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WO2018186067A1 - Fuel tank and method for molding fiber-reinforced resin member - Google Patents

Fuel tank and method for molding fiber-reinforced resin member Download PDF

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Publication number
WO2018186067A1
WO2018186067A1 PCT/JP2018/007701 JP2018007701W WO2018186067A1 WO 2018186067 A1 WO2018186067 A1 WO 2018186067A1 JP 2018007701 W JP2018007701 W JP 2018007701W WO 2018186067 A1 WO2018186067 A1 WO 2018186067A1
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WO
WIPO (PCT)
Prior art keywords
sheet
fiber reinforced
resin
fiber
resin sheet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2018/007701
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French (fr)
Japanese (ja)
Inventor
龍志 谷
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Yachiyo Industry Co Ltd
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Yachiyo Industry Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Yachiyo Industry Co Ltd filed Critical Yachiyo Industry Co Ltd
Priority to CN201880022639.6A priority Critical patent/CN110494315B/en
Priority to JP2019511098A priority patent/JP6616552B2/en
Publication of WO2018186067A1 publication Critical patent/WO2018186067A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/04—Extrusion blow-moulding
    • B29C49/0411—Means for defining the wall or layer thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • 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
    • 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
    • B65D25/34—Coverings or external coatings
    • B65D25/36—Coverings or external coatings formed by applying sheet material

