HONEYCOMB STRUCTURAL HIGH-PRESSURE SET TANK AND A MANUFACTURING PROCESS THEREFOR

Abstract

The present invention is directed to a new concept for a large-scale high-pressure Honeycomb Set Tank in an ISO container and for its manufacturing facilities. A process for manufacturing a plurality of honeycomb cells with a high degree of accuracy is also provided.

Claims

1. A high-pressure honeycomb tank container structure, comprising: a first plurality of cell tanks fixedly arranged adjacent each other; a second plurality of cell tanks fixedly arranged adjacent each other and along at least a first outer periphery of the first plurality of cell tanks; and a plurality of filler elements fixedly arranged adjacent each other and along at least a second outer periphery of the first plurality of cell tanks so as to occupy voids formed by the adjacent ones of the first plurality of cell tanks in the second outer periphery, wherein the first plurality of cell tanks, the second plurality of cell tanks and the plurality of fillers together form a hexahedron-shaped structure.

2. A high-pressure honeycomb tank container structure according to claim 1, wherein each of the first plurality of cell tanks is substantially hexagon-shaped in cross-section.

3. A high-pressure honeycomb tank container structure according to claim 2, wherein each of the first plurality of cell tanks includes a cylindrical tank having first and second connection ports operatively connected to top and bottom ends respectively of the cylindrical tank, a reinforcement FRP prepreg outer cover surrounding the cylindrical tank, a foam resin cover surrounding the cylindrical tank and the first and second height adaptors, and a prepreg outer shell, and the foam resin cover and the prepreg outer shell are hexagon-shaped in cross-section.

4. A high-pressure honeycomb tank container structure according to claim 1, wherein each of the second plurality of cell tanks is substantially pentagon-shaped in cross-section.

5. A high-pressure honeycomb tank container structure according to claim 4, wherein each of the second plurality of cell tanks includes a cylindrical tank having first and second connection ports operatively connected to top and bottom ends respectively of the cylindrical tank, a reinforcement FRP prepreg outer cover surrounding the cylindrical tank, first and second height adaptors operatively connected to the top and bottom ends respectively of the cylindrical tank, a foam resin cover surrounding the cylindrical tank and the first and second height adaptors, and a prepreg outer shell, and the foam resin cover and the prepreg outer shell are pentagon-shaped in cross-section.

6. A high-pressure honeycomb tank container structure according to claim 1, wherein each of plurality of filler elements is substantially trapezoid-shaped in cross-section.

7. A high-pressure honeycomb tank container structure according to claim 6, wherein each of the plurality of filler elements includes an elongated foam resin body and a prepreg outer shell, and foam resin body and the prepreg outer shell are trapezoid-shaped in cross-section.

8. A high-pressure honeycomb tank container structure according to claim 1, further comprising: a container wall assembly fixedly connected to surround the hexahedron-shaped structure, the container wall assembly including a top wall, a bottom wall, a front wall, a rear wall, a right side wall and a left side wall, each being formed with a flat steel inside plate and an outer corrugated steel plate.

9. A high-pressure honeycomb tank container structure according to claim 1, further comprising: a container cell assembly fixedly connected to surround the hexahedron-shaped structure, the container cell assembly including a bottom wall, a rear wall, and a left side wall, each being formed with a flat steel inside plate and an outer corrugated steel plate, and a rear cushion wall and a left side cushion wall, each formed from heat foam resin.

10. A high-pressure honeycomb tank container structure according to claim 1, further comprising: a container honeycomb cell assembly fixedly connected to surround the hexahedron-shaped structure, the container honeycomb cell assembly including a bottom wall, a rear wall, and a left side wall, each being formed with a flat steel inside plate and an outer corrugated steel plate, and a front cushion wall, a rear cushion wall, a right side cushion wall and a left side cushion wall, each formed from heat foam resin.

11. A high-pressure honeycomb tank container structure according to claim 3, wherein each of the first plurality of cell tanks further includes first and second height adaptors operatively connected to the top and bottom ends respectively of the cylindrical tank.

12. A high-pressure honeycomb tank container structure according to claim 5, wherein each of the second plurality of cell tanks further includes first and second height adaptors operatively connected to the top and bottom ends respectively of the cylindrical tank.

