The present disclosure relates to a fiber structure.
For example, a fiber structure described in Patent Literature 1 includes a liner and a fiber-reinforced base member that covers the liner from the outside. The liner includes a cylindrical body portion and dome portions. Each dome portion is continuous with the body portion in an axial direction in which a central axis of the body portion extends, and has a shape tapering toward the central axis. The fiber-reinforced base member includes first yarns and second yarns. The first yarns are arranged such that the yarn main axes extend in the axial direction. The second yarns are arranged such that the yarn main axes extend in a circumferential direction of the liner.
Such a fiber structure may be used as, for example, a pressure vessel filled with hydrogen gas for a fuel cell electric vehicle. When the pressure vessel is filled with hydrogen gas, an internal pressure acts on the liner, so that a load is applied to the liner. Since the magnitude of the applied load and the direction of the applied load are different between the body portion and the dome portions, the liner is likely to be distorted at the boundary between the body portion and each dome portion. The fiber-reinforced base member includes first sections covering regions including the boundary between the body portion and the dome portions, and second sections that are sections excluding the first sections. Since distortion is likely to occur at the boundary between the body portion and each dome portion, the fiber-reinforced base member is more likely to be affected by distortion of the liner in the first sections than in the second sections. When distortion occurs in a first section, the strength of the fiber structure decreases.
Therefore, the strength of the fiber structure may be increased by increasing the thickness of the entire fiber-reinforced base member. However, an increase in the thickness of the entire fiber-reinforced base member is increased unnecessarily increases the thickness of the second sections, which are less likely to be distorted than the first sections and thus do not need to be increased in strength. As a result, the weight of the fiber structure is increased unnecessarily. Also, the manufacturing costs increase unnecessarily.
In one aspect of the present disclosure, a fiber structure includes a liner and a fiber-reinforced base member. The liner that includes a cylindrical body portion, a dome portion, and a shoulder portion. The dome portion is continuous with the body portion in an axial direction in which a central axis of the body portion extends. The dome portion has a shape tapering toward the central axis. The shoulder portion is a part of the dome portion and is an area adjacent to the body portion. The fiber-reinforced base member covers the liner from outside. The fiber-reinforced base member includes first yarns arranged such that yarn main axes extend in the axial direction, and second yarns arranged such that yarn main axes extend in a circumferential direction of the liner. The fiber-reinforced base member includes a first section and a second section. The first section extends between the shoulder portion and the body portion so as to cover at least a boundary between the body portion and the dome portion. The second section is a section excluding the first section. An average degree of interlacing between the first yarns and the second yarns is lower in the first section than in the second section.
In another aspect of the present disclosure, a fiber structure includes a liner and a fiber-reinforced base member. The liner that includes a cylindrical body portion, a dome portion, and a shoulder portion. The dome portion is continuous with the body portion in an axial direction in which a central axis of the body portion extends. The dome portion has a shape tapering toward the central axis. The shoulder portion is a part of the dome portion and is an area adjacent to the body portion. The fiber-reinforced base member covers the liner from outside. The fiber-reinforced base member includes first yarns arranged such that yarn main axes extend in the axial direction, and second yarns arranged such that yarn main axes extend in a circumferential direction of the liner. The fiber-reinforced base member includes a first section and a second section. The first section extends between the shoulder portion and the body portion so as to cover at least a boundary between the body portion and the dome portion. The second section is a section excluding the first section. The first section is provided with a reinforcing member including reinforcement fibers arranged such that yarn main axes extend in the axial direction.
A first embodiment of the present disclosure will now be described with reference to
As shown in
The liner 21 is made of plastic. A direction in which a central axis L of the liner 21 extends is defined as an axial direction Y. The liner 21 includes a cylindrical body portion 23. The central axis of the body portion 23 agrees with the central axis L of the liner 21. The liner 21 includes dome portions 24 at the opposite ends in the axial direction in which the central axis of the body portion 23 extends. The liner 21 includes a boundary R between the body portion 23 and each dome portion 24. The boundaries R are each located at a position where the outer diameter of the liner 21 starts to decrease in the direction from the body portion 23 toward the corresponding dome portion 24.