Definitions

  • the present invention relates to a method for molding a fuel tank and a fiber reinforced resin member.
  • Patent Document 1 It is known to reinforce a fuel tank by welding a fiber reinforced resin member to a part of a resin tank body (Patent Document 1).
  • the fiber reinforced resin member used in the prior art is formed by laminating a fiber sheet and a matrix resin sheet.
  • a matrix resin sheet a polyethylene matrix resin having high affinity (adhesiveness) to the tank body is used.
  • the polyethylene matrix resin sheet is less impregnated into the fiber sheet than the engineering plastic (for example, polyamide) matrix resin sheet, and the strength of the resin itself is also low. Therefore, the fiber reinforced resin member made of a polyethylene matrix resin sheet has a problem that the strength is lower than that of the fiber reinforced resin member made of a polyamide matrix resin.
  • a fiber-reinforced resin member made of an engineering plastic (for example, polyamide) matrix resin sheet has a problem of low adhesion to the tank body.
  • the present invention was created to solve such problems, and a fuel tank comprising a fiber reinforced resin member capable of achieving both improvement in adhesion to the tank body and improvement in strength of the fuel tank. It is another object of the present invention to provide a method for molding a fiber-reinforced resin member.
  • the present invention provides a fuel tank in which a fiber reinforced resin member is welded to a wall surface of a resin tank body, and the fiber reinforced resin member is adjacent to the fiber sheet and the fiber sheet.
  • the matrix resin sheet and the adhesive resin sheet disposed on the surface side so as to face the tank body, and the matrix resin sheet is compared with the adhesive resin sheet.
  • the fiber sheet is highly impregnated or the strength of the resin itself is high, and the adhesive resin sheet has higher adhesion to the tank body than the matrix resin sheet.
  • the present invention is a method for molding a fiber reinforced resin member, which is molded according to the shape of the wall surface of the tank body before welding the fiber reinforced resin member to the wall surface of the resin tank body, A preparatory step of laminating a matrix resin sheet, and laminating an adhesive resin sheet having higher adhesion to the tank body than the matrix resin sheet as an outermost layer to form a laminate, and the laminate An arrangement step of arranging in a pair of molding dies, and a molding step of setting a temperature of one of the molding dies arranged on the adhesive resin sheet side lower than a temperature of the other molding die.
  • the adhesive resin sheet is provided on the fuel tank side of the fiber reinforced resin member, the adhesiveness to the tank body can be improved.
  • the matrix resin having higher impregnation property or higher resin strength than the adhesive resin sheet enters the fiber sheet, the strength of the fiber reinforced resin member can be increased, so that the strength of the fuel tank can also be increased. it can.
  • the fiber reinforced resin member is molded with a pair of molds, the temperature of one mold placed on the adhesive resin sheet side is set lower than the temperature of the other mold, thereby bonding Deterioration of the conductive resin sheet can be suppressed.
  • the molding method of the fuel tank and the fiber reinforced resin member of the present invention it is possible to achieve both improvement in adhesion to the tank body and improvement in the strength of the fuel tank.
  • FIG. 1 is a perspective view showing a fuel tank according to a first embodiment of the present invention. It is sectional drawing which shows the fiber reinforced resin member periphery of 1st embodiment. It is a perspective view which shows a fiber reinforced resin member. It is a perspective view which shows the preparatory process of the shaping
  • the fuel tank T is mounted on a moving means such as an automobile, a motorcycle, and a ship, and includes a tank body 1 and a plurality of fiber reinforced resin members 21 (eight in this embodiment). It is mainly composed of.
  • the tank body 1 is a resin-made hollow container for storing fuel such as gasoline, and has, for example, a multi-layer structure including a barrier layer.
  • the tank body 1 is mainly made of a thermoplastic resin such as polyethylene or high-density polyethylene.
  • the tank body 1 is molded by, for example, blow molding.
  • the tank body 1 includes a lower wall 11, an upper wall 12, a first side wall 13, a second side wall 14, a third side wall 15, and a fourth side wall 16.
  • a recess 3 that is continuous over the entire circumference is formed.
  • four recesses 3 are arranged in parallel in the front-rear direction with a gap therebetween.
  • the concave portion 3 has a bottom portion and a pair of side walls rising from the bottom portion, and is formed to open to the outside.
  • the recess 3 is formed with a constant cross section over the entire circumference. The number of the recesses 3 is not limited.
  • the fiber reinforced resin member 21 is a member that reinforces the tank body 1 and is provided on the outer surface of the tank body 1.
  • the fiber reinforced resin member 21 is a fiber reinforced resin (FRP: Fiber-Reinforced Plastics) formed by impregnating a fiber sheet 41 (see FIG. 4) with a resin.
  • FRP Fiber-Reinforced Plastics
  • the fiber reinforced resin member 21 is a thin belt-like member and is welded to the outer surface of the tank body 1.
  • the fiber reinforced resin member 21 is arranged in parallel in the front-rear direction with a gap between the outer surfaces of the tank body 1 as shown in FIGS. 1 and 2. Each fiber reinforced resin member 21 is disposed and integrally formed in each recess 3 of the tank body 1.
  • the fiber reinforced resin member 21 has a substantially U shape in appearance.
  • the fiber reinforced resin member 21 includes a bottom portion 21a and side walls 21b and 21b that rise from both sides in the front-rear direction of the bottom portion 21a. That is, the fiber reinforced resin member 21 is formed with a groove at the bottom 21a and the side walls 21b and 21b, and has a constant cross-sectional shape over the entire length.
  • the fiber reinforced resin member 21 arranged on the lower side is continuously arranged across the third side wall 15, the lower wall 11 and the fourth side wall 16.
  • the fiber reinforced resin member 21 disposed on the upper side is continuously disposed across the third side wall 15, the upper wall 12, and the fourth side wall 16.
  • the shape of the fiber reinforced resin member 21 is molded according to the shape of the tank body 1.
  • the arrangement position of the fiber reinforced resin member 21 may be appropriately set according to the shape and application of the tank body 1.
  • the fiber-reinforced resin member molding method includes a preparation process, an arrangement process, and a molding process.
  • the preparation step is a step in which a plurality of fiber sheets 41, a plurality of matrix resin sheets 42, and an adhesive resin sheet 43 are stacked to form a laminate 40.
  • the fiber sheet 41 is a thin sheet formed of carbon fiber, glass fiber, resin fiber, or the like.
  • the matrix resin sheet 42 is a thin film formed of a thermoplastic resin (high density polyethylene, polyethylene, polyamide (nylon), etc.) or a thermosetting resin (phenol resin, epoxy resin, etc.).
  • the matrix resin sheet 42 uses nylon in this embodiment.
  • As the matrix resin sheet 42 a material having a higher impregnation property to the fiber sheet 41 and / or a higher strength of the resin itself than the adhesive resin sheet 43 is used.
  • the matrix resin sheets 42 and the fiber sheets 41 are alternately arranged.
  • the adhesive resin sheet 43 is disposed on the outermost layer (surface) of the laminate 40.
  • the adhesive resin sheet 43 is a material that has lower impregnation with respect to the fiber sheet 41 and / or lower strength of the resin itself than the matrix resin sheet 42 but has high adhesion to the tank body 1.
  • a malein-modified thermoplastic resin can be used as the adhesive resin sheet 43.
  • the adhesive resin sheet 43 uses polyethylene (MAH-g-PE) modified with maleic anhydride.
  • the adhesive resin sheet 43 is higher in adhesiveness between the matrix resin sheet 42 and the adhesive resin sheet 43 than the adhesiveness between the matrix resin sheet 42 and the tank body 1.
  • the placement step is a step of placing the laminate 40 in the mold K as shown in FIG.
  • the mold K uses a first mold K1 disposed on the lower side and a second mold K2 disposed on the upper side. Both the first mold K1 and the second mold K2 are provided with temperature adjusting means M inside.
  • the laminate 40 is arranged so that the adhesive resin sheet 43 faces the second mold K2.
  • the molding step is a step of molding the fiber reinforced resin member 21 (see FIG. 3) with the molding die K as shown in FIG.
  • the temperature of the molding die K may be appropriately set to a temperature at which the laminate 40 can be molded, but in this embodiment, the temperature of the second die K2 is set lower than the temperature of the first die K1.
  • the melting point of the adhesive resin sheet (MAH-g-PE) 43 disposed in the outermost layer of the laminate 40 is about 120 to 140 ° C.
  • the melting point of the matrix resin sheet (nylon) 42 is about 176 to 265 ° C. .
  • the adhesive resin sheet 43 may be altered and deteriorated.
  • the temperature of the first mold K1 is raised to a temperature at which the matrix resin sheet 42 melts
  • the temperature of the second mold K2 is raised to a temperature at which the adhesive resin sheet melts and does not change.
  • a temperature difference is provided in the mold K to prevent the adhesive resin sheet 43 from deteriorating.
  • the fuel tank molding step is a step of molding the fuel tank by disposing the fiber reinforced resin member 21 in the fuel tank mold J as shown in FIG.
  • the fuel tank molding die J has a first die J1 that molds the lower side and a second die J2 that molds the upper side.
  • An installation projection J1a is formed on each of the one mold J1 and the other mold J2 of the fuel tank mold J.
  • the installation convex portions J1a are formed on the bottom surfaces of the one mold J1 and the other mold J2 with a predetermined gap therebetween.
  • the installation convex portion J1a is a portion where the fiber reinforced resin member 21 is disposed, and has a substantially rectangular cross section.
  • the installation convex part J1a is also a part for molding the concave part 3 of the tank body 1.
  • each fiber reinforced resin member 21 is disposed on each installation protrusion J1a of the one-side mold J1. At this time, it arrange
  • the fuel tank molding step is a step of blow molding the fuel tank T with the fuel tank mold J.
  • a cylindrical or sheet-like parison P is discharged from the die D between the one mold J1 and the other mold J2.
  • the parison P is, for example, a thermoplastic resin composed of a plurality of layers including a barrier layer inside.
  • the fuel tank mold J is preheated to a predetermined temperature so that the parison P is plastically deformed.
  • the parison P is transferred to the molding surface of the fuel tank mold J, and the parison P and the fiber reinforced resin member 21 are welded and integrated. Alternatively, the parison P may be sucked using the vacuuming means provided in the one mold J1 and the other mold J2, and the parison P may be transferred to the fuel tank mold J. When a predetermined time has elapsed, the mold is removed and the fuel tank T is taken out.
  • FIG. 7 is an enlarged cross-sectional view of a main part of portion A in FIG. FIG. 7 schematically shows a cross section of the fiber reinforced resin member 21 and the tank body 1.
  • the fiber reinforced resin member 21 includes an adhesive resin layer 31, a first fiber reinforced layer 32, a matrix resin layer 33, a second fiber reinforced layer 34, a matrix resin layer 33, and a second fiber reinforced layer 34 in order from the tank body 1 side. And a matrix resin layer 33.
  • the layer thickness and the number of layers are schematically shown and do not limit the present invention.
  • the adhesive resin layer 31 is formed between the tank body 1 and the first fiber reinforced layer 32.
  • the adhesive resin layer 31 is a layer formed by curing an adhesive resin (adhesive resin sheet 43).
  • the first fiber reinforced layer 32 is formed between the adhesive resin layer 31 and the matrix resin layer 33.
  • the first fiber reinforced layer 32 is a layer formed by impregnating the fiber sheet 41 with an adhesive resin (adhesive resin sheet 43) and a matrix resin (matrix resin sheet 42) and curing.
  • the matrix resin layer 33 is a layer formed by curing a matrix resin (matrix resin sheet 42).
  • the second fiber reinforced layer 34 is a layer formed between the matrix resin layers 33 and 33.
  • the second fiber reinforced layer 34 is a layer formed by impregnating the fiber sheet 41 with matrix resin (matrix resin sheet 42) on both sides and curing.
  • the matrix resin layers 33 and the second fiber reinforced layers 34 are alternately laminated.
  • the adhesive resin sheet 43 is provided on the fuel tank side of the fiber reinforced resin member 21, so that the adhesion to the tank body 1 is improved. Can do.
  • the strength of the fuel tank T can be increased because the matrix resin having a higher impregnation property and / or higher strength of the resin itself than the adhesive resin can enter the fiber sheet 41 to increase the strength of the fiber reinforced resin member 21. Can also be increased.
  • the matrix resin sheet 42 and the adhesive resin sheet 43 are sandwiched between the matrix resin sheet 42 and the adhesive resin sheet 43.
  • the fiber sheet 41 is impregnated and bonded together. Thereby, a strong first fiber reinforced layer (fiber reinforced layer) 32 can be formed.
  • an adhesive resin layer on the outermost layer of the tank body and then weld a fiber reinforced resin member to the outside of the tank body.
  • an adhesive resin layer low viscosity
  • surging occurs and the extrusion amount may not be stable.
  • this method there is a problem that the entire outermost layer of the tank body becomes an adhesive resin layer and the material cost of the adhesive resin layer increases.
  • the tank body 1 can be stably molded. Moreover, since the adhesive resin layer 31 should just be provided corresponding to the fiber reinforced resin member 21, material cost can be reduced.
  • the method for molding a fiber reinforced resin member according to this embodiment includes a preparation process, an arrangement process, and a molding process.
  • the layer structure of a fiber reinforced resin member is different from 1st embodiment, it demonstrates centering on a different part.
  • the first stacked body 40a and the second stacked body 40b are formed.
  • the first laminated body 40 a is formed by laminating a matrix resin sheet 42 and an adhesive resin sheet 43.
  • the first laminated body 40a is laminated by, for example, coextrusion.
  • the second laminate 40b is formed by alternately laminating the fiber sheets 41 and the matrix resin sheets 42.
  • the 2nd laminated body 40b has arrange
  • the second laminated body 40b is arranged on the first mold K1 side, and the first laminated body 40a is arranged on the second mold K2 side. Moreover, it arrange
  • the molding step is a step of molding the fiber reinforced resin member 21 (see FIG. 3) with the molding die K as shown in FIG. Similar to the first embodiment, the temperature of the second mold K2 is lower than the temperature of the first mold K1.
  • the fuel tank molding process is the same as that in the first embodiment.
  • FIG. 9 is an enlarged cross-sectional view of a main part of the fiber reinforced resin member according to the second embodiment.
  • the fiber reinforced resin member 21 is formed by laminating an adhesive resin layer 31, a matrix resin layer 33, and a second fiber reinforced layer 34 in order from the tank body 1 side, and thereafter the matrix resin layer 33 and The second fiber reinforced layers 34 are alternately formed.
  • the adhesive resin layer 31 is formed between the tank body 1 and the matrix resin layer 33.
  • the adhesive resin layer 31 is a layer formed by curing an adhesive resin (adhesive resin sheet 43).
  • the matrix resin layer 33 is formed between the adhesive resin layer 31 and the second fiber reinforced layer 34.
  • the matrix resin layer 33 is a layer formed by curing a matrix resin (matrix resin sheet 42).
  • the second fiber reinforced layer 34 is formed between the matrix resin layers 33 and 33.
  • the second fiber reinforced layer 34 is a layer formed by impregnating the fiber sheet 41 with matrix resins (matrix resin sheets 42, 42) on both sides and curing.
  • the adhesive resin layer 31 may be formed between the matrix resin layer 33 and the tank body 1.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Transportation (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Energy (AREA)
  • Sustainable Development (AREA)
  • Cooling, Air Intake And Gas Exhaust, And Fuel Tank Arrangements In Propulsion Units (AREA)
  • Laminated Bodies (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

