanks
- B60K15/063—Arrangement of tanks
- B60K15/067—Mounting of tanks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
- B60K15/03—Fuel tanks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
- B60K15/03—Fuel tanks
- B60K15/077—Fuel tanks with means modifying or controlling distribution or motion of fuel, e.g. to prevent noise, surge, splash or fuel starvation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D25/00—Details of other kinds or types of rigid or semi-rigid containers
- B65D25/02—Internal fittings
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M37/00—Apparatus or systems for feeding liquid fuel from storage containers to carburettors or fuel-injection apparatus; Arrangements for purifying liquid fuel specially adapted for, or arranged on, internal-combustion engines
- F02M37/0047—Layout or arrangement of systems for feeding fuel
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
- B60K15/03—Fuel tanks
- B60K2015/03032—Manufacturing of fuel tanks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
- B60K15/03—Fuel tanks
- B60K2015/03328—Arrangements or special measures related to fuel tanks or fuel handling
- B60K2015/0344—Arrangements or special measures related to fuel tanks or fuel handling comprising baffles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
- B60K15/03—Fuel tanks
- B60K2015/03328—Arrangements or special measures related to fuel tanks or fuel handling
- B60K2015/03453—Arrangements or special measures related to fuel tanks or fuel handling for fixing or mounting parts of the fuel tank together
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
- B60K15/03—Fuel tanks
- B60K2015/03486—Fuel tanks characterised by the materials the tank or parts thereof are essentially made from
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K15/00—Arrangement in connection with fuel supply of combustion engines or other fuel consuming energy converters, e.g. fuel cells; Mounting or construction of fuel tanks
- B60K15/03—Fuel tanks
- B60K15/077—Fuel tanks with means modifying or controlling distribution or motion of fuel, e.g. to prevent noise, surge, splash or fuel starvation
- B60K2015/0777—Fuel tanks with means modifying or controlling distribution or motion of fuel, e.g. to prevent noise, surge, splash or fuel starvation in-tank reservoirs or baffles integrally manufactured with the fuel Tank
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
- B60Y2200/00—Type of vehicle
- B60Y2200/90—Vehicles comprising electric prime movers
- B60Y2200/92—Hybrid vehicles
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/62—Hybrid vehicles
Definitions
- the present invention relates to a fuel tank, and more particularly to a steel fuel tank having a pressure resistance and a weight reduction.
- the present application claims priority based on Japanese Patent Application No. 2019-109355 filed in Japan on June 12, 2019, the contents of which are incorporated herein by reference.
- Patent Document 1 discloses a technique in which protrusions formed on the upper and lower surfaces of facing resin tanks are welded together to form a support. ing.
- the fuel tank Since the fuel tank is installed near the underbody of the vehicle and the road surface, the fuel tank and fuel are heated by the reflection from the road surface, especially in summer, and the fuel temperature rises to 50 ° C or higher. There is. It is considered that this softens the resin and the resin bends due to the weight of the fuel. Furthermore, the deflection increases as the vapor pressure of the fuel rises due to the temperature rise. By providing the support column, the bending is reduced and the amount of deformation of the fuel tank is suppressed.
- HV Hybrid Vehicle
- PHV Plug-in Hybrid Vehicle
- the operating time of the engine tends to be shortened, and the gasoline vapor generated inside the fuel tank is not purged by the engine and the internal pressure is increased. Is said to increase. Therefore, the pressure resistance of the fuel tank has been increased, and the rigidity of the resin tank has been improved by adding columns inside more than ever before.
- measures are taken by increasing the plate thickness, but increasing the plate thickness leads to an increase in the weight of the fuel tank and has been pointed out as having an effect on vehicle fuel efficiency.
- HVs and PHVs require a battery and a case to store it, which increases the weight of the entire vehicle. From the above, the demand for pressure reduction and weight reduction of fuel tanks is stronger than ever.
- Patent Document 2 a method of installing a resin strut inside a steel tank to improve pressure resistance and, as a result, to reduce the weight of the fuel tank is disclosed as Patent Document 2 in the name of the applicant.
- This method is a method of screwing a metal pedestal and screwing resin columns, but at least a parallel surface for installing the pedestal is required on the lower surface facing the upper surface of the fuel tank.
- HV and PHV batteries have tended to increase in capacity. Therefore, a large area under the vehicle floor is being used for mounting batteries.
- the fuel tank has been placed around the battery mounting position, and attempts have been made to minimize the horizontal projected area. That is, fuel tanks having a shape close to a cube or a rectangular parallelepiped are being adopted for HVs and PHVs. Furthermore, it is expected that the full capacity of the fuel tank will decrease due to the improvement of fuel efficiency.
- Patent Document 3 discloses a method of ensuring rigidity with a resin column having a universal joint structure at the periphery of the opening.
- the present invention proposes the following means.
- the fuel tank according to one aspect of the present invention is arranged in an internal space formed by facing a steel lower panel and a steel upper panel, and the lower panel and the upper panel facing each other.
- the lower end is fixed to the lower panel, and the second end is provided with at least one steel column fixed to the upper panel in a state of being arranged in a hole formed in the upper panel.
- a steel first nut fixed to the inner surface of the lower panel and fitted with the first end portion of the support column, and arranged on the inner surface of the upper panel and attached to the support column.
- a tin plating layer or a tin zinc plating layer may be provided on the outer surfaces of the support column, the first nut, and the second nut.
- the solder that seals between the upper panel and the second nut may be provided.
- a steel columnar beam may be attached to at least one pair of facing wall surfaces of the lower panel and the upper panel.
- the first baffle plate may be attached to the beam.
- a second baffle plate may be attached to the support column.
- the pressure resistance of the fuel tank can be increased and the weight can be reduced.
- FIG. 3 is a cross-sectional view showing an outline of a state in which the fuel tank 10 according to the embodiment of the present invention is separated into an upper panel 11 and a lower panel 12.
- the fuel tank 10 is, for example, a fuel tank for an automobile, and includes a steel upper panel 11 and a steel lower panel 12.
- the steel fuel tank 10 has an advantage that gasoline vapor does not easily leak because the shape is simple and the fuel tank 10 is made of metal as compared with the resin fuel tank.
- the upper panel 11 is formed at a recess 11a forming an internal space V for storing fuel and an edge of the recess 11a for joining the upper panel 11 and the lower panel 12. It has a flange portion 11b.
- the lower panel 12 has a recessed portion 12a forming an internal space V for storing fuel and a flange portion 12b formed on the edge of the recessed portion 12a for joining the upper panel 11 and the lower panel 12. And have.
- the flange portion 11b of the upper panel 11 and the flange portion 12b of the lower panel 12 are joined by, for example, seam welding.
- the internal space V is formed so that the upper panel 11 and the lower panel 12 face each other.
- the fuel tank 10 is often placed in the periphery of the battery mounting position in the vehicle. Therefore, it is preferable that the fuel tank 10 has a rectangular parallelepiped shape that can keep the horizontal projected area as small as possible while keeping the volume as large as possible.
- the corners between the adjacent surfaces of the six surfaces constituting the rectangular parallelepiped fuel tank 10 may be rounded.
- the fuel tank 10 includes a support column 100 extending in the direction in which the upper panel 11 and the lower panel 12 face each other in the internal space V.
- the support column 100 is a reinforcing member provided to increase the rigidity of the fuel tank 10.
- the strut 100 is made of a steel wire or bar (steel strut). The reason why steel is selected for the support column 100 here is that it is inexpensive and has high strength.