13. A high-pressure honeycomb tank container structure according to claim 3, further comprising: tank connection piping operatively connecting pairs of the first and second pluralities of cell tanks such that the first and second pluralities of cell tanks are connected in series, wherein each of the first and second pluralities of cell tanks includes a shutoff valve operatively connected to each of the first and second connection ports of the cylindrical tank therein, the tank connection piping connecting the shutoff valves between the pairs of the first and second pluralities of cell tanks.

14. A high-pressure honeycomb tank container structure according to claim 1, further comprising: a reinforcing frame assembly fixedly connected to surround the hexahedron-shaped structure, the reinforcing frame assembly including a top frame, a bottom frame, a front frame, a rear frame, a right side frame and a left side frame.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] FIG. 1 shows a concept chart of a heating and pressurizing system for a plurality of internal tanks using the references of (1) Internal Tank, (2) Internal Connection Pipe, (3) External Piping System, (4) Shut Off Valve, (5a) Air Compressor, (5b) Accumulator, (6) Electric Heater, (7) Flow Control Valve, (8) Discharge Tank, (9) Thermometer, (10) Pressure Gauge and (11) Heating Oven.

[0052] FIG. 2 shows a concept chart of an Internal Plastic Tank (24) using the references of (20) Plastic Tank, (21) Connection Port, (22) Screw Hole and (23) Domed Wing.

[0053] FIG. 3 shows a concept chart of an Internal Tank (28) using the references of (25) Plastic Tank, (26) Connection Port, and (27) Reinforcement FRP Prepreg.

[0054] FIG. 4(A), FIG. 4(B), FIG. 4(C), FIG. 4(D), FIG. 4(E) and FIG. 4(F) shows a manufacturing process chart of a Pentagon Cell Tank (40).

[0055] FIG. 4(A) shows a concept chart of an Internal Tank (31) using the references of (29) Reinforced Tank, and (30) Connection Port.

[0056] FIG. 4(B) shows a concept chart of an Internal Tank with Height Adapter (33) using the references of (31) Internal Tank and (32) Height Adaptor.

[0057] FIG. 4(C) shows a processing chart of a Pentagon Foam Resin using the references of (33) Internal Tank with Height Adapter, (34) Quadrangle Foam Resin and (35) Hexagon Foam Resin.

[0058] FIG. 4(D) shows a concept chart of a Pentagon Foam Resin with Internal Tank (36) using the references of (33) Internal Tank With Height Adapter, (34) Quadrangle Foam Resin and (35) Hexagon Foam Resin.

[0059] FIG. 4(E) shows a processing chart of a Pentagon Cell Tank using the references of (36) Pentagon Foam Resin with Internal Tank, (37) Quadrangle Prepreg and (38) Hexagon Prepreg.

[0060] FIG. 4(F) shows a concept chart of a Pentagon Cell Tank (40) using the references of (36) Pentagon Foam Resin with Internal Tank, (37) Quadrangle Prepreg, (38) Hexagon Prepreg and (39) Connection Cutting Lack.

[0061] FIG. 5(A), FIG. 5(B), FIG. 5(C), FIG. 5(D), FIG. 5(E) and FIG. 5(F) shows a manufacturing process chart of a Hexagon Cell Tank.

[0062] FIG. 5(A) shows a concept chart of an Internal Tank (43) using the references of (41) Reinforced Tank, and (42) Connection Port.

[0063] FIG. 5(B) shows a concept chart of an Internal Tank with Height Adapter (45) using the references of (43) Internal Tank and (44) Height Adaptor.

[0064] FIG. 5(C) shows a processing chart of a Hexagon Foam Resin with Internal Tank using the references of (45) Internal Tank with Height Adapter and (46) Hexagon Foam Resin.

[0065] FIG. 5(D) shows a concept chart of a Hexagon Foam Resin with Internal Tank (47) using the references of (45) Internal Tank With Height Adapter and (46) Hexagon Foam Resin.

[0066] FIG. 5(E) shows a processing chart of a Hexagon Cell Tank using the references of (47) Hexagon Foam Resin with Internal Tank and (48) Hexagon Prepreg.

[0067] FIG. 5(F) shows a concept chart of a Hexagon Cell Tank (50) using the references of (47) Hexagon Foam Resin With Internal Tank, (48) Hexagon Prepreg and (49) Connection Cutting Lack.