Provided is a fuel tank, in which a fiber-reinforced resin member is affixed to a wall surface of a resin tank body, characterized in that: the fiber-reinforced resin member includes the following which are layered, fiber sheets (41), matrix resin sheets (42) layered adjacent to the fiber sheets (41), and an adhesive resin sheet (43) disposed so as to face a tank body (1), on a surface side; compared to the adhesive resin sheet (43), the matrix resin sheets (42) can impregnate into the fiber sheets (41) at a higher degree and have a greater resin strength; and compared to the matrix resin sheets (42), the adhesive resin sheet (43) has greater adhesiveness to the tank body.

Description

燃料タンク及び繊維強化樹脂部材の成形方法Method for molding fuel tank and fiber reinforced resin member

　本発明は、燃料タンク及び繊維強化樹脂部材の成形方法に関する。 The present invention relates to a method for molding a fuel tank and a fiber reinforced resin member.

　樹脂製のタンク本体の一部に、繊維強化樹脂部材を溶着して燃料タンクの補強を図ることが知られている（特許文献１）。従来の技術で用いられる繊維強化樹脂部材は、繊維シートと、マトリックス樹脂シートとを積層させて形成されている。マトリックス樹脂シートには、タンク本体に親和性（接着性）の高いポリエチレン系のマトリックス樹脂が用いられている。 It is known to reinforce a fuel tank by welding a fiber reinforced resin member to a part of a resin tank body (Patent Document 1). The fiber reinforced resin member used in the prior art is formed by laminating a fiber sheet and a matrix resin sheet. For the matrix resin sheet, a polyethylene matrix resin having high affinity (adhesiveness) to the tank body is used.

特表２０１６－５１９６２３号公報JP-T-2016-519623

　しかし、ポリエチレン系のマトリックス樹脂シートは、エンジニアリングプラスチック系（例えばポリアミド系）のマトリックス樹脂シートに比べて繊維シートに対する含浸性が低く、また樹脂自体の強度も低い。そのため、ポリエチレン系のマトリックス樹脂シートからなる繊維強化樹脂部材は、ポリアミド系のマトリックス樹脂からなる繊維強化樹脂部材よりも強度が低くなるという問題がある。一方、エンジニアリングプラスチック系（例えばポリアミド系）のマトリックス樹脂シートからなる繊維強化樹脂部材は、タンク本体への接着性が低いという問題がある。 However, the polyethylene matrix resin sheet is less impregnated into the fiber sheet than the engineering plastic (for example, polyamide) matrix resin sheet, and the strength of the resin itself is also low. Therefore, the fiber reinforced resin member made of a polyethylene matrix resin sheet has a problem that the strength is lower than that of the fiber reinforced resin member made of a polyamide matrix resin. On the other hand, a fiber-reinforced resin member made of an engineering plastic (for example, polyamide) matrix resin sheet has a problem of low adhesion to the tank body.

　本発明は、このような課題を解決するために創作されたものであり、タンク本体への接着性の向上及び燃料タンクの強度の向上の両立を図ることができる繊維強化樹脂部材を備える燃料タンク及び繊維強化樹脂部材の成形方法を提供することを課題とする。 The present invention was created to solve such problems, and a fuel tank comprising a fiber reinforced resin member capable of achieving both improvement in adhesion to the tank body and improvement in strength of the fuel tank. It is another object of the present invention to provide a method for molding a fiber-reinforced resin member.

　前記課題を解決するため、本発明は、樹脂製のタンク本体の壁面に繊維強化樹脂部材が溶着された燃料タンクであって、前記繊維強化樹脂部材は、繊維シートと、前記繊維シートに隣接して積層されるマトリックス樹脂シートと、前記タンク本体に臨むように表面側に配置される接着性樹脂シートと、を含んで積層されるとともに、前記マトリックス樹脂シートは、前記接着性樹脂シートに比べて前記繊維シートに対する含浸性が高いまたは樹脂自体の強度が高く、前記接着性樹脂シートは、前記マトリックス樹脂シートに比べて前記タンク本体に対する接着性が高いことを特徴とする。 In order to solve the above problems, the present invention provides a fuel tank in which a fiber reinforced resin member is welded to a wall surface of a resin tank body, and the fiber reinforced resin member is adjacent to the fiber sheet and the fiber sheet. The matrix resin sheet and the adhesive resin sheet disposed on the surface side so as to face the tank body, and the matrix resin sheet is compared with the adhesive resin sheet. The fiber sheet is highly impregnated or the strength of the resin itself is high, and the adhesive resin sheet has higher adhesion to the tank body than the matrix resin sheet.