- the support column 100 may be carbon steel or stainless steel, and may be appropriately coated with plating or the like.
- the number of columns 100 included in the fuel tank 10 is not limited, and may be one or two or more.
- the deformation of the fuel tank 10 can be efficiently suppressed while reducing the volume occupied by the columns in the internal space V as much as possible.
- deformation of the upper panel 11 and the lower panel 12 can be efficiently suppressed.
- by arranging the columns 100 so as to surround the periphery of the first hole 11c for mounting the pump deformation of the fuel tank 10 including the upper panel 11 and the lower panel 12 can be efficiently suppressed.
- the internal pressure rises to, for example, about 40 kPa.
- the force applied to the inner surface of the upper panel 11 and the inner surface of the lower panel 12 of the fuel tank 10 shown in FIG. 1 is 40 kN / m 2 . Assuming that the inner area of the fuel tank 10 is 1 m 2 , a force of 40 kN (4.08 tons) is applied to this inner surface. Not all of this force is applied to the support column 100, but it is necessary to design an appropriate plate thickness and to share the load applied to the wall surface of the fuel tank 10 and the load applied to the support column 100.
- a tensile force of several tens to several hundreds of kgf is applied to the support column 100 at the time of positive pressure, and a similar compressive force is applied at the time of negative pressure.
- a tensile or compressive force of 100 kgf (980 N) is applied and a strut 100 having a diameter of 6 mm is used
- the stress applied to the strut 100 is the formula (100 ⁇ 9.8 ⁇ (3 ⁇ 3 ⁇ 3.14)). Therefore, it becomes 34.6 MPa. Since the tensile strength of the steel material of S10C specified in JIS-G-4051: 2016 is 310 MPa or more, it can be seen that even a diameter of 6 mm has sufficient strength.
- the significance of installing the support column 100 is to suppress the displacement of the panels 11 and 12 due to pressure. Therefore, the length of the support column 100 must not change significantly due to stress.
- the stress applied to the strut 100 is below the elastic limit, preferably less than half of the yield point.
- Yield point is generally defined as 0.2% proof stress, that is, a load that leaves 0.2% permanent strain during a tensile test.
- the diameter of the column 100 should be designed so that the load is less than half of the yield point in the sense that it is used in the complete elastic region. Good.
- the steel support column 100 has a diameter of 6 mm and is a portion located in the internal space V according to the height dimension of the fuel tank 10. .. It is assumed that the height of the fuel tank 10 (the length of the portion of the support column 100 located in the internal space V) is 200 mm. In this case, the portion of the steel column 100 located in the internal space V has a volume of 5.65 cm 3 and a mass of 44.4 g.
- the allowable stress at the time of use can be set to about 150 MPa or less, which is a complete elastic region.
- a resin support when applied to a fuel tank 10 having the same internal pressure as the above-mentioned predetermined internal pressure and having the same height dimension, it is made of a general resin (for example, polyacetal). Considering that the columns have low tensile strength, yield strength, etc., low melting point of about 160 degrees Celsius, and low stability of mechanical properties such as Young's modulus, strength, and complete elastic range against changes in environmental temperature. Therefore, it is necessary to set the allowable stress during use to about 10 MPa or less for the design. Therefore, when a resin support is used, its size is at least 24 mm in diameter and 200 mm in height (length).
- a general resin for example, polyacetal
- the portion located in the internal space V of the resin column has a volume of 90 cm 3 and a mass of 128 g, and both the volume and the mass are larger than those of the steel column.
- the difference in volume is very large.
- the steel support column 100 can have a smaller volume and a smaller mass while maintaining the required strength as compared with the resin support column 100. Therefore, the fuel tank 10 in the present embodiment can reduce the volume occupied by the columns 100 in the internal space V of the fuel tank 10 as much as possible. Therefore, the effective volume (volume) for storing the fuel in the internal space V of the fuel tank 10 can be secured as large as possible.
- the fuel tank 10 including the support column 100 can be made lighter, and the proof stress against internal pressure can be increased.
- Screw processing is performed on both ends of the support column 100 to fix it with nuts.
- the first male screw 101 is formed at the lower end (first end) of the support column 100
- the second male screw 102 is formed at the upper end (second end) of the support column 100.
- the annular flange 105 is fixed at the position of the support column 100 according to the height inside the fuel tank 10.
- the flange 105 is installed in a state in which the central axis when the annular flange 105 is viewed in a plan view extends along the axis of the support column 100 in a direction perpendicular to the entire circumference of the support column 100.
- the support column 100 can receive the load from the upper panel 11 over a wide area via the flange 105, so that the second hole 11d formed in the upper panel 11 Deformation in the vicinity of the second hole 11d including the inner edge of the second hole 11d can be suppressed. Therefore, the durability of the fuel tank 10 can be improved.
- the upper panel 11 may be displaced and deformed with the outer peripheral edge of the flange 105 as a fulcrum at the time of negative pressure, resulting in fatigue. Therefore, the outer diameter of the flange 105 is set so as to pass the target positive / negative pressure fatigue test. Further, as shown in FIG.
- the upper surface of the flange 105 is provided with a slight taper that is inclined downward as it goes outward in the radial direction of the flange 105, so that the upper comes into contact with the outer peripheral edge of the flange 105.
- the amount of distortion on the panel 11 side can be reduced.
- the fuel tank 10 must also be considered for collision safety. That is, in the event of a collision, the panels 11 and 12 to which the support columns 100 are attached must be destroyed to prevent fuel from leaking. Therefore, the diameter of the screw and the height of the thread at the bottom of the support column 100 are broken so that the screwed portion between the first nut 21 and the support column 100 attached to the chamber stay 20 on the lower panel 12 side shown in FIGS. 2 and 3 is broken. And the number of threads can be adjusted.
- the support column 100 should be surface-treated in order to prevent corrosion. Electrogalvanization, electrotin plating, electrotin zinc plating, electronickel plating are recommended. That is, a zinc plating layer, a tin plating layer, a tin zinc plating layer, and a nickel plating layer may be provided on the outer surface of the support column 100. When tin-galvanized steel sheets are used for the panels 11 and 12 and the baffle stay, it is preferable to select electrogalvanized tin-zinc plating in order to prevent electrolytic corrosion inside the fuel tank 10.
- the support column 100 is attached by the first steel nut 21.
- a circular chamber stay 20 is used for attaching the first nut 21 on the lower panel 12 side.
- FIG. 5 shows a state in which the first nut 21 is attached to the chamber stay 20 at three places.
- a hole having a diameter 1 mm larger than the hole diameter of the first nut 21 is drilled in the mounting portion of the first nut 21 on the chamber stay 20.
- the first nut 21 is projected welded there.
- a projection may be provided on the first nut 21 side, or a projection (projection) may be provided on the chamber stay 20 side.
- the first nut 21 is provided on the inner surface of the lower panel 12 corresponding to the support column 100.
- the chamber stay 20 to which the first nut 21 is attached is attached to the lower panel 12 by spot welding.
- the reinforcement (reinforcing member) 22 is attached to the outer surface side of the lower panel 12, the pressure is increased. Deformation of the lower panel 12 due to fluctuation can be suppressed.
- the welded portion formed by spot welding in FIG. 6 is indicated by reference numeral 23.
- the reinforcement 22 is attached, a gap may be generated between the lower panel 12 and the reinforcement 22 when the pressure fluctuates. If dust enters this gap, there is a concern that the pressure fatigue strength of the fuel tank 10 will decrease. Therefore, it is effective to apply an elastic coating film to the peripheral edge of the reinforcement 22 so that dust does not enter the mating portion (gap).
