# US 11,441,734 B2 · Method of producing high-pressure tank, and high-pressure tank

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- Number: US 11,441,734 B2
- Document ID: US11441734B2
- Status: Granted
- Kind: B2
- Application number: 17/173,255
- Filed: 2021-02-11
- Published: 2021-09-23
- Granted: 2022-09-13
- Earliest claimed: 2020-03-17
- Assignees: Toyota Jidosha Kabushiki Kaisha
- Applicants: Toyota Jidosha Kabushiki Kaisha
- Inventors: Manabu Fujii; Naoki Ueda
- Web page: https://patentgrep.com/patent/US11441734B2

## CPC

- F17C 1/16: constructed of plastics materials {(shaping of plastics B29C)}
- B29C 70/0035: {comprising two or more matrix materials}
- B29C 70/205: {the structure being shaped to form a three-dimensional configuration}
- B29C 70/32: on a rotating mould, former or core
- B29C 70/326: {by rotating the mould around its axis of symmetry}
- B29C 70/84: by moulding material on preformed parts to be joined {(joining plastic parts by moulding B29C65/70)}
- B29C 70/86: Incorporated in coherent impregnated reinforcing layers, {e.g. by winding}
- F17C 1/06: built-up from wound-on bands or filamentary material, e.g. wires
- F17C 13/04: Arrangement or mounting of valves (valves per se F16K {; snap-coupling of nipples F16L37/00})
- B29C 66/1162: {Single bevel to bevel joints, e.g. mitre joints}
- B29C 66/543: {joining more than two hollow-preforms to form said hollow articles}
- B29C 66/636: {using a support which remains in the joined object}
- B29C 66/723: {being multi-layered (B29C66/7292, B29C66/72941 take precedence)}
- B29C 66/7392: {characterised by the material of at least one of the parts being a thermoplastic}
- B29C 66/73921: {characterised by the materials of both parts being thermoplastics}
- B29C 66/7394: {characterised by the material of at least one of the parts being a thermoset}
- B29C 66/73941: {characterised by the materials of both parts being thermosets}
- B29K 2101/10: Thermosetting resins
- B29K 2101/12: Thermoplastic materials
- B29K 2307/04: Carbon
- B29K 2995/0067: non-permeable
- B29L 2031/7156: {Pressure vessels}
- F17C 2201/0104: cylindrical
- F17C 2201/0109: with exteriorly curved end-piece
- F17C 2201/056: Small (<1 m3)
- F17C 2203/012: on or in the wall, e.g. ribs
- F17C 2203/0604: Liners
- F17C 2203/0621: with three layers
- F17C 2203/066: Plastics
- F17C 2203/0663: in form of fibers or filaments
- F17C 2203/0668: axially wound
- F17C 2205/0323: Valves
- F17C 2209/2163: with a mandrel
- F17C 2209/232: of walls
- F17C 2221/012: Hydrogen
- F17C 2221/033: Methane, e.g. natural gas, CNG, LNG, GNL, GNC, PLNG
- F17C 2223/0123: gaseous, e.g. CNG, GNC
- F17C 2223/036: Very high pressure (>80 bar)
- F17C 2270/0168: by vehicles
- Y02E 60/32: Hydrogen storage
- F17C: VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES (storing fluids in natural or artificial cavities or chambers in the earth B65G5/00; construction or assembling of bulk storage containers employing civil-engineering techniques E04H7/00; variable-capacity gas-holders F17B; liquefaction or refrigeration machines, plants, or systems F25)
- 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 (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

A method of producing a high-pressure tank including a liner and a reinforcement layer made of fiber-reinforced resin includes a process of forming at least a domed member included in the reinforcement layer. The process includes placing first fiber bundles to form a part of a protruding portion and a part of a domed main body, and placing second fiber bundles to cover the first fiber bundles. The first fiber bundles are placed, such that a fiber direction of the first fiber bundles in the protruding portion follows an axial direction of the protruding portion, and resin with which the fiber bundles are impregnated is solidified while the first fiber bundles are being placed. The second fiber bundles are placed, such that the fiber direction of the second fiber bundles intersects with the fiber direction of the first fiber bundles.

## Claims

### Claim 1

A method of producing a high-pressure tank, the high-pressure tank including a liner that contains gas, and a reinforcement layer that is made of fiber-reinforced resin and covers an outer surface of the liner, the reinforcement layer having a cylindrical member, and two domed members provided at opposite ends of the cylindrical member and formed integrally with the cylindrical member, one of the domed members including a domed main body, and a cylindrical protruding portion that protrudes from the domed main body and has a gas channel used for filling and discharge of the gas, the method comprising:
a process of forming at least the one of the domed members,
wherein the process of forming at least the one of the domed members includes
placing first fiber bundles impregnated with a first resin, such that the first fiber bundles form a part of the protruding portion and a part of the domed main body, and
placing second fiber bundles impregnated with a second resin, such that the second fiber bundles cover the first fiber bundles,
wherein the first fiber bundles are placed, such that a fiber direction of the first fiber bundles in the protruding portion follows an axial direction of the protruding portion, and the first fiber bundles extend continuously from the protruding portion to the domed main body, and the first resin with which the first fiber bundles are impregnated is solidified while the first fiber bundles are being placed, and
wherein the second fiber bundles are placed, such that a fiber direction of the second fiber bundles intersects with the fiber direction of the first fiber bundles.

### Claim 2 (depends on 1)

The method of producing the high-pressure tank according to claim 1, wherein:
the first resin is thermoplastic resin;
the second resin is thermosetting resin;
while the first fiber bundles are placed in a condition where the first resin is softened, the first resin with which the first fiber bundles are impregnated is solidified; and
the second fiber bundles are placed in a condition where the second resin is uncured, and then the second resin is heated and cured.

### Claim 3 (depends on 2)

The method of producing the high-pressure tank according to claim 2, wherein, when the two domed members are formed, surfaces of the domed members which contact with the gas are formed by the first fiber bundles.

### Claim 4

A high-pressure tank comprising:
a liner configured to contain gas; and
a reinforcement layer made of fiber-reinforced resin and configured to cover an outer surface of the liner, the reinforcement layer having a cylindrical member, and two domed members provided at opposite ends of the cylindrical member and formed integrally with the cylindrical member, one of the domed members including a domed main body, and a protruding portion that protrudes from the domed main body, and has a gas channel used for filling and discharge of the gas,
wherein the domed main body and the protruding portion are formed by first fiber bundles impregnated with a first resin and second fiber bundles impregnated with a second resin,
wherein the first fiber bundles constitute a part of the protruding portion and a part of the domed main body, and are placed continuously from the protruding portion to the domed main body, such that a fiber direction of the first fiber bundles in the protruding portion follows an axial direction of the protruding portion, and
wherein the second fiber bundles cover the first fiber bundles, and are placed such that a fiber direction of the second fiber bundles intersects with the fiber direction of the first fiber bundles.

### Claim 5 (depends on 4)

The high-pressure tank according to claim 4, wherein:
the first resin is thermoplastic resin;
the second resin is thermosetting resin; and
surfaces of the domed members which contact with the gas are formed by the first fiber bundles.

### Claim 6 (depends on 1)

The method of producing the high-pressure tank according to claim 1, wherein the first fiber bundles are placed on an outer periphery of an insert that is placed inside the protruding portion and has a female thread on an inner circumferential surface.

### Claim 7 (depends on 4)

The high-pressure tank according to claim 4, wherein:
a cylindrical insert is placed inside the protruding portion; and
the insert has a female thread on an inner circumferential surface.