[0068] FIG. 6(A) shows a processing chart of a Trapezoid Filler using the references of Trapezoid Foam Resin (51), Flat Board Prepreg (52) and Trapezoid Prepreg (53).

[0069] FIG. 6(B) shows a concept chart of a Trapezoid Filler (54) using the references of Trapezoid Foam Resin (51), Flat Board Prepreg (52) and Trapezoid Prepreg (53).

[0070] FIG. 7 shows an image chart of a Honeycomb Set Tank (59) using the references of (55) Internal Tank, (56) Pentagon Cell Tank, (57) Hexagon Cell Tank and (58) Trapezoid Filler.

[0071] FIG. 8(A) shows a plan chart of a Container Wall Assembly (66). FIG. 8(B) shows a front chart of a Container Wall Assembly (66).

[0072] FIG. 8(A) and FIG. 8(B) shows a concept chart of a Container Wall Assembly (66) using the references of (60) Bottom Wall, (61) Top Wall, (62) Rear Wall, (63) Front Wall, (64) Left Side Wall and (65) Right Side Wall.

[0073] FIG. 9(A) shows a processing plan chart of a Container Honeycomb Cell. FIG. 9(B) shows a processing front chart of a Container Honeycomb Cell.

[0074] FIG. 9(A) and FIG. 9(B) shows a processing chart of a Container Honeycomb Cell using the references of (67) Bottom Wall, (68) Rear Wall, (69) Left Side Wall, (70) Rear Cushion Wall, (71) Left Side Cushion Wall, (72) Pentagon Honeycomb Cell, (73) Hexagon Honeycomb Cell and (74) Trapezoid Filler.

[0075] FIG. 10(A) shows a concept plan chart of a Container Honeycomb Cell (87). FIG. 10(B) shows a concept front chart of a Container Honeycomb Cell (87).

[0076] FIG. 10(A) and FIG. 10(B) show a concept chart of a Container Honeycomb Cell (87) using the references of (75) Bottom Wall, (76) Rear Wall, (77) Front Wall, (78) Left Side Wall, (79) Right Side Wall, (80) Rear Cushion Wall, (81) Front Cushion Wall, (82) Left Side Cushion Wall, (83) Right Side Cushion Wall, (84) Pentagon Honeycomb Cell, (85) Hexagon Honeycomb Cell and (86) Trapezoid Filler.

[0077] FIG. 11(A) shows a processing plan chart of a Container Honeycomb Cell Tank with Height Adapter (91). FIG. 11(B) shows a processing front chart.

[0078] FIG. 11(A) and FIG. 11(B) show a processing chart of a Container Honeycomb Cell Tank With Height Adapter (91) using the reference of Container Honeycomb Cell (88), Internal Tank (89) and Height Adapter (90).

[0079] FIG. 12(A) shows a plan chart of a Container Honeycomb Cell Tank Top Piping. FIG. 12(B) shows a front chart of a Container Honeycomb Cell Tank Top Piping.

[0080] FIG. 12(A) and FIG. 12(B) show a processing chart of a Container Honeycomb Cell Tank Top Piping (98) using the reference of Internal Tank (92), Pentagon Honeycomb Cell (93), Hexagon Honeycomb Cell (94), Height Adapter (95), Shut Off Valve (96) and Top Piping (97).

[0081] FIG. 13(A) show a plan chart of a Honeycomb Container Tank with Piping. FIG. 13(B) show a front chart of a Honeycomb Container Tank with Piping.

[0082] FIG. 13(A) and FIG. 13(B) show a concept chart of a Honeycomb Container Tank With Piping (114) using the reference of, Internal Tank (99), Pentagon Honeycomb Cell (100), Hexagon Honeycomb Cell (101), Cushion Wall (102), Bottom Wall (103), Top Wall (104), Rear Wall (105), Front Wall (106), Left Side Wall (107), Right Side Wall (108), Shut Off Valve (109), Top Piping (110), Bottom Piping (111), Entrance Connection (112) and Exit Connection (113).

[0083] FIG. 14(A) shows a plan chart of a Reinforcement Frame Device (121). FIG. 14(B) shows a front chart of a Reinforcement Frame Device (121).