- the gap can be closed by pouring tin-zinc solder into the gap. In particular, when solder is used, the strength is secured in terms of surface, so that the effect of the reinforcement 22 is enhanced.
- the diameter of the reinforcement 22 is increased by about 0 to 20 mm from the diameter of the chamber stay 20. Without the reinforcement 22, stress concentration occurs on the welded portion 23 where the chamber stay 20 and the lower panel 12 are spot-welded, and the lower panel 12 is likely to be deformed.
- the position of the welded portion 23 by spot welding is not particularly specified, but it is preferably near the portion where the first nut 21 is projected welded, where stress tends to concentrate when the pressure fluctuates. Examples of the welded portion 23 are shown in FIGS. 5 and 6.
- the first nut 21 is fixed to the inner surface of the lower panel 12 via the chamber stay 20.
- the first male screw 101 formed at the lower end of the support column 100 is fitted to the first nut 21, and the lower panel 12 and the support column 100 are connected via the first nut 21 and the chamber stay 20. As a result, the lower end of the support column 100 is fixed to the lower panel 12.
- the lower end of the support column 100 may be fixed to the lower panel 12 by welding or the like.
- the support column 100 on the upper panel 11 side is also attached by the second nut 107.
- the upper panel 11 is formed with a first hole 11c for mounting the pump.
- the first hole 11c is formed in the center of the upper panel 11 in a plan view.
- a second hole (hole) 11d for mounting the support column 100 is opened in the upper panel 11.
- a second hole 11d is opened at a portion directly above the mounting position of the first nut 21 on the lower panel 12 side.
- the diameter of the second hole 11d is the same as the diameter of the support column 100, and when a hole expanding process of about 0.5 mm larger than the diameter of the second hole 11d is performed toward the outer surface side of the upper panel 11, the second hole 11d is formed.
- the upper end of the support column 100 can be easily attached. Further, you may put your hand through the first hole 11c, adjust the position of the support column 100, and insert the upper end portion of the support column 100 into the second hole 11d. In addition, stress concentration is likely to occur at the edge of the second hole 11d of the upper panel 11. Adding a taper to the second hole 11d by drilling is also effective in alleviating stress concentration due to deformation of the panels 11 and 12 during pressurization and depressurization.
- the lower portion of the upper end portion of the support column 100 is arranged in the second hole 11d, and the upper portion of the upper end portion of the support column 100 projects upward from the second hole 11d. That is, a part of the support column 100 is arranged in the internal space V.
- the flange 105 is arranged on the inner surface of the upper panel 11.
- the support column 100 is attached by screwing the second nut 107 from the outside.
- the second nut 107 is fixed to the upper end portion of the support column 100 by being fitted to the second male screw 102 formed on the upper end portion of the support column 100 in a state of being arranged on the outer surface of the upper panel 11.
- the second nut 107 and the flange 105 sandwich the upper panel 11 in the vertical direction.
- the upper end of the support column 100 is fixed to the upper panel 11.
- the upper end of the support column 100 may be fixed to the upper panel 11 by welding or the like.
- a packing (seal, gasket, or O-ring, not shown) is installed between the second nut 107 and the upper panel 11 to ensure the sealing property.
- the material of the packing is not particularly specified, but in consideration of the durability of long-term specifications, a donut-shaped washer 108A (see FIG. 4) in which a solder sheet is punched may be used. After the washer 108A is screwed into the support column 100 with the second nut 107, heat is applied to the portion to melt the washer 108A, and the washer 108A is further cooled and solidified to obtain the solder 108. As a result, the solder 108 seals between the upper panel 11 and the second nut 107, and the airtightness of the fuel tank 10 can be ensured.
- plating treatment on the nuts 21 and 107 is preferable, and electrogalvanizing, electrotin plating, electrotin zinc plating, and nickel nickel plating are recommended. That is, it is preferable that the outer surfaces of the nuts 21 and 107 are provided with a zinc plating layer, a tin plating layer, a tin zinc plating layer, and a nickel plating layer.
- tin-galvanized steel sheets are used for the panels 11 and 12
- electric tin-zinc plating is preferable from the viewpoint of reducing the concern about electrolytic corrosion.
- electrogalvanization is excellent in solder wettability.
- Electrotin galvanization is preferred.
- Electrotin-zinc plating is also preferable from the viewpoint of ensuring airtightness.
- Beam structure [Beam structure / mounting structure]
- the column 100 By installing the column 100 on the edge of the pump, it is possible to suppress the displacement of the upper and lower surfaces of the panels 11 and 12 at the time of positive and negative pressure, but the wrinkles are the seam-welded flanges 11b and 12b of the fuel tank 10. Appears in the vicinity of. That is, the displacement of the wall surfaces of the panels 11 and 12 becomes large.
- the seam-welded flanges 11b and 12b of the fuel tank 10 are reinforced with reinforcement and attached to the vehicle frame with bolts via the reinforcement, the lateral direction (panels 11 and 12 are displaced due to the rigidity of the vehicle frame. The displacement in the direction orthogonal to the opposite direction) can be suppressed, but when the fuel tank 10 is attached to the vehicle frame with a belt, the lateral displacement of the fuel tank 10 cannot be suppressed.
- FIG. 8 it is preferable to provide a steel columnar beam 30 inside the fuel tank 10.
- a steel attachment 31 attachment for attaching the beam 30 shown in FIGS. 8 and 9 is attached to the wall surface by spot welding.
- the beam 30 is shown by a chain double-dashed line in FIG.
- the fixture 31 has a hat-shaped structure, and flanges 30a provided at both ends of the beam 30 are fitted therein.
- fins 32 for preventing disconnection to the opening 31a of the hat-shaped structure.
- the steel fin 32 When the flange 30a is fitted into the fitting 31, the steel fin 32 is bent inward, and after fitting, the flange 30a is prevented from coming off by the springback of the fin 32.
- the size of the fins 32 is designed to be strong enough to fit manually.
- the flange shape of the beam 30 may be circular or quadrangular. In the case of a quadrangle, if it is trapezoidal, the upper bottom is shorter than the lower bottom, and it is inserted into the space of the steel fixture 31 from the upper end side, the mounting becomes easy.
- the strength of the fixture 31 is controlled by the plate thickness and material of the fixture 31. However, it is also possible to ensure the strength of the fixture 31 on the surface by pouring solder metal into the gap of the fixture 31.
- the beam 30 has a flange structure having a flange 30a at one end and a screw structure 34 at the other end.
- a nut 34a is attached to a quadrangular steel plate by projection welding, and a threaded portion 34b of the beam 30 is screwed into the nut 34a to form a flange 30a on the other end side. Since the length of the beam 30 can be adjusted by the rotation speed at the time of screwing, it is possible to absorb the variation in the inner diameter of the panels 11 and 12 due to the pressing accuracy of the panels 11 and 12.
- both ends of the beam 30 may have a flange structure, or both ends may have a flange structure using screws and nuts.
- a flange structure using nuts and screws it is necessary to increase the diameter of the U-shaped opening 31a of the fixture 31 which is a hat-shaped metal fitting.
- two beams 30 having a flange structure at one end and a screw structure at the other end are prepared, and screwed into the screw structure of the two beams 30 with an extension nut 35 used for bolt fastening. You can also let it.
- the beam 30 is attached to at least one pair of facing wall surfaces of the upper panel 11 and the lower panel 12.