Each dome portion 24 is continuous with the body portion 23 in the axial direction of the body portion 23. Each dome portion 24 has a shape tapering toward the central axis of the body portion 23. The axial direction of each dome portion 24 agrees with the axial direction of the liner 21. Each dome portion 24 includes a first curved portion 24a, a linear portion 24b, and a second curved portion 24c. The first curved portion 24a is a portion connected to the body portion 23. The first curved portion 24a extends between the boundary R and the linear portion 24b. A first end of the linear portion 24b is connected to the first curved portion 24a. A second end of the linear portion 24b is connected to the second curved portion 24c. Therefore, the linear portion 24b extends between the first curved portion 24a and the second curved portion 24c. The second curved portion 24c extends so as to taper from the second end of the linear portion 24b. The second curved portion 24c is connected to a ferrule 25. The first curved portion 24a occupies, for example, 50% of the dome portion 24. For example, 50% of the length in the axial direction of the dome portion 24 is the length in the axial direction of the first curved portion 24a.
The liner 21 includes shoulder portions A1. In the present embodiment, the entire first curved portion 24a of each dome portion 24 is the shoulder portion A1. The shoulder portion A1 refers to a portion of the dome portion 24 that extends from the boundary R so as to taper in a curving manner. The shoulder portion A1 is an end region of each dome portion 24 adjacent to the body portion 23. Further, the shoulder portion A1 refers to a portion of the dome portion 24 from the boundary R to the central portion of the dome portion 24 in the axial direction.
The liner 21 includes the ferrule 25 at the distal end of each dome portion 24. Each ferrule 25 protrudes outward in the axial direction from the corresponding dome portion 24. The ferrules 25 are made of metal. The ferrules 25 are made of, for example, stainless steel. Each ferrule 25 includes a hole portion 26 that is connected to with the space in the liner 21. Further, the liner 21 includes a valve 27 and a screw 28. The valve 27 is attached to the hole portion 26 of the ferrule 25 located at a first end 21a in the axial direction of the liner 21. The screw 28 is threaded into the hole portion 26 of the ferrule 25 located at a second end 21b in the axial direction of the liner 21.
As shown in
The warps 31 are arranged such that yarn main axes extend in the circumferential direction Z of the liner 21. The direction in which the yarn main axes of the warps 31 extend, i.e., the yarn main axis direction of the warps 31, is indicated by reference symbol X2. The warps 31 are arranged in the axial direction Y of the liner 21, and are disposed in the body portion 23 and the dome portions 24 so as to be parallel to each other. The cross-sectional shape of each warp 31 is flat. Each warp 31 is a fiber bundle composed of multiple reinforcement fibers that are continuous fibers. The reinforcement fibers are, for example, carbon fibers. The fiber-reinforced base member 22 is a woven fabric.
The wefts 30 and the warps 31 are arranged to be orthogonal to each other, and the yarn main axis direction X1 of the wefts 30 agrees with the axial direction Y of the liner 21. Thus, the liner 21 is reinforced in the axial direction Y. Since the yarn main axis direction X2 of the warps 31 agrees with the circumferential direction Z of the liner 21, the liner 21 is reinforced in the radial direction.
As shown in
The second sections 41 include a linear portion 42 and two curved portions 43. The linear portion 42 covers, from the outside, a part of the body portion 23, specifically, an intermediate region in the axial direction of the body portion 23. The linear portion 42 connects the first sections 40 to each other. Each curved portion 43 covers a part of the first curved portion 24a, the entire second curved portion 24c, and the entire linear portion 24b from the outside.
As shown in
As shown in
The fiber-reinforced base member 22 of the present embodiment is woven by changing the manner in which the wefts 30 and the warps 31 are wound around the liner 21 between the first sections 40 and the second sections 41. As such, the structure of the fiber-reinforced base member 22 is different between the first sections 40 and the second sections 41.
Operation of the first embodiment will now be described.
For example, when the high-pressure tank 10 is filled with hydrogen gas, the internal pressure acts on the liner 21, so that a load is applied to the liner 21. Since the magnitude of the applied load and the direction of the applied load are different between the body portion 23 and the dome portions 24, the liner 21 is likely to be distorted at the boundaries R between the body portion 23 and the dome portions 24. Therefore, in the fiber-reinforced base member 22, each first section 40, which covers the portion of the liner 21 including a boundary R, is more likely to be affected by the distortion of the liner 21 than the second sections 41, which are sections excluding the first sections 40.
