Patent Description:
There is known a pressure vessel including a liner that has a cylindrical section and paired dome sections formed on both sides of the cylindrical section and a reinforcement layer that is formed outside the liner and that is made of a fiber reinforced resin material (for example, see Patent Literatures <NUM> and <NUM>).

The reinforcement layer is generally formed by filament winding method. Hoop winding is a winding method in which fiber reinforcement members <NUM> are wound in a direction substantially orthogonal to the axis O of a pressure vessel <NUM> as illustrated in <FIG>. Low-angle helical winding is a winding method in which the fiber reinforcement members <NUM> are wound at a low orientation angle θ2 with respect to the axis O as illustrated in <FIG>. High-angle helical winding is a winding method in which the fiber reinforcement members <NUM> are wound at a high orientation angle θ1 with respect to the axis O as illustrated in <FIG>. Generally, the hoop winding is performed to reinforce a cylindrical section <NUM> and the low-angle helical winding is performed to reinforce portions around distal ends of dome sections <NUM>. In many cases, the high-angle helical winding is performed to mainly reinforce sections that cannot be sufficiently reinforced by the hoop winding or the low-angle helical winding, specifically shoulder sections <NUM> that are sections of the dome sections <NUM> close to the cylindrical section <NUM>.

Patent Literature <NUM> describes a technique in which the hoop winding is applied to reinforce shoulder sections. Specifically, Patent Literature <NUM> describes a technique in which a hoop layer is formed in end portions of a cylindrical section of a liner to be extended surfaces of the shoulder sections. Specifically, hoop dome sections of the hoop layer are designed as a structure that serves as part of the shoulder sections of the liner.

<CIT> discloses a pressure vessel comprising a liner including a cylindrical section and paired dome sections, and shock absorbing layers disposed on a radially outer side of the liner over the dome sections. The shock absorbing layers are formed of a glass fibre composite wound around the liner.

However, in the technique of Patent Literature <NUM>, the hoop dome sections of the hoop layer are formed to be the extended surfaces of the shoulder sections. Specifically, the hoop dome sections of the hoop layer have a structure in which the thickness decreases toward the distal ends of the dome sections of the liner. Accordingly, the strength of the reinforcement in the shoulder sections gradually decreases toward the distal ends of the dome sections of the liner.

The present invention has been created to solve the aforementioned problem and an object is to provide a pressure vessel that can achieve suppression of a decrease of strength in dome sections of a liner.

In order to solve the aforementioned problem, the present invention is a pressure vessel comprising: a liner including a cylindrical section and paired dome sections; and a reinforcement layer formed outside the liner and made of a fiber reinforced resin material, wherein the reinforcement layer includes: bulging sections formed respectively in shoulder sections (4A) of the paired dome sections by high-angle helical winding to bulgein a radial direction of the liner; wherein each of the bulging sections is continuously formed from and integrally formed with a high-angle helical winding layer covering the cylindrical section of the liner, each of the bulging sections is formed in a mountain shape locally having an increased thickness in the radial direction of the liner by winding strands of the high-angle helical winding such that the strands overlap one another in a circumferential direction densely and without gaps to bulge in the radial direction of the liner, while in the cylindrical section the strands are wound adjacent to one another and are tightly packed; and an intermediate section formed outside of the high angle helical winding layer with respect to the radial direction of the liner, across the portion between vertices of the bulging sections, by hoop winding or near-hoop winding in which winding is performed at a higher angle than the high-angle helical winding.

According to the present invention, the following effects can be obtained.

Moreover, in the present invention, the intermediate section may be formed to first extend from the vertex of each of the bulging sections in a curved surface shape to be an extended surface of a tilted surface of the bulging section on the outer side in an axial direction and formed to then extend parallel to the axial direction of the liner.

According to the present invention, the steps of the bulging sections can be eliminated in a simple structure.

The present invention can achieve suppression of a decrease of strength in the dome sections of the liner.