- the wall surface of the fuel tank 10 tries to be displaced due to the pressure fluctuation.
- the beam structure suppresses this, but stress is concentrated on the spot welded portion of the mounting tool 31 that supports the beam 30.
- the places where stress is concentrated are the mating surfaces of the panels 11 and 12 of the fuel tank 10 and the steel fixture 31 for beam mounting, and the heat-affected zone during spot welding. Due to the pressure fluctuation, the plastic deformation of the panels 11 and 12 gradually progresses, and finally the panels 11 and 12 of the fuel tank 10 are damaged. From the viewpoint of preventing this, it is preferable to install a strength reinforcing reinforcement plate on the opposite side of the steel fixture 31 for beam mounting. As a result, the stress concentration on the heat-affected zone can be dispersed.
- the reinforcement plate should be about the same thickness as the panels 11 and 12, and the size should be the same as or larger than the size of the mounting tool 31 for beam mounting by about 0 to 20 mm in both vertical and horizontal directions.
- a gap is formed between the lower panel 12 and the reinforcement 22, and there is a concern that dust from the outside may enter into the gap and reduce the fatigue strength. Therefore, in order to prevent the adhesion of dust, it is necessary to apply an elastic coating film to the gap or close the gap portion by soldering.
- baffle plate Installation of baffle plate>
- the high-pressure tank is necessary for the fuel tank of a hybrid vehicle (HV) or a plug-in hybrid vehicle (PHV) as described above.
- HV hybrid vehicle
- PSV plug-in hybrid vehicle
- the engine is running for a short time and the interior of the vehicle is quiet. Therefore, it becomes easy to hear the rocking sound of the fuel during operation.
- Supports or beams can be used to suppress fuel swing.
- the fuel tank 10 may include a sheet-shaped second baffle plate 40 (also referred to as a vertical panel).
- the second baffle plate 40 is arranged in the internal space V of the fuel tank 10 so that the thinnest plate thickness direction is along the horizontal direction, that is, the plate surface is along the vertical direction.
- the second baffle plate 40 may be attached to the support column 100.
- a hole 41 is formed in the side surface of a sheet-shaped second baffle plate 40 made of resin processed into a cylindrical shape (hollow cylindrical shape), and fins 42 are further provided to suppress the flow of fuel.
- a small-diameter hollow cylindrical cylindrical structure 43 through which the support column 100 can be passed is attached on the side surface of the cylindrical (hollow cylindrical) second baffle plate 40.
- a second baffle plate 40 can be passed from the upper part of the support column 100, and the second baffle plate 40 can be attached in a state where the support column 100 is fitted in the baffle plate 40. ..
- the second baffle plate 40 is made of resin, the weight per volume occupied in the internal space V can be reduced.
- the second baffle plate 40 is not limited to the resin material, and may be made of another material such as steel.
- the fuel tank 10 may include a sheet-shaped first baffle plate 50 (also referred to as a horizontal panel).
- the first baffle plate 50 is arranged in the internal space V of the fuel tank 10 so that the thinnest plate thickness direction is along the vertical direction, that is, the plate surface is along the horizontal direction.
- the first baffle plate 50 may be attached to the support column 100. If two or more beams 30 are installed, the thickness direction of the sheet moves up and down in a state where these beams 30 are used to span the plurality of beams 30 in the lateral direction (horizontal direction). If the sheet-shaped first baffle plate 50 is provided along the direction (vertical direction), the falling fuel can be received and the splash noise can be reduced. That is, since the first baffle plate 50 is supported in a state of being straddled over the plurality of beams 30, it is possible to withstand the impact of the falling fuel and prevent the liquids from colliding with each other, resulting in a splash sound. Can be effectively reduced.
- a vertical panel is formed by forming a plate-like body extending in the vertical direction from one end or both ends of the first baffle plate 50 made of resin so that the cross-sectional shape of one end or both ends of the first baffle plate 50 is L-shaped. It is also possible to have the function of.
- the type of resin forming the second baffle plate 40 and the first baffle plate 50 is not particularly limited, but high-density polyethylene, polyacetal, nylon and the like can be considered.
- the baffle plates 40 and 50 are to be painted and baked after being assembled in the fuel tank 10, it is necessary to select a resin corresponding to the baking temperature. The melting point of the resin must be above the baking temperature.
- the resin baffle plates 40 and 50 need not be obtained by integral molding.
- the sheet-shaped plate material may be divided into several parts and molded, and they may be joined by a snap-fit structure.
- the support column 100 After the upper end of the support column 100 is passed through the second hole 11d, the support column 100 is fixed from the outside of the upper panel 11 with the second nut 107 via the sealing packing. In this way, the support column 100 can be easily constructed in the internal space V of the fuel tank 10.
- At least one support column 100 is installed in the fuel tank 10, preferably three or more columns. With one strut 100, the displacement of the panels 11 and 12 due to pressure is not sufficiently suppressed, and the panels 11 and 12 may be deformed with the place where the strut 100 is installed as a fulcrum, and strain may be collected around the strut 100. is there. In the two columns 100, there is a concern that the panels 11 and 12 may rotate around the line connecting the ends of the two columns 100. If the three columns 100 are installed, the surface connecting the ends of the three columns 100 is completely fixed, and the rigidity of the fuel tank 10 is ensured. If four or more columns 100 are installed, the load on each column 100 is reduced, but the load of the installation work of the columns 100 is increased.
- the fuel tank is installed in a vehicle and is used as a fuel, for example, as a member for storing gasoline.
- the gasoline stored in the fuel tank is located in an exhaust pipe that passes near the fuel tank due to the outside air and structure.
- the temperature is raised under the influence. Therefore, the vapor pressure of gasoline rises, and the inside of the fuel tank becomes positive pressure.
- the vapor pressure of the fuel may decrease due to the decrease in temperature, and the inside of the fuel tank may become negative pressure.
- the amount of liquid may decrease and the pressure inside the fuel tank may decrease.
- gasoline vapor is purged to the engine side through the canister during operation, and the pressure inside the fuel tank drops.
- the inside of the fuel tank repeats positive pressure and negative pressure. If the shape of the fuel tank changes due to this pressure change, there is a concern that the strain generated in a part of the panel will exceed the yield point of the steel and enter the plastic region, causing low cycle fatigue. Since the amount of deformation of the fuel tank can be suppressed by increasing the plate thickness, the plate thickness is usually designed so as not to cause low cycle fatigue.
- vibration fatigue that is, high cycle fatigue
- the fuel tank is attached to the bottom of the vehicle with bolts or belts. When the vehicle travels, vibrations from the road surface are transmitted to the fuel tank.
- the fuel tank has a predetermined vibration eigenvalue, and when the plate thickness is lowered, the eigenvalue is lowered, the frequency approaches the input frequency from the road surface, and a resonance phenomenon is likely to occur. Therefore, the plate thickness may be determined in order to avoid vibration fatigue. As described above, conventionally, it has been difficult to reduce the plate thickness of a steel fuel tank in order to avoid pressure fatigue and vibration fatigue.
- Patent Document 2 a method of installing a resin strut inside a steel tank to improve pressure resistance and, as a result, to reduce the weight of the fuel tank is disclosed as Patent Document 2 in the name of the applicant.
- This method is a method of screwing a metal pedestal and screwing resin columns, but at least a parallel surface for installing the pedestal is required on the lower surface facing the upper surface of the fuel tank. Therefore, in order to prevent deformation due to pressure around the pump opening of the fuel tank, it is the present invention that a support can be installed in a very small area called a nut instead of a pedestal.