[0084] FIG. 14(A) and FIG. 14(B) shows a concept chart of a Reinforcement Frame Device (121) using the references of (115) Bottom Frame, (116) Top Frame, (117) Rear Frame, (118) Front Frame, (119) Left Side Frame and (120) Right Side Frame.

[0085] FIG. 15(A) shows a plan chart of a High-Pressure Container Tank (134). FIG. 15(B) shows a front chart of a High-Pressure Container Tank (134).

[0086] FIG. 15(A) and FIG. 15(B) shows a concept chart of a High-Pressure Container Tank (134) using the references of (122) Container Wall, (123) Container Base Palette, (124) Pentagon Honeycomb Cell, (125) Hexagon Honeycomb Cell, (126) Trapezoid Filler, (127) Cushion Wall, (128) Internal Tank, (129) Shut Off Valve, (130) Internal Tank Piping, (131) Entrance Connection, (132) Exit Connection and (133) Control Board.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0087] The embodiments of the present invention will be described hereinbelow in conjunction with the above-described drawings. Referring to the attached drawings as follows, a concrete execution of the manufacturing process of a large-scale high-pressure gasholder in which a plurality of internal tanks have been accumulated in honeycomb structure is explained.

[0088] FIG. 1 shows a concept chart of a Heating and Pressurizing System for a plurality of internal tanks. The Heating and Pressurizing System for a plurality of internal tanks is composed of Internal Tanks (1), Internal Connection Pipes (2), External Piping System (3), Shut Off Valves (4), (5a) Air Compressor, (5b) Accumulator, Electric Heater (6), Flow Control Valve (7), Discharge Tank (8), Thermometer (9), Pressure Gauge (10) and Heating Oven (11).

[0089] Each Internal Tank (1) is manufactured from plastic cylindrical tank reinforced by thermosetting carbon fiber prepreg. The Internal Tank (1) has two connection ports in it. A plurality of Internal Tanks (1) are connected in series by these connection ports. Internal Connection Pipes (2) continuously connect the Internal Tanks (1). The Internal Connection Pipes (2) are made of stainless steel.

[0090] External Piping System (3) is composed of Shut Off Valve (4), (5a) Air Compressor, (5b) Accumulator, Electric Heater (6), Flow Control Valve (7), Discharge Tank (8), Thermometer (9) and Pressure Gauge (10). Two Shut Off Valves (4) have adhered to the entrance and the exit of the External Piping System (3).

[0091] External Piping System (3) is pressurized and heated by Air Compressor (5a) and Electric Heater (6), Accumulator (5b) controls the pressure fluctuation of compress air. Air Compressor (5a) pressurizes a line of Internal Tanks (1) connected with the External Piping System (3), However, Electric Heater (6) cannot heat a plurality of Internal Tanks (1) at the same time because the Electric Heater (6) is only partially heating compressed air in External Piping System (3). It is necessary to make the compressed air heated by Electric Heater (6) circulate to heat Internal Tank (1).

[0092] Flow Control Valve (7) is attached to the External Piping System (3). The External Piping System (3) ends at Flow Control Valve (7); thus the compressed air of the External Piping System (3) is discharged into Discharge Tank (8). The Discharge Tank (8) is at atmospheric pressure. Compressed air discharged into the Discharge Tank (8) is decompressed to atmospheric pressure, and inputted from the entrance of the Air Compressor (5a). Thus, the compressed air heated by the Electric Heater (6) circulates in a line of Internal Tanks (1) and through the External Piping System (3).

[0093] Thermometer (9) and Pressure Gauge (10) are mounted along External Piping System (3) to measure temperature and pressure, Heating Oven (11) heats the entire container from the outside of the container. The inside of Heating Oven (11) is at one atmospheric pressure. The system for heating and pressurizing Internal Tanks (1) is placed in Heating Oven (11). When a heatproof performance of Air Compressor (5a) is insufficient, Air Compressor (5a) may be implemented outside of the oven.

[0094] A line of Internal Tanks (1) are pressurized statically when Air Flow Control Valve (7) is not open. It is easy to pressurize the inside of Internal Tanks (1) to about 20 atmospheric pressures with Air Compressor (5a). When Air Flow Control Valve (7) is opened, compressed air bleeds from Air Flow Control Valve (7). However, when the flowing quantity of Air Compressor (5a) is large enough, the inside pressure of the Internal Tanks (1) can be kept about 20 atmospheric pressures, because Air Flow Control Valve (7) controls the amount of the bleed air.