A pressure vessel of the present invention can be applied as a vessel that stores a low-pressure gas such as LPG, a high-pressure gas such as hydrogen gas, and other fluids. As illustrated in <FIG>, the pressure vessel <NUM> of the present invention includes a liner <NUM> and a reinforcement layer <NUM> formed outside the liner <NUM> by filament winding and made of a fiber reinforced resin material.

The liner <NUM> includes a cylindrical section <NUM> having a cylindrical shape with a substantially constant cross section and dome sections <NUM>, <NUM> formed at both ends of the cylindrical section <NUM>. A metal boss <NUM> is integrally molded with the liner <NUM> at the center of a flat surface section 4B of at least one dome section <NUM> to be coaxial with an axis O of the liner <NUM>. The liner <NUM> is made of a synthetic resin material such as, for example, polyethylene and is formed by injection molding, blow molding, or the like.

Each dome section <NUM> has a shape including a shoulder section 4A that has a curved shape with a decreasing diameter from an end portion of the cylindrical section <NUM> and the flat surface section 4B that is formed on a distal end side of the shoulder section 4A and that forms a surface substantially orthogonal to the axis O. The configuration may be such that no flat surface section 4B is formed and a section from the end portion of the cylindrical section <NUM> to the boss <NUM> is formed to have a curved shape with a decreasing diameter.

The reinforcement layer <NUM> is formed by winding strands, made of bundles of reinforcement fibers, on an outer surface of the liner <NUM> rotated about the axis O by a not-illustrated rotating apparatus. The reinforcement layer <NUM> includes bulging sections <NUM> that are formed in the shoulder sections 4A of the respective dome sections <NUM> by high-angle helical winding to bulge and an intermediate section <NUM> that are formed across a portion between vertices 7A of the paired bulging sections <NUM> by hoop winding or near-hoop winding in which the strands are wound at a higher angle than the high-angle helical winding.

The hoop winding is a winding method in which the strands are wound in a direction substantially orthogonal to the axis O of the pressure vessel as described in <FIG>. The high-angle helical winding is a winding method in which the strands are wound at a high orientation angle θ1 with respect to the axis O as described in <FIG>. The low-angle helical winding is a winding method in which the strands are wound at a low orientation angle θ2 with respect to the axis O as described in <FIG>. The orientation angle θ1 of the high-angle helical winding is within a range of about <NUM>° to <NUM>° with respect to the axis O. The orientation angle θ2 of the low-angle helical winding is about a minimum angle at which the strands can be wound around the boss <NUM> or higher and <NUM>° or lower.

In the embodiment, the high-angle helical winding is performed on the surfaces of the cylindrical section <NUM> and the shoulder sections 4A of the liner <NUM>. As illustrated in <FIG>, since the diameter dimension of each shoulder section 4A is smaller than the diameter dimension of the cylindrical section <NUM>, the strands <NUM> are wound to overlap one another in a circumferential direction in the shoulder section 4A when the strands <NUM> are wound adjacent to one another while being tightly packed in the cylindrical section <NUM>. Thus, the thickness in a radial direction increases by an amount corresponding to this overlapping and the mountain-shaped bulging section <NUM> is formed in each shoulder section 4A.

In <FIG>, the shoulder section 4A is tilted in a curved shape. Accordingly, if the viscosity of an impregnation resin material for the strands is low, the strands slip while being wound on the shoulder section 4A. Gaps thereby open and the strands cannot be densely wound. Thus, a high-viscosity impregnation resin material with predetermined viscosity or higher is preferably used as the impregnation resin material for the strands. As a result of tests performed by the present inventors by using an impregnation resin with high viscosity, it was found that the strands could be densely wound on the surfaces of the shoulder sections of the liner <NUM> with almost no slipping. However, when the thickness of the strands gradually increases, the slipping is more likely to occur in an outer portion of the strands in the radial direction. Accordingly, the shape of each bulging section <NUM> is a mountain shape including tilted surfaces 7B, 7C that have gradually-curving surface shapes and that are nearer respectively to the cylindrical section <NUM> and the flat surface section 4B in relation to the vertex 7A with the vertex 7A being the most bulging point. In the embodiment, the lengths of the tilted surfaces are such that the tilted surface 7C is longer than the tilted surface 7B. Note that the bulging section <NUM> may be formed by, for example, changing the orientation angle θ1 of the high-angle helical winding, the rotation speed of the liner <NUM>, and the like.