- baffles are used for beam structures.
- a square baffle is press-fitted inside the fuselage that has become a square cylinder, and the flanges at the four corners of the baffle are fixed by spot welding. I had something to do. This is possible when there are few parts installed inside, but it is expected that various parts for pressure adjustment will be installed in the high-pressure tank for PHV, and it is possible that it will interfere with the baffle. In such a case, if the beam structure is columnar, there is little interference with the parts.
- the fuel tank 10 according to the present embodiment described above can be designed by using, for example, a computer simulation using the finite element method. Specifically, first, when the internal pressure of the fuel tank 10 is set to a positive pressure or a negative pressure without providing the support column 100, a position having a high strain range generated in the fuel tank is obtained. The support column 100 is attached to a position close to the maximum strain range position and accessible from the first hole 11c for the fuel tank 10. Since one support column 100 is unstable, two columns 100 are installed if possible. Next, the third column 100 is installed at the apex of the isosceles triangle whose base is the point where the two columns 100 are installed.
- a second hole 11d is drilled in the vicinity of the first hole 11c for mounting the pump on the upper panel 11, the support column 100 is penetrated, and the screw is fastened with the second nut 107.
- a metal pedestal with a thickness of 2 to 4 mm called the retainer 15 shown in FIG. 1 is mounted on the peripheral edge of the opening of the first hole 11c in the upper panel 11, but the support column 100 is installed in the vicinity thereof. preferable. This is because, when assembling the fuel tank 10, it is possible to work by putting a hand from the retainer 15, and by utilizing the rigidity of the retainer 15, it is possible to prevent fatigue of the mounting portion of the support column 100 on the upper panel 11 side.
- the force applied to the strut 100 is calculated by computer simulation, and the diameter of the strut 100 that can secure sufficient tensile force and buckling force is determined.
- the strength of the support column 100 is preferably twice or more the force applied to the support column 100. This is because the strut 100 is used in the completely elastic region to prevent fatigue fracture of the strut 100.
- An appropriate support column 100 is installed around the retainer 15, and the pressure is further calculated. If the bulge increases in the lateral direction and the strain increases in the vicinity of the seam-welded flange portions 11b and 12b, and there is a concern about fatigue fracture, the beam 30 is installed. The installation location of the beam 30 is in the vicinity of the portion where the strain is large.
- the plate thickness of a general high-pressure tank made of steel is 1.6 mm. Further, the sum of the weights of the upper panel 11 and the lower panel 12 is 16 kg. It has been found that when the three columns 100 are installed in the fuel tank 10, the plate thickness can be reduced to 1.2 mm while ensuring the same pressure resistance as when the plate thickness is 1.6 mm.
- the weight of the panel at this time is 12 kg. Further, when the plate thickness was 1.0 mm, the possibility of fatigue cracks was shown near the seam weld bead. Therefore, it was found that the pressure resistance can be secured even with a plate thickness of 1.0 mm by adding one beam 30.
- the weight of the panel at this time is 10 kg. When a steel column 100 having a diameter of 6 mm is used, the weight of the column 100 and the beam 30 including the weight of the nut is 100 g or less per beam. Even if this weight is added, the weight can be significantly reduced from the original weight.
- the steel fuel tank 10 is integrally formed by pressing the upper panel 11 with a flange and the lower panel 12 separately, attaching internal parts, and then seam welding the flange portions 11b and 12b on top of each other. It is processed into parts of. Since the rigidity of the side surface of the fuel tank 10 is increased by the seam welded portion, the rigidity of the upper and lower surfaces is relatively low. Therefore, by connecting the upper and lower surfaces of the fuel tank 10 with the columns 100, the overall rigidity of the fuel tank 10, that is, the pressure resistance can be increased. The internal pressure of the fuel tank 10 is evenly applied to the inner surface of the fuel tank 10.
- the deformation of the surface having low rigidity becomes large, which causes pressure fatigue fracture.
- the rigidity of the upper and lower surfaces was increased and the amount of change was reduced by installing the columns 100 on the upper and lower surfaces, a phenomenon was observed in which fatigue fracture occurred in the seam weld bead portion on the side surface. That is, when the upper and lower surfaces are not supported by the columns 100, the rigidity of the upper and lower surfaces is lower than the rigidity of the side surfaces, but when the upper and lower surfaces are supported by the columns 100, the relationship between the high and low rigidity is reversed and the rigidity of the side surfaces is higher. It is lower than the rigidity of the lower surface.
- the surface (side surface) surrounded by the width W and the height H is the WH surface
- the pressure applied to the WH surface is the PWH
- the surface (side surface) surrounded by the length L and the height H is the LH surface.
- PLH be the pressure applied to the surface.
- Seam welding lines (welding beads) are continuously provided on the WH surface and the LH surface, which are the side surfaces of the fuel tank 10, so as to orbit the fuel tank 10.
- the shape of the fuel tank 10 can be roughly classified into a cubic tank, a flat tank, and a rectangular parallelepiped tank.
- the cubic tank has a shape in which the width W, the length L, and the height H are substantially the same.
- the flat tank has a shape in which the width W and the length L are substantially equal, and the height H is smaller than the width W and the length L.
- the rectangular parallelepiped tank has a shape in which the width W or the height H is large and the length L is small.
- the concept of the support column 100 and the beam 30 when the shape of the fuel tank 10 is a cubic tank, a flat tank, and a rectangular parallelepiped tank will be described below. (1) In the case of a cubic tank In a PHV, a battery or a device for controlling the battery is installed under the rear seat, and a fuel tank may be installed next to it. Its shape is close to that of a cube.
- the pressure applied to the opposing surfaces is the same. Since the side surface has a higher rigidity than the upper and lower surfaces due to the flange structure of seam welding, it is possible to equalize the rigidity of the entire fuel tank 10 by providing the columns 100 on the upper and lower surfaces having relatively low rigidity. Installation of 30 is unnecessary.
- the height H of the fuel tank 10 may be set to about 100 to 200 mm in order to take a large space inside the vehicle.
- the pressure resistance of the fuel tank can be increased and the weight can be reduced.