　また、本発明は、樹脂製のタンク本体の壁面に繊維強化樹脂部材を溶着する前に、前記タンク本体の壁面の形状に合わせて成形する繊維強化樹脂部材の成形方法であって、繊維シートと、マトリックス樹脂シートとを積層させるとともに、最外層に前記マトリックス樹脂シートに比べて前記タンク本体に対する接着性が高い接着性樹脂シートとを積層させて積層体を形成する準備工程と、前記積層体を一対の成形型に配置する配置工程と、前記接着性樹脂シート側に配置された一方の前記成形型の温度を、他方の成形型の温度よりも低く設定する成形工程と、を含むことを特徴とする。 Further, the present invention is a method for molding a fiber reinforced resin member, which is molded according to the shape of the wall surface of the tank body before welding the fiber reinforced resin member to the wall surface of the resin tank body, A preparatory step of laminating a matrix resin sheet, and laminating an adhesive resin sheet having higher adhesion to the tank body than the matrix resin sheet as an outermost layer to form a laminate, and the laminate An arrangement step of arranging in a pair of molding dies, and a molding step of setting a temperature of one of the molding dies arranged on the adhesive resin sheet side lower than a temperature of the other molding die. And

　かかる構成によれば、繊維強化樹脂部材の燃料タンク側に接着性樹脂シートを設けているため、タンク本体に対する接着性を高めることができる。一方、接着性樹脂シートよりも含浸性が高いまたは樹脂自体の強度が高いマトリックス樹脂が繊維シートに入り込むことにより、繊維強化樹脂部材の強度を高めることができるため、燃料タンクの強度も高めることができる。また、繊維強化樹脂部材を一対の成形型にて成形する際に、接着性樹脂シート側に配置された一方の成形型の温度を、他方の成形型の温度よりも低く設定することで、接着性樹脂シートの変質を抑制することができる。 According to this configuration, since the adhesive resin sheet is provided on the fuel tank side of the fiber reinforced resin member, the adhesiveness to the tank body can be improved. On the other hand, since the matrix resin having higher impregnation property or higher resin strength than the adhesive resin sheet enters the fiber sheet, the strength of the fiber reinforced resin member can be increased, so that the strength of the fuel tank can also be increased. it can. Further, when the fiber reinforced resin member is molded with a pair of molds, the temperature of one mold placed on the adhesive resin sheet side is set lower than the temperature of the other mold, thereby bonding Deterioration of the conductive resin sheet can be suppressed.

　本発明の燃料タンク及び繊維強化樹脂部材の成形方法によれば、タンク本体への接着性の向上及び燃料タンクの強度の向上の両立を図ることができる。 According to the molding method of the fuel tank and the fiber reinforced resin member of the present invention, it is possible to achieve both improvement in adhesion to the tank body and improvement in the strength of the fuel tank.

本発明の第一実施形態に係る燃料タンクを示す斜視図である。1 is a perspective view showing a fuel tank according to a first embodiment of the present invention. 第一実施形態の繊維強化樹脂部材周りを示す断面図である。It is sectional drawing which shows the fiber reinforced resin member periphery of 1st embodiment. 繊維強化樹脂部材を示す斜視図である。It is a perspective view which shows a fiber reinforced resin member. 第一実施形態に係る繊維強化樹脂部材の成形方法の準備工程を示す斜視図である。It is a perspective view which shows the preparatory process of the shaping | molding method of the fiber reinforced resin member which concerns on 1st embodiment. 第一実施形態に係る繊維強化樹脂部材の成形方法の配置工程及び成形工程を示す断面図である。It is sectional drawing which shows the arrangement | positioning process and shaping | molding process of the shaping | molding method of the fiber reinforced resin member which concern on 1st embodiment. 燃料タンク成形工程を示す断面図である。It is sectional drawing which shows a fuel tank formation process. 図２のＡ部分の要部拡大断面図である。It is a principal part expanded sectional view of the A section of FIG. 第二実施形態に係る繊維強化樹脂部材の成形方法の配置工程及び成形工程を示す断面図である。It is sectional drawing which shows the arrangement | positioning process and shaping | molding process of the shaping | molding method of the fiber reinforced resin member which concerns on 2nd embodiment. 第二実施形態に係る繊維強化樹脂部材の要部拡大断面図である。It is a principal part expanded sectional view of the fiber reinforced resin member which concerns on 2nd embodiment.

　以下、本発明の実施形態に係る燃料タンク及び燃料タンクの製造方法を、図面を参照して説明する。以下の説明において、「前後」、「左右」、「上下」を言うときは、図１に示した方向を基準とする。なお、各方向は、燃料タンクＴを説明する上で便宜上設定したものであり、燃料タンクＴを車両に搭載したときの方向を限定する趣旨ではない。 Hereinafter, a fuel tank and a method for manufacturing the fuel tank according to an embodiment of the present invention will be described with reference to the drawings. In the following description, when referring to “front and rear”, “left and right”, and “up and down”, the direction shown in FIG. 1 is used as a reference. Each direction is set for convenience in describing the fuel tank T, and is not intended to limit the direction when the fuel tank T is mounted on the vehicle.

　燃料タンクＴは、図１に示すように、自動車やバイク並びに船舶等の移動手段に搭載されるものであり、タンク本体１と、複数の繊維強化樹脂部材２１（本実施形態では８つ）とで主に構成されている。 As shown in FIG. 1, the fuel tank T is mounted on a moving means such as an automobile, a motorcycle, and a ship, and includes a tank body 1 and a plurality of fiber reinforced resin members 21 (eight in this embodiment). It is mainly composed of.

　タンク本体１は、ガソリン等の燃料を貯溜する樹脂製の中空容器であり、例えばバリア層を含んだ複数層構造になっている。タンク本体１は、例えば、ポリエチレン、高密度ポリエチレン等の熱可塑性樹脂を主な材料としている。タンク本体１は、例えばブロー成形等によって成形される。 The tank body 1 is a resin-made hollow container for storing fuel such as gasoline, and has, for example, a multi-layer structure including a barrier layer. The tank body 1 is mainly made of a thermoplastic resin such as polyethylene or high-density polyethylene. The tank body 1 is molded by, for example, blow molding.

　タンク本体１は、下壁１１と、上壁１２と、第一側壁１３、第二側壁１４、第三側壁１５及び第四側壁１６とで構成されている。タンク本体１の下壁１１、上壁１２、第三側壁１５及び第四側壁１６には、全周に亘って連続する凹部３が形成されている。凹部３は、本実施形態では間をあけて前後方向に平行に４つ並設されている。凹部３は、底部及び当該底部から立ち上がる一対の側壁を有し、外側に開放するように形成されている。凹部３は、全周に亘って一定の断面で形成されている。凹部３の個数は限定されるものではない。 The tank body 1 includes a lower wall 11, an upper wall 12, a first side wall 13, a second side wall 14, a third side wall 15, and a fourth side wall 16. In the lower wall 11, the upper wall 12, the third side wall 15, and the fourth side wall 16 of the tank body 1, a recess 3 that is continuous over the entire circumference is formed. In the present embodiment, four recesses 3 are arranged in parallel in the front-rear direction with a gap therebetween. The concave portion 3 has a bottom portion and a pair of side walls rising from the bottom portion, and is formed to open to the outside. The recess 3 is formed with a constant cross section over the entire circumference. The number of the recesses 3 is not limited.