The intermediate section <NUM> is a layer that is formed across the portion between the paired vertices 7A by the hoop winding or the near-hoop winding in which the strands are wound at least at a higher angle than the orientation angle θ1 of the high-angle helical winding in the bulging sections <NUM>, and is formed outside a high-angle helical layer <NUM> formed on the surface of the cylindrical section <NUM> and outside the tilted surfaces 7B of the bulging sections <NUM>. No step is thus formed between the intermediate section <NUM> and the vertex 7A of each bulging section <NUM> and the bulging section <NUM> and the intermediate section <NUM> are smoothly connected each other.

As illustrated in <FIG>, the shape of the surface of the intermediate section <NUM> connected to the vertex 7A is formed to first extend from the vertex 7A in a curved surface shape to be an extended surface <NUM> of the tilted surface of the bulging section <NUM> on the outer side in the axis O direction, that is the tilted surface 7C and is formed to then extend parallel to the axis O direction. The bulging section <NUM> and the intermediate section <NUM> can be thereby smoothly connected to each other.

An outer layer <NUM> wound in at least one of the hoop winding, the low-angle helical winding, and the high-angle helical winding is formed outside the bulging sections <NUM> and the intermediate section <NUM>. Generally, the outer layer <NUM> is formed of a mixed layer of the hoop winding and the low-angle helical winding. However, in the present invention, the winding method of the outer layer <NUM> is not limited to a particular method. As can be seen from <FIG>, the thickness of the outer layer <NUM> between the paired vertices 7A is substantially constant.

The following effects can be obtained in the configuration in which the reinforcement layer <NUM> includes the bulging sections <NUM> that are formed in the respective dome sections <NUM> by the high-angle helical winding to bulge and the intermediate section <NUM> that is formed across the portion between the vertices 7A of the paired bulging sections <NUM> by the hoop winding or the near-hoop winding in which the strands are wound at a higher angle than the high-angle helical winding.

The intermediate section <NUM> is formed to first extend from the vertex 7A in a curved surface shape to be the extended surface <NUM> of the tilted surface 7C of the bulging section <NUM> on the outer side in the axis O direction and is formed to then extend parallel to the axis O direction of the liner <NUM>. This can eliminate the steps of the bulging sections <NUM> in a simple structure.

Claim 1:
A pressure vessel (<NUM>) comprising:
a liner (<NUM>) including a cylindrical section (<NUM>) and paired dome sections (<NUM>); and
a reinforcement layer (<NUM>) formed outside the liner (<NUM>) and made of a fiber reinforced resin material, wherein
the reinforcement layer (<NUM>) includes:
bulging sections (<NUM>) formed respectively in shoulder sections (4A) of the paired dome sections (<NUM>) by high-angle helical winding to bulge in a radial direction of the liner (<NUM>); wherein
each of the bulging sections (<NUM>) is continuously formed from and integrally formed with a high-angle helical winding layer (<NUM>) covering the cylindrical section (<NUM>) of the liner (<NUM>),
each of the bulging sections (<NUM>) is formed in a mountain shape locally having an increased thickness in the radial direction of the liner (<NUM>) by winding strands of the high-angle helical winding such that the strands overlap one another in a circumferential direction densely and without gaps to bulge in the radial direction of the liner (<NUM>), while in the cylindrical section (<NUM>) the strands are wound adjacent to one another and are tightly packed; and
an intermediate section (<NUM>) formed outside of the high angle helical winding layer (<NUM>) with respect to the radial direction of the liner, across the portion between vertices of the bulging sections (<NUM>), by hoop winding or near-hoop winding in which winding is performed at a higher angle than the high-angle helical winding.