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Abstract
Description
本願は、2019年6月12日に、日本に出願された特願2019-109355号に基づき優先権を主張し、その内容をここに援用する。
樹脂タンクの軽量化を可能とした技術の一つとして、例えば特許文献1には、対向する樹脂タンクの上下面に形成された内部へ突出する突起同士を溶着して支柱とする技術が開示されている。
本発明は、上記問題に鑑みてなされたものであり、燃料タンクの耐圧性を高め、かつ、軽量化を実現することを目的とする。
(1)本発明の一態様に係る燃料タンクは、鋼製のロアーパネルおよび鋼製のアッパーパネルと、前記ロアーパネルと前記アッパーパネルとを対向させて形成された内部空間に配置され、第1端部が前記ロアーパネルに固定され、第2端部が、前記アッパーパネルに形成された穴内に配置された状態で前記アッパーパネルに固定された少なくとも1つの鋼製の支柱と、を備える。
(2)上記(1)において、前記ロアーパネルの内面に固定され、前記支柱の前記第1端部が嵌め合わされた鋼製の第1ナットと、前記アッパーパネルの内面に配置され、前記支柱に固定されたフランジと、前記アッパーパネルの外面に配置され、前記支柱の前記第2端部が嵌め合わされて前記フランジとの間に前記アッパーパネルを挟む鋼製の第2ナットと、を備えてよい。
(3)上記(2)において、前記支柱、前記第1ナット、および前記第2ナットの外面に、スズめっき層、もしくは、スズ亜鉛めっき層を備えてよい。
(4)上記(2)又は(3)において、前記アッパーパネルと、前記第2ナットとの間を密閉する半田を備えてよい。
(5)上記(1)から(4)のいずれかにおいて、前記ロアーパネルおよび前記アッパーパネルの少なくとも一方の対向する一対の壁面に、鋼製で円柱状の梁が取り付けられていてよい。
(6)上記(5)において、前記梁に、第1バッフル板が取り付けられていてよい。
(7)上記(1)から(6)のいずれかにおいて、前記支柱に、第2バッフル板が取り付けられていてよい。
まず、図1から図3に基づいて、本発明の一実施形態に係る燃料タンクの概略構成について説明する。なお、図3は、本発明形態に係る燃料タンク10を、アッパーパネル11とロアーパネル12とに分離した状態の概略を示す断面図である。
内部空間Vは、アッパーパネル11とロアーパネル12とを対向させて形成される。
燃料タンク10は、車両におけるバッテリー搭載位置の周辺部に置かれることが多い。このため、燃料タンク10の容積をできるだけ大きく保ちつつ、水平投影面積を極力小さくできる直方体状であることが好ましい。なお、直方体状の燃料タンク10を構成する6つの面における隣り合う面同士の間の角部は、丸まっていてよい。
[支柱構造]
本実施形態に係る燃料タンク10は、内部空間Vに、アッパーパネル11とロアーパネル12との対向する方向に延びる支柱100を備える。支柱100は、燃料タンク10の剛性を高めるために設けられる補強部材である。支柱100は、鋼製の線材又は棒材(鋼製支柱)から成る。ここで支柱100に鋼を選んだのは、安価でかつ高い強度を有することによる。なお、支柱100は、炭素鋼又はステンレス鋼であってよく、適宜、めっき等の被覆処理がなされていてもよい。なお、燃料タンク10が備える支柱100の数に制限はなく、1つでもよいし、2つ以上でもよい。支柱100は、3つであると、内部空間Vにおいて支柱によって占有される体積をできるだけ低減しつつ、燃料タンク10の変形を効率的に抑制できる。特に、燃料タンク10において比較的大きな変形が見込まれる箇所を変形解析計算によって求め、それらの箇所に3つの支柱100を配置することが好ましい。このように支柱を配置することにより、アッパーパネル11及びロアーパネル12の変形を効率的に抑制できる。特に、ポンプ取付け用の第1穴11cの周囲を囲むように支柱100を配置することにより、アッパーパネル11及びロアーパネル12を備える燃料タンク10の変形を効率的に抑制できる。
高圧タンクの場合、内圧は例えば40kPa程度まで上昇する。図1に挙げた燃料タンク10のアッパーパネル11の内面およびロアーパネル12の内面に掛かる力は、40kN/m2となる。燃料タンク10の内面積が1m2であると仮定すると、この内面に40kN(4.08トン)の力が掛かることになる。この力すべてが支柱100に掛かるわけではないが、適正な板厚を設計し、燃料タンク10の壁面に掛かる荷重と、支柱100に掛かる荷重を分担するように設計を行う必要がある。
例えば、燃料タンク10に所定の内圧が作用することを想定した場合、鋼製の支柱100は、6mmの直径で、燃料タンク10の高さ寸法に応じて、内部空間Vに位置する部分となる。仮に燃料タンク10の高さ(支柱100のうち、内部空間Vに位置する部分の長さ)を200mmと仮定する。この場合、鋼製の支柱100の内部空間Vに位置する部分は、5.65cm3の体積と44.4gの質量を有している。そして、鋼製の支柱100の降伏点強度が300MPaである場合、完全弾性域となる約150MPa以下を、使用時の許容応力に設定できる。これに対して、上述の所定の内圧と同じ内圧が作用し、かつ、同じ高さ寸法を有する燃料タンク10に樹脂製の支柱を適用する場合、一般的な樹脂製(例えば、ポリアセタール等)の支柱は、引張強度、降伏強度等の強度が低く、融点が摂氏160度程度と低く、環境温度の変化に対するヤング率、強度、完全弾性域等の機械的性質の安定性が低いことを考慮して、使用時の許容応力を約10MPa以下に設定して設計する必要がある。このため樹脂製の支柱を用いる場合、その大きさは、少なくとも24mmの直径で、200mmの高さ(長さ)を有するものになる。この場合、樹脂製の支柱の内部空間Vに位置する部分は、90cm3の体積と128gの質量を有するものとなり、鋼製の支柱と比べ体積、質量ともに大きい値になる。特に体積の差は非常に大きいものとなる。このように、鋼製の支柱100は、樹脂製の支柱100に比べて、必要な強度を保ちつつ小さい体積、小さい質量とすることができる。よって、本実施形態における燃料タンク10は、燃料タンク10の内部空間Vにおける支柱100による占有体積をできるだけ小さくすることができる。このため、燃料タンク10の内部空間Vにおける、燃料の貯留のための有効体積(容積)をできるだけ大きく確保できる。それに加え、支柱100の強度を保ちつつ軽量化を実現できるため、支柱100を含む燃料タンク10を軽量にできるとともに、内圧への耐力を高めることができる。
支柱100の取付けは、鋼製の第1ナット21で行う。
図5に示すように、ロアーパネル12側の第1ナット21の取付けには、円形のチャンバーステー20を利用する。図5は、チャンバーステー20に第1ナット21を3か所取り付けた状態を示すものである。チャンバーステー20上の第1ナット21の取付け部には、第1ナット21の穴径よりも1mm大きい径の穴を開ける。そこに第1ナット21をプロジェクション溶接する。第1ナット21側にプロジェクションを設けてもよいし、チャンバーステー20側にプロジェクション(突起)を設けてもよい。
第1ナット21は、支柱100に対応して、ロアーパネル12の内面に設ける。
リンフォース22を取り付けた場合、圧力変動時にロアーパネル12とリンフォース22との間に隙間が発生する可能性がある。この隙間に砂塵が入り込むと、燃料タンク10の圧力疲労強度が低下する懸念がある。そこで、合わせ部(隙間)に砂塵が入り込まないように、リンフォース22の周縁部に弾力性のある塗膜を施すことが有効である。あるいは、スズ亜鉛はんだを隙間に流しこむことで、隙間を塞ぐこともできる。特にはんだを用いると強度が面で確保されるので、リンフォース22の効果が高まる。
第1ナット21に支柱100の下端部に形成された第1雄ネジ101を嵌め合わせ、第1ナット21およびチャンバーステー20を介してロアーパネル12と支柱100とを接続する。これにより、ロアーパネル12に支柱100の下端部を固定する。