　繊維強化樹脂部材２１は、タンク本体１を補強する部材であって、タンク本体１の外面に設けられている。繊維強化樹脂部材２１は、繊維シート４１（図４参照）に樹脂を含浸させて形成された繊維強化樹脂（ＦＲＰ：Fiber-Reinforced Plastics）である。繊維強化樹脂部材２１は、薄い帯状の部材であって、タンク本体１の外面にそれぞれ溶着されている。 The fiber reinforced resin member 21 is a member that reinforces the tank body 1 and is provided on the outer surface of the tank body 1. The fiber reinforced resin member 21 is a fiber reinforced resin (FRP: Fiber-Reinforced Plastics) formed by impregnating a fiber sheet 41 (see FIG. 4) with a resin. The fiber reinforced resin member 21 is a thin belt-like member and is welded to the outer surface of the tank body 1.

　繊維強化樹脂部材２１は、図１及び図２に示すように、タンク本体１の外面に間をあけて前後方向に平行に並設されている。各繊維強化樹脂部材２１は、タンク本体１の各凹部３に配置され一体形成されている。繊維強化樹脂部材２１は、外観視略Ｕ字状を呈する。繊維強化樹脂部材２１は、底部２１ａと、底部２１ａの前後方向両側から立ち上がる側壁２１ｂ，２１ｂとで構成されている。つまり、繊維強化樹脂部材２１には底部２１ａと、側壁２１ｂ，２１ｂとで凹溝が形成されており、全長に亘って一定の断面形状になっている。 The fiber reinforced resin member 21 is arranged in parallel in the front-rear direction with a gap between the outer surfaces of the tank body 1 as shown in FIGS. 1 and 2. Each fiber reinforced resin member 21 is disposed and integrally formed in each recess 3 of the tank body 1. The fiber reinforced resin member 21 has a substantially U shape in appearance. The fiber reinforced resin member 21 includes a bottom portion 21a and side walls 21b and 21b that rise from both sides in the front-rear direction of the bottom portion 21a. That is, the fiber reinforced resin member 21 is formed with a groove at the bottom 21a and the side walls 21b and 21b, and has a constant cross-sectional shape over the entire length.

　下側に配置された繊維強化樹脂部材２１は、第三側壁１５、下壁１１及び第四側壁１６に亘って連続的に配置されている。また、上側に配置された繊維強化樹脂部材２１は、第三側壁１５、上壁１２及び第四側壁１６に亘って連続的に配置されている。繊維強化樹脂部材２１の形状は、タンク本体１の形状に合わせて成形されている。また、繊維強化樹脂部材２１の配置位置はタンク本体１の形状や用途に応じて適宜設定すればよい。 The fiber reinforced resin member 21 arranged on the lower side is continuously arranged across the third side wall 15, the lower wall 11 and the fourth side wall 16. The fiber reinforced resin member 21 disposed on the upper side is continuously disposed across the third side wall 15, the upper wall 12, and the fourth side wall 16. The shape of the fiber reinforced resin member 21 is molded according to the shape of the tank body 1. The arrangement position of the fiber reinforced resin member 21 may be appropriately set according to the shape and application of the tank body 1.

　次に、繊維強化樹脂部材成形方法について説明する。繊維強化樹脂部材の成形方法は、準備工程と、配置工程と、成形工程と、を行う。 Next, a fiber reinforced resin member molding method will be described. The fiber-reinforced resin member molding method includes a preparation process, an arrangement process, and a molding process.

　準備工程は、図４に示すように、複数の繊維シート４１と、複数のマトリックス樹脂シート４２と、接着性樹脂シート４３と、を重ね合わせて積層体４０を形成する工程である。繊維シート４１は、炭素繊維、ガラス繊維又は樹脂繊維等で形成された薄いシートである。 As shown in FIG. 4, the preparation step is a step in which a plurality of fiber sheets 41, a plurality of matrix resin sheets 42, and an adhesive resin sheet 43 are stacked to form a laminate 40. The fiber sheet 41 is a thin sheet formed of carbon fiber, glass fiber, resin fiber, or the like.

　マトリックス樹脂シート４２は、熱可塑性樹脂（高密度ポリエチレン、ポリエチレン、ポリアミド（ナイロン）等）又は熱硬化性樹脂（フェノール樹脂、エポキシ樹脂等）で形成された薄いフィルムである。マトリックス樹脂シート４２は、本実施形態ではナイロンを用いている。マトリックス樹脂シート４２は、接着性樹脂シート４３に比べて繊維シート４１に対する含浸性が高いおよび／または樹脂自体の強度が高いものを用いている。マトリックス樹脂シート４２と繊維シート４１とは交互に配置する。 The matrix resin sheet 42 is a thin film formed of a thermoplastic resin (high density polyethylene, polyethylene, polyamide (nylon), etc.) or a thermosetting resin (phenol resin, epoxy resin, etc.). The matrix resin sheet 42 uses nylon in this embodiment. As the matrix resin sheet 42, a material having a higher impregnation property to the fiber sheet 41 and / or a higher strength of the resin itself than the adhesive resin sheet 43 is used. The matrix resin sheets 42 and the fiber sheets 41 are alternately arranged.

　接着性樹脂シート４３は、積層体４０の最外層（表面）に配置される。接着性樹脂シート４３は、マトリックス樹脂シート４２に比べて繊維シート４１に対する含浸性が低いおよび／または樹脂自体の強度が低いが、タンク本体１に対する接着性が高い材料である。接着性樹脂シート４３は、マレイン変性させた熱可塑性樹脂を用いることができる。本実施形態では、接着性樹脂シート４３は、無水マレイン酸で変性させたポリエチレン（ＭＡＨ－ｇ－ＰＥ）を用いている。また、接着性樹脂シート４３は、マトリックス樹脂シート４２と接着性樹脂シート４３との接着性が、マトリックス樹脂シート４２とタンク本体１との接着性に比べて高いものを用いている。 The adhesive resin sheet 43 is disposed on the outermost layer (surface) of the laminate 40. The adhesive resin sheet 43 is a material that has lower impregnation with respect to the fiber sheet 41 and / or lower strength of the resin itself than the matrix resin sheet 42 but has high adhesion to the tank body 1. As the adhesive resin sheet 43, a malein-modified thermoplastic resin can be used. In this embodiment, the adhesive resin sheet 43 uses polyethylene (MAH-g-PE) modified with maleic anhydride. In addition, the adhesive resin sheet 43 is higher in adhesiveness between the matrix resin sheet 42 and the adhesive resin sheet 43 than the adhesiveness between the matrix resin sheet 42 and the tank body 1.

　配置工程は、図５に示すように、積層体４０を成形型Ｋに配置する工程である。成形型Ｋは、下側に配置される第一型Ｋ１と、上側に配置される第二型Ｋ２を用いている。第一型Ｋ１及び第二型Ｋ２とも内部に温度調節手段Ｍを備えている。配置工程では、接着性樹脂シート４３が、第二型Ｋ２に対向するように積層体４０を配置する。 The placement step is a step of placing the laminate 40 in the mold K as shown in FIG. The mold K uses a first mold K1 disposed on the lower side and a second mold K2 disposed on the upper side. Both the first mold K1 and the second mold K2 are provided with temperature adjusting means M inside. In the arranging step, the laminate 40 is arranged so that the adhesive resin sheet 43 faces the second mold K2.