In this regard, in each first section 40, the average degree of interlacing between the wefts 30 and the warps 31 is lower than that in each second section 41 in the present embodiment. Therefore, in each first section 40, meandering of the wefts 30 and the warps 31 is likely to be suppressed. This increases the strength of the first sections 40, which are more likely to be affected by distortion of the liner 21 than the second sections 41. Accordingly, the strength of the fiber structure 20 is increased. As a result, even when the high-pressure tank 10 is filled with hydrogen gas, and the internal pressure acts on the liner 21, the high-pressure tank 10 is unlikely to be deformed.
The first embodiment provides the following advantages.
(1-1) Since the magnitude of the applied load and the direction of the applied load are different between the body portion 23 and the dome portions 24, the liner 21 is likely to be distorted at the boundaries R between the body portion 23 and the dome portions 24. Therefore, in the fiber-reinforced base member 22, each first section 40, which covers the portion of the liner 21 including a boundary R, is more likely to be affected by the distortion of the liner 21 than the second sections 41, which are sections excluding the first sections 40. In this regard, in each first section 40, the average degree of interlacing between the wefts 30 and the warps 31 is lower than that in each second section 41. This suppresses meandering of the wefts 30 and the warps 31 in the first sections 40. Since this increases the strength of the first sections 40, which are more likely to be affected by distortion of the liner 21 than the second sections 41, the strength of the fiber structure 20 is increased. In order to increase the strength of the fiber structure 20, for example, the thickness of the entire fiber-reinforced base member 22 may be increased. In this case, the thickness of the second sections 41, which are less likely to be distorted than the first sections 40 and do not need to be increased in strength, is also increased unnecessarily. The present embodiment does not cause such an issue. As a result, the weight of the fiber structure 20 does not increase unnecessarily, and the manufacturing costs do not increase unnecessarily. As described above, it is possible to increase the strength of the fiber structure 20 while limiting an increase in the weight and the manufacturing costs.
(1-2) A fiber-reinforced base member 22 that is a woven fabric is suitable as the fiber-reinforced base member 22 for reinforcing the liner 21.
(1-3) The wefts 30 and the warps 31 are not interlaced with each other in the first sections 40. This configuration more readily suppresses meandering of the wefts 30 and the warps 31 in the first sections 40 than in a case in which the wefts 30 and the warps 31 are interlaced. Since this further increases the strength of the first sections 40, which are more likely to be affected by distortion of the liner 21 than the second sections 41, the strength of the fiber structure 20 is further increased.
A second embodiment of the present disclosure will now be described with reference to
As shown in
In
Operation of the second embodiment will now be described.
The first sections 40 are provided with the reinforcing members 50, which include the reinforcement fibers F1 arranged such that yarn main axes extend in the axial direction of the body portion 23. The reinforcing members 50 thus increase the strength of the first sections 40, which are more likely to be affected by distortion of the liner 21 than the second sections 41. Accordingly, the strength of the fiber structure 20 is increased. As a result, even when the high-pressure tank 10 is filled with hydrogen gas, and the internal pressure acts on the liner 21, the high-pressure tank 10 is unlikely to be deformed.
The second embodiment provides the following advantages.
(2-1) The first sections 40 are provided with the reinforcing members 50, which include the reinforcement fibers F1 arranged such that yarn main axes extend in the axial direction of the body portion 23. Since the reinforcing members 50 increase the strength of the first sections 40, which are more likely to be affected by distortion of the liner 21 than the second sections 41, the strength of the fiber structure 20 is increased. In order to increase the strength of the fiber structure 20, for example, the thickness of the entire fiber-reinforced base member 22 may be increased. In this case, the thickness of the second sections 41, which are less likely to be distorted than the first sections 40 and do not need to be increased in strength, is also increased unnecessarily. The present embodiment does not cause such an issue. As a result, the weight of the fiber structure 20 does not increase unnecessarily, and the manufacturing costs do not increase unnecessarily. As described above, it is possible to increase the strength of the fiber structure 20 while limiting an increase in the weight and the manufacturing costs.
(2-2) The reinforcing members 50, which are unidirectional prepregs, are suitable as a configuration for increasing the strength of the first sections 40.
The above-described embodiments may be modified as follows. The above-described embodiments and the following modifications can be combined as long as the combined modifications remain technically consistent with each other.