なお、支柱100の下端部は、溶接等によりロアーパネル12に固定されてもよい。
また、アッパーパネル11のうち第2穴11dの縁部に、応力集中が起きやすくなる。穴広げ加工により第2穴11dにテーパーを付けることは、加減圧時のパネル11,12の変形に伴う応力集中の緩和にも効果がある。
支柱100の上端部における下方の部分は第2穴11d内に配置され、支柱100の上端部における上方の部分は第2穴11dよりも上方に突出している。すなわち、支柱100の一部が、内部空間Vに配置されている。フランジ105は、アッパーパネル11の内面に配置されている。
密封性確保のため、第2ナット107とアッパーパネル11の間にはパッキン(シール、ガスケット、または、オーリング、不図示)を設置する。パッキンの材質は特に規定するものではないが、長期仕様の耐久性を考慮すると、半田シートを打ち抜いたドーナッツ状のワッシャー108A(図4参照)でもよい。第2ナット107で支柱100にワッシャー108Aを螺合した後、その部位に熱を加えワッシャー108Aを溶融させ、さらにワッシャー108Aを冷却して固化させて半田108とする。これにより、半田108がアッパーパネル11と第2ナット107との間を密閉(シーリング)し、燃料タンク10の密閉性を確保することができる。
特に、パネル11,12にスズ亜鉛めっき鋼板を用いる場合、電食懸念軽減の意味合いから、電気スズ亜鉛めっきが好ましい。また、支柱100とナット21,107の締結部のシーリングに半田金属を用い、熱を掛けてこの半田金属を溶融させ密閉性を確保する場合は、電気スズ亜鉛めっきは半田濡れ性に優れることから、電気スズ亜鉛めっきが好ましい。電気スズ亜鉛めっきは、密閉性確保の観点からも好ましい。
[梁構造・取付け構造]
ポンプの辺縁部に支柱100を設置すると、正負圧時のパネル11,12の上面、底面の変位を抑制することができるが、そのしわ寄せが燃料タンク10のシーム溶接されたフランジ部11b,12bの近傍に現れる。すなわち、パネル11,12の壁面の変位が大きくなる。燃料タンク10のシーム溶接されたフランジ部11b,12bをリンフォースで補強し、リンフォースを介して、ボルトで車両フレームに取り付ける場合は、車両フレームの剛性の効果で横方向(パネル11,12が対向する方向に直交する方向)の変位は抑えられるが、ベルトで車両フレームに取り付ける場合は、燃料タンク10の横方向の変位を抑えることができない。
取付具31はハット型構造となっており、梁30の両端に設けられたフランジ30aがその中に嵌合する。取り付けた梁30が外れないようにするため、ハット型構造の開口部31aに抜け防止用のフィン32を取り付けるとよい。フランジ30aを取付具31に嵌め入れる時は、鋼製のフィン32が内側に折れ曲り、嵌合後は、フィン32のスプリングバックにより、フランジ30aが外れないようにする。手作業で嵌合できるような強度とするように、フィン32のサイズを設計する。また、梁30のフランジ形状は円形でも良いし、四角形でも良い。四角形の場合は、台形とし、上底を下底よりも短くし、上端側から鋼製の取付具31の空間に挿入すると、取付けが容易となる。
梁30は、アッパーパネル11およびロアーパネル12の少なくとも一方の対向する一対の壁面に取り付けられる。
但し、先にも記したように圧力変動時にロアーパネル12とリンフォース22との間に隙間が生じ、ここに外部からの砂塵類が入り込み、疲労強度を低下させる懸念がある。そこで、砂塵付着防止のため、弾性のある塗膜を隙間に付与するか、隙間部分を半田付けで塞ぐことが必要となる。
高圧タンクは前述のようにハイブリッド車(HV)やプラグインハイブリッド車(PHV)の燃料タンクに必要である。このような車種ではエンジンの稼動している時間が短く、車室内は静かである。よって、運転時に燃料の揺動音が聞こえやすくなる。燃料揺動抑制に、支柱あるいは梁を利用することができる。
樹脂製のバッフル板40,50は、一体成型で得る必要はない。シート状の板材をいくつかの部品に分けて成形し、それらをスナップフィット構造で繋ぎ合わせてもよい。
[支柱]
アッパーパネル11とロアーパネル12を対向させ、互いのフランジ部11b,12bを重ね合わせるようにすると、ロアーパネル12に取り付けられた支柱100の上端部がアッパーパネル11の上面に開けられた第2穴11dを貫通する。この第2穴11dは、ポンプ取付け用の第1穴11cの周辺に設けられる。このため、支柱100の配置精度が悪く支柱100がアッパーパネル11の第2穴11dを貫通できなかったとしても、ポンプ取付け用の第1穴11cから手を入れて支柱100の位置を調整することで、簡単に支柱100の上端部を第2穴11dに入れることが可能である。支柱100の上端部を第2穴11dに貫通させた後は、支柱100をアッパーパネル11の外側からシール用パッキンを介して第2ナット107で固定する。このように、燃料タンク10の内部空間Vに容易に支柱100を構築することができる。
このように、従来、鋼製の燃料タンクでは、圧力疲労および振動疲労を回避するために板厚を薄くすることが困難であった。
上下面を繋ぐ支柱構造を検討して行くなかで、燃料タンクにおいてシーム溶接するフランジ部近傍の横方向の膨れが問題となった。扁平型燃料タンクの場合は上下方向の膨れが大きく、横方向の膨れはそれほど問題とならなかったが、上下面の間隔が大きい、すなわち高さのある燃料タンクの場合は、上下の膨れを抑えると横方向が膨れる現象が見られた。この膨れを抑える方法としては燃料タンクをフロアーに取り付けるバンドを用いることが一般的であるが、このバンドもアッパー面をフロアーに当て、ロアー側からバンドで支える構造のため、横方向の膨れには殆ど効果がなかった。
上述した本実施形態に係る燃料タンク10は、例えば有限要素法を用いたコンピューターシミュレーションを用いて設計が可能である。具体的には、まず支柱100を設けない状態で、燃料タンク10の内部圧力を正圧あるいは負圧にした場合に、燃料タンクに生じるひずみ範囲の高い位置を求める。この最大ひずみ範囲位置に近く、燃料タンク10用の第1穴11cから手を入られる場所に支柱100を取り付けるようにする。1本の支柱100では不安定であることから、できれば支柱100を2本設置する。次いで、支柱100を2本設置した点を底辺とした二等辺三角形を成す頂点部に、3本目の支柱100を設置する。アッパーパネル11のポンプ取付け用の第1穴11cの近傍に第2穴11dを明けて、支柱100を貫通させて第2ナット107によりネジ止めを行う。ポンプ取付けのため、図1に示すリテーナー15と言う厚さ2~4mmの金属製の台座が、アッパーパネル11における第1穴11cの開口周縁部に取り付けられるが、支柱100の設置はその近傍が好ましい。燃料タンク10の組み立て時に、リテーナー15から手を入れて作業できることと、リテーナー15の剛性を利用し、アッパーパネル11側の支柱100の取付け部の疲労を防ぐことができるからである。
一具体例として、一般的な鋼製の高圧タンクの板厚として1.6mmを仮定する。また、そのアッパーパネル11とロアーパネル12の重量の和を16kgとする。かかる燃料タンク10に3本の支柱100を設置すると、板厚が1.6mmの場合と同等の耐圧性を確保しながら、1.2mmに板厚を下げ得ることが判明した。この時のパネルの重量は、12kgである。更に板厚を1.0mmとすると、シーム溶接ビード付近に疲労き裂の可能性が示された。そこで、梁30を1本追加することで、1.0mmの板厚でも耐圧性が確保されることが判明した。この時のパネルの重量が10kgである。直径6mmの鋼製の支柱100を用いると、ナットの重量を含めて支柱100や梁30の重量は1本当たり、100g以下である。この重量を加えても、元の重量より大幅な軽量化ができる。
鋼製の燃料タンク10は、フランジ付きのアッパーパネル11とロアーパネル12とを別々にプレス加工し、内部の部品類を取り付けた後、フランジ部11b,12bを重ねてシーム溶接することより、一体の部品に加工される。燃料タンク10の側面はそのシーム溶接部により剛性が高められていることから、上下面の剛性が相対的に低くなる。そのため、燃料タンク10の上下面を支柱100で繋ぐことで、燃料タンク10の全体の剛性、すなわち、耐圧性を高めることができる。