　成形工程は、図５に示すように、成形型Ｋによって繊維強化樹脂部材２１（図３参照）を成形する工程である。成形工程では、成形型Ｋの温度は積層体４０が成形可能な温度に適宜設定すればよいが、本実施形態では、第二型Ｋ２の温度を、第一型Ｋ１の温度よりも低く設定している。積層体４０の最外層に配置される接着性樹脂シート（ＭＡＨ－ｇ－ＰＥ）４３の融点は約１２０～１４０℃であり、マトリックス樹脂シート（ナイロン）４２の融点は約１７６～２６５℃である。マトリックス樹脂シート４２に合わせて成形型Ｋを昇温させると接着性樹脂シート４３が変質して劣化するおそれがある。 The molding step is a step of molding the fiber reinforced resin member 21 (see FIG. 3) with the molding die K as shown in FIG. In the molding step, the temperature of the molding die K may be appropriately set to a temperature at which the laminate 40 can be molded, but in this embodiment, the temperature of the second die K2 is set lower than the temperature of the first die K1. ing. The melting point of the adhesive resin sheet (MAH-g-PE) 43 disposed in the outermost layer of the laminate 40 is about 120 to 140 ° C., and the melting point of the matrix resin sheet (nylon) 42 is about 176 to 265 ° C. . When the temperature of the mold K is raised in accordance with the matrix resin sheet 42, the adhesive resin sheet 43 may be altered and deteriorated.

　そのため、例えば、第一型Ｋ１の温度をマトリックス樹脂シート４２が溶融する温度まで昇温させるとともに、第二型Ｋ２の温度を接着性樹脂シートが溶融しつつ変質しない温度まで昇温させるなどして成形型Ｋに温度差を設けて接着性樹脂シート４３の劣化を防いでいる。 Therefore, for example, the temperature of the first mold K1 is raised to a temperature at which the matrix resin sheet 42 melts, and the temperature of the second mold K2 is raised to a temperature at which the adhesive resin sheet melts and does not change. A temperature difference is provided in the mold K to prevent the adhesive resin sheet 43 from deteriorating.

　繊維強化樹脂部材２１が形成されたら、燃料タンク成形工程に移行する。燃料タンク成形工程は、図６に示すように、燃料タンク用成形型Ｊに繊維強化樹脂部材２１を配置して燃料タンクを成形する工程である。燃料タンク用成形型Ｊは、ロワー側を成形する一方型Ｊ１と、アッパー側を成形する他方型Ｊ２とを有する。燃料タンク用成形型Ｊの一方型Ｊ１及び他方型Ｊ２には、それぞれ設置凸部Ｊ１ａが形成されている。設置凸部Ｊ１ａは、一方型Ｊ１及び他方型Ｊ２の底面に所定の間隔をあけてそれぞれ形成されている。設置凸部Ｊ１ａは、繊維強化樹脂部材２１が配置される部位であって、断面略矩形に形成されている。設置凸部Ｊ１ａは、タンク本体１の凹部３を成形する部位でもある。 When the fiber reinforced resin member 21 is formed, the process proceeds to the fuel tank molding process. The fuel tank molding step is a step of molding the fuel tank by disposing the fiber reinforced resin member 21 in the fuel tank mold J as shown in FIG. The fuel tank molding die J has a first die J1 that molds the lower side and a second die J2 that molds the upper side. An installation projection J1a is formed on each of the one mold J1 and the other mold J2 of the fuel tank mold J. The installation convex portions J1a are formed on the bottom surfaces of the one mold J1 and the other mold J2 with a predetermined gap therebetween. The installation convex portion J1a is a portion where the fiber reinforced resin member 21 is disposed, and has a substantially rectangular cross section. The installation convex part J1a is also a part for molding the concave part 3 of the tank body 1.

　燃料タンク成形工程では、まず、一方型Ｊ１の各設置凸部Ｊ１ａに各繊維強化樹脂部材２１を配置する。このとき、最外層に形成された接着性樹脂シート４３がパリソンＰを向くように（内側を向くように）配置する。一方型Ｊ１及び他方型Ｊ２は所定の温度に予め加熱されているため、繊維強化樹脂部材２１を配置すると繊維強化樹脂部材２１と一方型Ｊ１及び他方型Ｊ２とが落下しない程度に張り付いた状態になる。 In the fuel tank molding step, first, each fiber reinforced resin member 21 is disposed on each installation protrusion J1a of the one-side mold J1. At this time, it arrange | positions so that the adhesive resin sheet 43 formed in the outermost layer may face the parison P (it faces inner side). Since the one mold J1 and the other mold J2 are preheated to a predetermined temperature, when the fiber reinforced resin member 21 is disposed, the fiber reinforced resin member 21, the one mold J1, and the other mold J2 are stuck to each other so as not to fall. become.

　燃料タンク成形工程は、燃料タンク用成形型Ｊで燃料タンクＴをブロー成形する工程である。燃料タンク成形工程では、一方型Ｊ１と他方型Ｊ２との間に筒状又はシート状のパリソンＰをダイＤから吐出させる。パリソンＰは、例えば、内部にバリア層を含んで複数層で構成された熱可塑性樹脂である。燃料タンク用成形型Ｊは、パリソンＰが塑性変形するように所定の温度まで予め加熱させておく。 The fuel tank molding step is a step of blow molding the fuel tank T with the fuel tank mold J. In the fuel tank forming step, a cylindrical or sheet-like parison P is discharged from the die D between the one mold J1 and the other mold J2. The parison P is, for example, a thermoplastic resin composed of a plurality of layers including a barrier layer inside. The fuel tank mold J is preheated to a predetermined temperature so that the parison P is plastically deformed.

　そして、パリソンＰが燃料タンク用成形型Ｊの成形面に転写されるとともに、パリソンＰと繊維強化樹脂部材２１とが溶着して一体化する。なお、一方型Ｊ１及び他方型Ｊ２に設けられた真空引き手段を用いてパリソンＰを吸引し、パリソンＰを燃料タンク用成形型Ｊに転写させてもよい。所定の時間が経過したら脱型し、燃料タンクＴを取り出す。 The parison P is transferred to the molding surface of the fuel tank mold J, and the parison P and the fiber reinforced resin member 21 are welded and integrated. Alternatively, the parison P may be sucked using the vacuuming means provided in the one mold J1 and the other mold J2, and the parison P may be transferred to the fuel tank mold J. When a predetermined time has elapsed, the mold is removed and the fuel tank T is taken out.

　図７は、図２のＡ部分の要部拡大断面図である。図７は、繊維強化樹脂部材２１及びタンク本体１の断面を模式的に示すものである。繊維強化樹脂部材２１は、タンク本体１側から順番に接着性樹脂層３１、第一繊維強化層３２、マトリックス樹脂層３３、第二繊維強化層３４、マトリックス樹脂層３３、第二繊維強化層３４及びマトリックス樹脂層３３で構成されている。なお、層の厚さや層の数は模式的に示すものであって、本発明を限定するものではない。 FIG. 7 is an enlarged cross-sectional view of a main part of portion A in FIG. FIG. 7 schematically shows a cross section of the fiber reinforced resin member 21 and the tank body 1. The fiber reinforced resin member 21 includes an adhesive resin layer 31, a first fiber reinforced layer 32, a matrix resin layer 33, a second fiber reinforced layer 34, a matrix resin layer 33, and a second fiber reinforced layer 34 in order from the tank body 1 side. And a matrix resin layer 33. The layer thickness and the number of layers are schematically shown and do not limit the present invention.