[0095] After heat treatment process, Shut Off Valves (4) are closed. The thermosetting carbon fiber prepreg layers melt at about 130° C., and are merged mutually at that temperature. However, it is impossible that FRP made from the thermosetting carbon fiber prepreg obtains structural strength when FRP structure is not cooled enough. Therefore, internal pressure of the Internal Tanks (1) cannot be lowered until the Internal Tanks (1) get cold enough. When the Shut Off Valves (4) are shut, the container tank can be taken out from Heating Oven (11) with the internal pressure of the Internal Tanks (1) maintained. The Manufacturing operation effect improves because the container tank may be cooled outside of the Heating Oven (11).

[0096] FIG. 2 shows a concept chart of an Internal Plastic Tank (24) that is composed of Plastic Tank (20) and Connection Port (21). Plastic Tank (20) is a cylindrical tank manufactured from plastic and it has two Connection Ports (21) at top and bottom. Connection Port (21) is made of stainless steel. Connection Port (21) has one penetrating hole, and a plurality of Screw Holes (22) for attachment. Plastic Tank (20) and two Connection Ports (21) are built in one body. The connection port (21) has a Domed Wing (23) at the bottom of the Connection Port (21). Therefore, Connection Port (21) is prevented from being pushed out from Plastic Tank (20) by internal pressure.

[0097] FIG. 3 shows a concept chart of an Internal Tank (28). Internal Tank (28) is composed of a Plastic Tank (25), a Connection Port (26), and Reinforcement FRP Prepreg (27). The Plastic Tank (25) is a cylindrical tank manufactured from plastic and it has two Connection Ports (26) at the top and bottom. Plastic Tank (25) is reinforced with Reinforcement FRP Prepreg (27). Reinforcement FRP Prepreg (27) is made from thermosetting carbon fiber prepreg. The Plastic Tank (25) can be easily reinforced, because thermosetting prepreg is a soft and sticky cloth at room temperature. Internal Tank (28) is kept in the freezer at minus 5° C. or less to prevent deterioration of the thermosetting prepreg.

[0098] FIG. 4(A), FIG. 4(B), FIG. 4(C), FIG. 4(D), FIG. 4(E) and FIG. 4(F) show the manufacturing process chart of a Pentagon Cell Tank (40).

[0099] FIG. 4(A) shows a concept chart of an Internal Tank (31). Internal Tank (31) is composed of a Reinforced Tank (29) and a Connection Port (30). Reinforced Tank (29) is reinforced by thermosetting carbon prepreg. Connection Port (30) is a connection port to the adjoining honeycomb cell tank, and it is used for the processing work as well. Two Connection Ports (30) are placed at the top and the bottom of the Reinforced Tank (29).

[0100] FIG. 4(B) shows a concept chart of an Internal Tank with Height Adapter (33). The Internal Tank with Height Adapter (33) is composed of Internal Tank (31) and Height Adaptor (32). Height Adaptor (32) is made of steel and used as a bottom support adaptor and a hanging fitting for the Internal Tank (31).

[0101] It is difficult to maintain the height position of Connection Port (30) constant because Internal Tank (31) slips down by gravity if there is no support. Height Adaptor (32) is used as bottom support of Internal Tank (31). Height Adaptor (32) maintains the height position of Connection Port (30), accurately. Additionally, Height Adaptor (32) is used also for a fitting when Internal Tank (31) is hung down by crane while work process.