燃料タンク10の内圧は、燃料タンク10の内面に均等に掛かる。よって、剛性の低い面の変形が大きくなり、それが起因して圧力疲労破壊が発生する。上下面に支柱100を設置することで上下面の剛性を高めて変化量を低減すると、側面のシーム溶接ビード部に疲労破壊が生じる現象が見られた。すなわち、上下面が支柱100で支持されていない場合、上下面の剛性は側面の剛性より低いが、上下面を支柱100で支持すると、この剛性の高低の関係は逆転し、側面の剛性は上下面の剛性より低くなる。
そして、支柱100を設置することで上下面の剛性が側面の剛性を上回った時にこの側面の疲労き裂が見られるという知見が得られた。このような場合には梁構造(ロアーパネル12及びアッパーパネル11の少なくとも一方に、鋼製で円柱状の梁30が取り付けられている構造)を採用することで更なる耐圧性改善の得られることが分かった。梁構造を用いるべき燃料タンク10の形状を補足説明する。
以下、直方体状の燃料タンク10の寸法を、幅W、長さL及び高さHとし、幅Wと長さLで囲まれる面(上下面)をWL面とし、WL面に掛かる圧力をPWLとする。同様に、幅Wと高さHで囲まれる面(側面)をWH面とし、WH面に掛かる圧力をPWHとし、長さLと高さHで囲まれる面(側面)をLH面とし、LH面に掛かる圧力をPLHとする。燃料タンク10の側面となるWH面及びLH面には、シーム溶接ライン(溶接ビード)が、燃料タンク10を周回するように、連続的に設けられている。
燃料タンク10の形状は、立方体タンク、扁平タンク及び直方体タンクの3つに大別することができる。立方体タンクは、幅W、長さL及び高さHが実質的に等しい形状である。扁平タンクは、幅Wと長さLとが実質的に等しく、高さHが幅W及び長さLより小さい形状である。直方体タンクは、幅W又は高さHを大きくとり、長さLを小さくとった形状である。
燃料タンク10の形状が、立方体タンク、扁平タンク及び直方体タンクのそれぞれの場合における、支柱100と梁30の考え方を以下に説明する。
(1)立方体タンクの場合
PHVでは後部座席の下にバッテリーあるいはバッテリーを制御する装置が設置され、燃料タンクがその横に設置されることがある。その形状は立方体に近い形状となる。燃料タンクの容量をVoとし、表面積をSとする時、容積効率Vo/Sを最大化する6面体は立方体であり、理にかなった形状とも言える。
立方体であるので、PWL=PWH=PLHとなる。ここで相対する面に掛かる圧力は同じである。側面はシーム溶接のフランジ構造により剛性が上下面より高いので、相対的に剛性の低い上下面に支柱100を設けることで、燃料タンク10の全体の剛性を均等化することが可能であり、梁30の設置は不要である。
(2)扁平タンクの場合
車内空間を広く取るために燃料タンク10の高さHを100~200mm程度とすることがある。このような燃料タンク10では上下面の面積が広がるため、圧力負荷は側面に掛かる負荷よりも相対的に大きくなる。すなわち、PWL>PWH(PLH)であることから、支柱100の設置で上下面の剛性を上げても、側面の剛性を上回ることはない。よって、梁30の設置は不要である。
(3)直方体タンクの場合
バッテリーの後方に燃料タンク10を設置することがある。このような場合、車両の左右方向に沿う燃料タンク10の幅W又は高さHを大きくとり、車両の前後方向に沿う長さLを小さくとった直方体タンクが採用されることとなる。このような燃料タンク10に掛かる内圧は次のようになる。
(長さL=高さHの時)PWL=PWH あるいは
(長さL<高さHの時)PWL<PWH
上下面に支柱100を設置すると上下面の剛性が上がるため、WH面の剛性が最も低くなる。これを補うために梁30が必要となる。
L<Hの場合で梁30の設置を検討すると、幅Wと高さHの比が1.5を超える場合において、梁30を設置することが好ましい。WH面の圧力による変形を抑えている(支持している)のは、その両側面にあるLH面であるので、幅Wが大きくなると、それに連れてWH面のたわみも大きくなり、WH面の中央部の変形が大きくなる。このため、WH面の圧力変動による疲労破壊が懸念されるようになる。そこで、好ましくは、W/H>1.5の時に梁30を1本以上設置することで、変形を抑え、圧力剛性及び疲労耐性を高めることができる。燃料タンク10には燃料を吸い上げるためのポンプが設置されるので、それを避ける位置に設置するとよい。梁30を設置する位置と本数は、コンピューターシミュレーションにより決定する。
11 アッパーパネル
12 ロアーパネル
30 梁
40 第2バッフル板
50 第1バッフル板
100 支柱
108 半田
V 内部空間
Claims (7)
- 鋼製のロアーパネルおよび鋼製のアッパーパネルと、
前記ロアーパネルと前記アッパーパネルとを対向させて形成された内部空間に配置され、第1端部が前記ロアーパネルに固定され、第2端部が、前記アッパーパネルに形成された穴内に配置された状態で前記アッパーパネルに固定された少なくとも1つの鋼製の支柱と、を備える燃料タンク。 - 前記ロアーパネルの内面に固定され、前記支柱の前記第1端部が嵌め合わされた鋼製の第1ナットと、
前記アッパーパネルの内面に配置され、前記支柱に固定されたフランジと、
前記アッパーパネルの外面に配置され、前記支柱の前記第2端部が嵌め合わされて前記フランジとの間に前記アッパーパネルを挟む鋼製の第2ナットと、
を備える請求項1に記載の燃料タンク。 - 前記支柱、前記第1ナット、および前記第2ナットの外面に、スズめっき層、もしくは、スズ亜鉛めっき層を備える請求項2に記載の燃料タンク。
- 前記アッパーパネルと、前記第2ナットとの間を密閉する半田を備える請求項2または3に記載の燃料タンク。
- 前記ロアーパネルおよび前記アッパーパネルの少なくとも一方の対向する一対の壁面に、鋼製で円柱状の梁が取り付けられている請求項1から4のいずれか1項に記載の燃料タンク。
- 前記梁に、第1バッフル板が取り付けられている請求項5に記載の燃料タンク。
- 前記支柱に、第2バッフル板が取り付けられている請求項1から6のいずれか一項に記載の燃料タンク。
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- 2020-06-12 WO PCT/JP2020/023141 patent/WO2020251001A1/ja unknown
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US11885464B2 (en) * | 2021-05-27 | 2024-01-30 | Hyundai Motor Company | Low profile flat bombe for LPG storage and method for manufacturing the same |
Also Published As
Publication number | Publication date |
---|---|
EP3984900B1 (en) | 2024-04-24 |
US20220332184A1 (en) | 2022-10-20 |
CN113950427A (zh) | 2022-01-18 |
KR20220016215A (ko) | 2022-02-08 |
JPWO2020251001A1 (ja) | 2020-12-17 |
US11932104B2 (en) | 2024-03-19 |
KR102641247B1 (ko) | 2024-02-29 |
JP7307367B2 (ja) | 2023-07-12 |
EP3984900A1 (en) | 2022-04-20 |
EP3984900A4 (en) | 2022-10-26 |
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