　接着性樹脂層３１は、タンク本体１と第一繊維強化層３２の間に形成されている。接着性樹脂層３１は、接着性樹脂（接着性樹脂シート４３）が硬化して形成された層である。
　第一繊維強化層３２は、接着性樹脂層３１と、マトリックス樹脂層３３との間に形成されている。第一繊維強化層３２は、繊維シート４１に接着性樹脂（接着性樹脂シート４３）及びマトリックス樹脂（マトリックス樹脂シート４２）とが含浸し、硬化して形成された層である。 The adhesive resin layer 31 is formed between the tank body 1 and the first fiber reinforced layer 32. The adhesive resin layer 31 is a layer formed by curing an adhesive resin (adhesive resin sheet 43).
The first fiber reinforced layer 32 is formed between the adhesive resin layer 31 and the matrix resin layer 33. The first fiber reinforced layer 32 is a layer formed by impregnating the fiber sheet 41 with an adhesive resin (adhesive resin sheet 43) and a matrix resin (matrix resin sheet 42) and curing.

　マトリックス樹脂層３３は、マトリックス樹脂（マトリックス樹脂シート４２）が硬化して形成された層である。
　第二繊維強化層３４は、マトリックス樹脂層３３，３３の間に形成された層である。第二繊維強化層３４は、繊維シート４１に、両側のマトリックス樹脂（マトリックス樹脂シート４２）が含浸し、硬化して形成された層である。マトリックス樹脂層３３と第二繊維強化層３４は交互に積層されている。 The matrix resin layer 33 is a layer formed by curing a matrix resin (matrix resin sheet 42).
The second fiber reinforced layer 34 is a layer formed between the matrix resin layers 33 and 33. The second fiber reinforced layer 34 is a layer formed by impregnating the fiber sheet 41 with matrix resin (matrix resin sheet 42) on both sides and curing. The matrix resin layers 33 and the second fiber reinforced layers 34 are alternately laminated.

　以上説明した本実施形態に係る燃料タンク及び燃料タンクの製造方法によれば、繊維強化樹脂部材２１の燃料タンク側に接着性樹脂シート４３を設けているため、タンク本体１に対する接着性を高めることができる。一方、接着性樹脂よりも含浸性が高いおよび／または樹脂自体の強度が高いマトリックス樹脂が繊維シート４１に入り込むことにより、繊維強化樹脂部材２１の強度を高めることができるため、燃料タンクＴの強度も高めることができる。 According to the fuel tank and the method for manufacturing the fuel tank according to the present embodiment described above, the adhesive resin sheet 43 is provided on the fuel tank side of the fiber reinforced resin member 21, so that the adhesion to the tank body 1 is improved. Can do. On the other hand, the strength of the fuel tank T can be increased because the matrix resin having a higher impregnation property and / or higher strength of the resin itself than the adhesive resin can enter the fiber sheet 41 to increase the strength of the fiber reinforced resin member 21. Can also be increased.

　また、本実施形態によれば、繊維強化樹脂部材２１が成形されるとき、マトリックス樹脂シート４２と接着性樹脂シート４３とは、マトリックス樹脂シート４２と接着性樹脂シート４３との間に挟まれた繊維シート４１に含浸して接着し合う。これにより、強固な第一繊維強化層（繊維強化層）３２を形成することができる。 Further, according to the present embodiment, when the fiber reinforced resin member 21 is molded, the matrix resin sheet 42 and the adhesive resin sheet 43 are sandwiched between the matrix resin sheet 42 and the adhesive resin sheet 43. The fiber sheet 41 is impregnated and bonded together. Thereby, a strong first fiber reinforced layer (fiber reinforced layer) 32 can be formed.

　ここで、例えば、タンク本体の最外層に接着性樹脂層を成形した後に、当該タンク本体の外側に繊維強化樹脂部材を溶着することも考えられる。しかし、通常、成形機のスクリュー及び樹脂が流通する流路は高粘度向けの設計になっているため、複数層構造のブロー成形を行う際に、最外層に接着性樹脂層（低粘度のものが多い）を設けると、サージングが発生し押出量が安定しないおそれがある。また、この方法であると、タンク本体の最外層全部が接着性樹脂層となり、接着性樹脂層の材料コストが嵩むという問題もある。 Here, for example, it is also conceivable to form an adhesive resin layer on the outermost layer of the tank body and then weld a fiber reinforced resin member to the outside of the tank body. However, since the flow path through which the screw and resin of the molding machine normally circulate is designed for high viscosity, an adhesive resin layer (low viscosity) is used as the outermost layer when blow molding with a multi-layer structure. If there are many), surging occurs and the extrusion amount may not be stable. Further, in this method, there is a problem that the entire outermost layer of the tank body becomes an adhesive resin layer and the material cost of the adhesive resin layer increases.

　しかし、本実施形態のように、接着性樹脂層３１（接着性樹脂シート４３）を繊維強化樹脂部材２１の最外層に設けるようにすれば、タンク本体１の成形を安定して行うことができる。また、接着性樹脂層３１も繊維強化樹脂部材２１に対応して設ければよいため、材料コストを低減することができる。 However, if the adhesive resin layer 31 (adhesive resin sheet 43) is provided on the outermost layer of the fiber reinforced resin member 21 as in this embodiment, the tank body 1 can be stably molded. . Moreover, since the adhesive resin layer 31 should just be provided corresponding to the fiber reinforced resin member 21, material cost can be reduced.

［第二実施形態］
　次に、本発明の第二実施形態に係る燃料タンク及び燃料タンクの繊維強化樹脂部材の成形方法について説明する。本実施形態に係る繊維強化樹脂部材の成形方法は、準備工程と、配置工程と、成形工程と、を行う。第二実施形態では、繊維強化樹脂部材の層構成が第一実施形態と相違するため、相違する部分を中心に説明する。 [Second Embodiment]
Next, a method for molding a fuel tank and a fiber reinforced resin member for the fuel tank according to the second embodiment of the present invention will be described. The method for molding a fiber reinforced resin member according to this embodiment includes a preparation process, an arrangement process, and a molding process. In 2nd embodiment, since the layer structure of a fiber reinforced resin member is different from 1st embodiment, it demonstrates centering on a different part.

　図８に示すように、準備工程では、第一積層体４０ａ及び第二積層体４０ｂを形成する。第一積層体４０ａは、マトリックス樹脂シート４２と、接着性樹脂シート４３とを積層させて形成されている。第一積層体４０ａは、例えば、共押出によって積層させている。第二積層体４０ｂは、繊維シート４１と、マトリックス樹脂シート４２とを交互に積層させて形成されている。第二積層体４０ｂは、第一積層体４０ａに対向する位置に繊維シート４１を配置している。 As shown in FIG. 8, in the preparation step, the first stacked body 40a and the second stacked body 40b are formed. The first laminated body 40 a is formed by laminating a matrix resin sheet 42 and an adhesive resin sheet 43. The first laminated body 40a is laminated by, for example, coextrusion. The second laminate 40b is formed by alternately laminating the fiber sheets 41 and the matrix resin sheets 42. The 2nd laminated body 40b has arrange | positioned the fiber sheet 41 in the position facing the 1st laminated body 40a.