As shown in
As shown in
As shown in
This configuration ensures that even if the fiber-reinforced base member 22 is a woven fabric, the structural disintegration of the first section 40 is prevented by the first auxiliary yarns 60 and the second auxiliary yarns 61, which are interlaced with the wefts 30 and the warps 31. This further readily increases the strength of the first section 40.
Moreover, by placing the first auxiliary yarns 60 between the wefts 30 and placing the second auxiliary yarns 61 between the warps 31, gaps are more likely to form between the yarns of the fiber structure 20. Consequently, when impregnating the fiber structure 20 with the matrix resin Ma using, for example, the RTM method, the matrix resin Ma infiltrates through these gaps. Therefore, the fiber structure 20 is readily impregnated with the matrix resin Ma.
As shown in
As shown in
In the first embodiment, each first section 40 may be provided with a reinforcing member.
In the first embodiment, the second sections 41 are formed by plain-weaving, but the present disclosure is not limited thereto. For example, the second sections 41 may be formed by twill weaving or multi-layer weaving. In other words, the weaving method of the fiber-reinforced base member 22 is not particularly limited.
In the first embodiment, the wefts 30 and the warps 31 may be interlaced in the first sections 40 as long as the average degree of interlacing between the wefts 30 and the warps 31 is lower in the first sections 40 than in the second sections 41. In other words, the average degree of interlacing in the first sections 40 between the wefts 30 and the warps 31 may be changed as long as it is lower than that in the second sections 41. Further, the degree of interlacing in the first sections 40 does not necessarily need to be constant. For example, the degree of interlacing in each first sections 40 may gradually decrease from the body portion 23 toward the corresponding dome portion 24, or may gradually increase from the body portion 23 toward the corresponding dome portion 24.
In each of the above-described embodiments, each second section 41 may lack the linear portion 42 and include only the two curved portions 43. In this case, the first sections 40 may extend between an end portion of one of the dome portions 24 that is close to the corresponding boundary R and an end portion of the other dome portion 24 that is close to the corresponding boundary R. That is, the first sections 40 may be provided not only in regions covering the boundaries R, but also in a region covering the entire body portion 23. In other words, the first sections 40 may be modified as long as the first sections 40 extend between each shoulder portion A1 and the body portion 23 so as to cover at least the boundary R between the body portion 23 and each dome portion 24.
In each of the above-described embodiments, each dome portion 24 does not necessarily include the linear portion 24b. In other words, each dome portion 24 may be formed by the first curved portion 24a and the second curved portion 24c. In this case, for example, the shoulder portion A1 may be modified as long as it extends from the boundary R to the boundary between the first curved portion 24a and the second curved portion 24c.
In each of the above-described embodiments, each dome portion 24 does not necessarily include the linear portion 24b and the second curved portion 24c. In other words, the dome portion 24 may include only by the first curved portion 24a. In this case, the shoulder portion A1 may be modified as long as it extends from the boundary R to the central portion of the first curved portion 24a.
In the above-described embodiments, the first curved portion 24a may occupy less than 50% of the dome portion 24. In other words, the first curved portion 24a may be modified as long as it is configured to be the shoulder portion A1.
In each of the above-described embodiments, the wefts 30 may fiber bundles formed by bundling of non-reinforcement fibers.
In each of the above-described embodiments, the warps 31 may fiber bundles formed by bundling of non-reinforcement fibers.
In each of the above-described embodiments, the reinforcement fibers forming the wefts 30 and the warps 31 are not limited to carbon fibers. The reinforcement fibers forming the wefts 30 and the warps 31 may be other fibers that are generally referred to as having high elasticity and high strength, such as glass fibers, silicon carbide-based ceramic fibers, aramid fibers, or ultra-high molecular weight polyethylene fibers.
In each of the above-described embodiments, the liner 21 is made of plastic. However, the present disclosure is not limited to this. The liner 21 may be made of, for example, aluminum.
In each of the above-described embodiments, the high-pressure tank 10 is not limited to a tank used as a hydrogen source mounted on a battery electric vehicle equipped with a fuel cell. The high-pressure tank 10 may be employed for a hydrogen source for a hydrogen engine or a heat pump. The high-pressure tank 10 may be used as a hydrogen source for a home fuel cell.
Number | Date | Country | Kind |
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2022-045492 | Mar 2022 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2023/008889 | 3/8/2023 | WO |