[0102] FIG. 4(C) shows a processing chart of Pentagon Foam Resin. Pentagon Foam Resin is manufactured by uniting Quadrangle Foam Resin (34) and Hexagon Foam Resin (35) to surround the Internal Tank (31). Quadrangle Foam Resin (34) is in the shape of a foursquare pillar cut in half in the vertical direction. When two Quadrangle Foam Resins (34) are matched together, it becomes a square. Hexagon Foam Resin (35) is in the shape of a hexagon pillar cut in half in the vertical direction. When two Hexagon Foam Resins (35) is matched together, it becomes a hexagon. When Quadrangle Foam Resin (34) and Hexagon Foam Resin (35) are matched together, it becomes a pentagon pillar that has a cylindrical vacant space. Cylinder diameter is made 2 mm to 5 mm bigger than the radius of a Tank Assembly with Height Adapter (33). The length of Quadrangle Foam Resin (34) and Hexagon Foam Resin (35) is manufactured as well as Tank Assembly with Height Adapter (33). Quadrangle Foam Resin (34) and Hexagon Foam Resin (35) are made from foam resin which begins to foam at about 110° C. The heat foam of Quadrangle Foam Resin (34) and Hexagon Foam Resin (35) continues until they are completely cooled.

[0103] FIG. 4(D) shows a concept chart of a Pentagon Foam Resin with Internal Tank (36). Pentagon Foam Resin with Internal Tank (36) is composed of Tank Assembly with Height Adapter (33), Quadrangle Foam Resin (34) and Hexagon Foam Resin (35). Tank Assembly with Height Adapter (33) is placed in the pentagon pillar with cylindrical vacant space. It is also possible to insert Tank Assembly with Height Adapter (33) from the upper side in the inside of the pentagon pillar that has cylindrical vacant space. Quadrangle Foam Resin (34) and Hexagon Foam Resin (35) are united with the pressure sensitive adhesive double-coated tape. As for the base material of the double-coated tape, a cotton cloth is preferable.

[0104] FIG. 4(E) shows a processing chart of a Pentagon Cell Tank. The Pentagon Cell Tank is manufactured by attaching Quadrangle Prepreg (37) and Hexagon Prepreg (38) to Pentagon Foam Resin with Internal Tank (36). Quadrangle Prepreg (37) is a shell made of carbon fiber or glass fiber thermoplastic prepreg, in the shape of a foursquare pillar cut in half in the vertical direction. Quadrangle Prepreg (37) is attached to Pentagon Foam Resin with Internal Tank (36) for structural reinforcement. Hexagon Prepreg (38) is a shell made of carbon fiber or glass fiber thermoplastic prepreg, whose shape is a cutting into the half of hexagon pillars in the vertical direction. Hexagon Prepreg (38) is attached to Pentagon Foam Resin with Internal Tank (36) for structural reinforcement. The length of Quadrangle Prepreg (37) and Hexagon Prepreg (38) is manufactured as well as Pentagon Foam Resin with Internal Tank (36). The parts manufactured from thermoplastic prepreg soften at about 100° C., and are merged at about 130° C.

[0105] FIG. 4(F) shows a concept chart of a Pentagon Cell Tank (40). Pentagon Cell Tank (40) is composed of Pentagon Foam Resin with Internal Tank (36), Quadrangle Prepreg (37) and Hexagon Prepreg (38). Connection Cutting Lack (39) is cut in Pentagon Cell Tank (40). Connection Cutting Lacks (39) are placed at the top and the bottom of Pentagon Cell Tank (40). Honeycomb structure set tank is composed of the array of plurality of Pentagon Cell Tanks (40), which is a basic component of the honeycomb structure set tank. Pentagon Cell Tanks (40) compose the material of the honeycomb structure set tank in the surrounding periphery. Quadrangle Prepreg (37) and Hexagon Prepreg (38) are the honeycomb cell walls. Connection Cutting Lack (39) is a cutting lack for the connection of the internal tanks built into Pentagon Cell Tank (40). Quadrangle Prepreg (37) and Hexagon Prepreg (38) are attached to Pentagon Foam Resin with Internal Tank (36) with pressure sensitive adhesive double-coated tape. As for the base material of the double-coated tape, a cotton cloth is preferable.

[0106] FIG. 5(A), FIG. 5(B), FIG. 5(C), FIG. 5(D), FIG. 5(E) and FIG. 5(F) shows a manufacturing process chart of a Hexagon Cell Tank.

[0107] FIG. 5(A) shows a concept chart of an Internal Tank (43). Internal Tank (43) is composed of Reinforced Tank (41) and Connection Port (42). Reinforced Tank (41) is reinforced by thermosetting carbon prepreg. Connection Port (42) is a connection port to the adjoining honeycomb cell tank, and it is used for processing work as well. Two Connection Ports (42) are placed at the top and the bottom of each Reinforced Tank (41).