　配置工程では、第二積層体４０ｂを第一型Ｋ１側に配置するとともに、第一積層体４０ａを第二型Ｋ２側に配置する。また、第一積層体４０ａのうち、接着性樹脂シート４３が第二型Ｋ２に対向するように配置する。 In the arranging step, the second laminated body 40b is arranged on the first mold K1 side, and the first laminated body 40a is arranged on the second mold K2 side. Moreover, it arrange | positions so that the adhesive resin sheet 43 may oppose the 2nd type | mold K2 among the 1st laminated bodies 40a.

　成形工程は、図８に示すように、成形型Ｋによって繊維強化樹脂部材２１（図３参照）を成形する工程である。第一実施形態と同様に、第二型Ｋ２の温度は、第一型Ｋ１の温度よりも低くなっている。燃料タンク成形工程は、第一実施形態と同様である。 The molding step is a step of molding the fiber reinforced resin member 21 (see FIG. 3) with the molding die K as shown in FIG. Similar to the first embodiment, the temperature of the second mold K2 is lower than the temperature of the first mold K1. The fuel tank molding process is the same as that in the first embodiment.

　図９は、第二実施形態に係る繊維強化樹脂部材の要部拡大断面図である。図９に示すように、繊維強化樹脂部材２１は、タンク本体１側から順番に、接着性樹脂層３１、マトリックス樹脂層３３、第二繊維強化層３４が積層され、その後はマトリックス樹脂層３３と第二繊維強化層３４とが交互に形成されている。 FIG. 9 is an enlarged cross-sectional view of a main part of the fiber reinforced resin member according to the second embodiment. As shown in FIG. 9, the fiber reinforced resin member 21 is formed by laminating an adhesive resin layer 31, a matrix resin layer 33, and a second fiber reinforced layer 34 in order from the tank body 1 side, and thereafter the matrix resin layer 33 and The second fiber reinforced layers 34 are alternately formed.

　接着性樹脂層３１は、タンク本体１とマトリックス樹脂層３３との間に形成されている。接着性樹脂層３１は、接着性樹脂（接着性樹脂シート４３）が硬化して形成された層である。
　マトリックス樹脂層３３は、接着性樹脂層３１と第二繊維強化層３４との間に形成されている。マトリックス樹脂層３３は、マトリックス樹脂（マトリックス樹脂シート４２）が硬化して形成された層である。 The adhesive resin layer 31 is formed between the tank body 1 and the matrix resin layer 33. The adhesive resin layer 31 is a layer formed by curing an adhesive resin (adhesive resin sheet 43).
The matrix resin layer 33 is formed between the adhesive resin layer 31 and the second fiber reinforced layer 34. The matrix resin layer 33 is a layer formed by curing a matrix resin (matrix resin sheet 42).

　第二繊維強化層３４は、マトリックス樹脂層３３，３３の間に形成されている。第二繊維強化層３４は、繊維シート４１に、両側のマトリックス樹脂（マトリックス樹脂シート４２，４２）が含浸し、硬化して形成された層である。 The second fiber reinforced layer 34 is formed between the matrix resin layers 33 and 33. The second fiber reinforced layer 34 is a layer formed by impregnating the fiber sheet 41 with matrix resins (matrix resin sheets 42, 42) on both sides and curing.

　第二実施形態に係る燃料タンクであっても、第一実施形態と略同等の効果を奏することができる。また、図９に示す第二実施形態のように、マトリックス樹脂層３３とタンク本体１との間に接着性樹脂層３１が形成されるようにしてもよい。 Even in the fuel tank according to the second embodiment, substantially the same effect as that of the first embodiment can be obtained. Further, as in the second embodiment shown in FIG. 9, the adhesive resin layer 31 may be formed between the matrix resin layer 33 and the tank body 1.

　１　　　タンク本体
　２１　　繊維強化樹脂部材
　４１　　繊維シート
　４２　　マトリックス樹脂シート
　４３　　接着性樹脂シート
　Ｔ　　　燃料タンク DESCRIPTION OF SYMBOLS 1 Tank main body 21 Fiber reinforced resin member 41 Fiber sheet 42 Matrix resin sheet 43 Adhesive resin sheet T Fuel tank

Claims (3)

　樹脂製のタンク本体の壁面に繊維強化樹脂部材が溶着された燃料タンクであって、
　前記繊維強化樹脂部材は、繊維シートと、前記繊維シートに隣接して積層されるマトリックス樹脂シートと、前記タンク本体に臨むように表面側に配置される接着性樹脂シートと、を含んで積層されるとともに、
　前記マトリックス樹脂シートは、前記接着性樹脂シートに比べて前記繊維シートに対する含浸性が高いまたは樹脂自体の強度が高く、
　前記接着性樹脂シートは、前記マトリックス樹脂シートに比べて前記タンク本体に対する接着性が高いことを特徴とする燃料タンク。 A fuel tank in which a fiber reinforced resin member is welded to the wall surface of a resin tank body,
The fiber reinforced resin member is laminated including a fiber sheet, a matrix resin sheet laminated adjacent to the fiber sheet, and an adhesive resin sheet disposed on the surface side so as to face the tank body. And
The matrix resin sheet has a high impregnation property for the fiber sheet or the strength of the resin itself as compared to the adhesive resin sheet,
The fuel tank according to claim 1, wherein the adhesive resin sheet has higher adhesion to the tank body than the matrix resin sheet. 　前記マトリックス樹脂シートと前記接着性樹脂シートとの間に挟まれた前記繊維シートにマトリックス樹脂及び接着性樹脂が含浸して繊維強化層が形成されていることを特徴とする請求項１に記載の燃料タンク。 2. The fiber reinforced layer is formed by impregnating the fiber sheet sandwiched between the matrix resin sheet and the adhesive resin sheet with a matrix resin and an adhesive resin. Fuel tank. 　樹脂製のタンク本体の壁面に繊維強化樹脂部材を溶着する前に、前記タンク本体の壁面の形状に合わせて成形する繊維強化樹脂部材の成形方法であって、
　繊維シートと、マトリックス樹脂シートとを積層させるとともに、最外層に前記マトリックス樹脂シートに比べて前記タンク本体に対する接着性が高い接着性樹脂シートとを積層させて積層体を形成する準備工程と、
　前記積層体を一対の成形型に配置する配置工程と、
　前記接着性樹脂シート側に配置された一方の前記成形型の温度を、他方の成形型の温度よりも低く設定する成形工程と、を含むことを特徴とする繊維強化樹脂部材の成形方法。 Before the fiber reinforced resin member is welded to the wall surface of the resin tank body, the fiber reinforced resin member is molded according to the shape of the wall surface of the tank body.
A preparatory step of laminating a fiber sheet and a matrix resin sheet, and laminating an adhesive resin sheet having higher adhesion to the tank body than the matrix resin sheet in the outermost layer, and forming a laminate,
An arrangement step of arranging the laminate in a pair of molds;
A molding step of setting a temperature of one of the molding dies disposed on the adhesive resin sheet side to be lower than a temperature of the other molding die.
PCT/JP2018/007701 2017-04-06 2018-03-01 Fuel tank and method for molding fiber-reinforced resin member Ceased WO2018186067A1 (en)

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