[0108] FIG. 5(B) shows a concept chart of an Internal Tank with Height Adapter (45). Internal Tank with Height Adapter (45) is composed of internal Tank (43) and Height Adaptor (44). Height Adaptor (44) is made of steel and used as a bottom support adaptor and a hanging fitting of Internal Tank (43).

[0109] It is difficult to maintain the height position of Connection Ports (42) constant because Internal Tank (43) slips down by gravity if there is no support. Height Adaptor (44) is used as the bottom support of Internal Tank (43). Height Adaptor (44) maintains the height position of Connection Port (43), accurately. Additionally, Height Adaptor (44) is used also for a fitting when Internal Tank (31) is hung down by crane while work process.

[0110] FIG. 5(C) shows a processing chart of Hexagon Foam Resin. Hexagon Foam Resin is manufactured by uniting of two Hexagon Foam Resins (46). Hexagon Foam Resin (46) is in the shape of a hexagon pillar cut in half in the vertical direction. When two Hexagon Foam Resins (46) are matched together, they become a hexagon pillar that has cylindrical vacant space. The cylinder diameter is made 2 mm to 5 mm bigger than radiuses of Tank Assembly with Height Adapter (45). Hexagon Foam Resin (46) is manufactured as well as Tank. Assembly with Height Adapter (45). Hexagon Foam Resin (46) is made from foam resin which begins to foam at about 110° C. The heat foam of Hexagon Foam Resin (46) continues until it is completely cooled.

[0111] FIG. 5(D) shows a concept chart of a Hexagon Foam Resin with Internal Tank (47). Hexagon Foam Resin with Internal Tank (47) is composed of Tank Assembly with Height Adapter (45), and two Hexagon Foam Resins (46). Tank Assembly with Height Adapter (45) is placed in the hexagon pillar with cylindrical vacant space. It is also possible to insert Tank Assembly with Height Adapter (45) from the upper side in the inside of the hexagon pillar that has the cylindrical vacant space. Two Hexagon Foam Resins (46) are united with the pressure sensitive adhesive double-coated tape. As for the base material of the double-coated tape, a cotton cloth is preferable.

[0112] FIG. 5(E) shows a processing chart of a Hexagon Cell Tank. Hexagon Cell Tank is manufactured by attaching two Hexagon Prepregs (48) to Hexagon Foam Resin with Internal Tank (47). Hexagon Prepreg (48) is a shell made of carbon fiber or glass fiber thermoplastic prepreg, in the shape of a hexagon pillar cut in half in the vertical direction. Hexagon Prepreg (48) is attached to Hexagon Foam Resin with Internal Tank (47) for structural reinforcement. The length of Hexagon Prepreg (48) is manufactured as well as Hexagon Foam Resin with Internal Tank (47). The parts manufactured from thermoplastic prepreg soften at about 100° C., and are merged at about 130° C.

[0113] FIG. 5(F) shows a concept chart of a Hexagon Cell Tank (50). Hexagon Cell Tank (50) is composed of Hexagon Foam Resin with Internal Tank (47) and two Hexagon Prepregs (48). Connection Cutting Lack (49) is cut in Hexagon Cell Tank (50). Connection Cutting Lacks (49) are placed at the top and the bottom of Hexagon Cell Tank (50). The honeycomb structure set tank is composed of an array of a plurality of Hexagon Cell Tanks (50), which is a basic component of the honeycomb structure set tank. Hexagon Cell Tank (50) embodies the material of the honeycomb structure set tank in the central part. Two Hexagon Prepregs (48) are the honeycomb cell walls. Connection Cutting Lack (49) is a cutting lack for the connection of internal tanks built into Hexagon Cell Tank (50). Two Hexagon Prepregs (38) are attached to Hexagon Foam Resin with Internal Tank (47) with pressure sensitive adhesive double-coated tape. As for the base material of the double-coated tape, a cotton cloth is preferable.

[0114] FIG. 6(A) shows a processing chart of a Trapezoid Filler. Trapezoid Filler is manufactured by attaching Flat Board Prepreg (52) and Trapezoid Prepreg (53) to Trapezoid Foam Resin (51). Trapezoid Foam Resin (51) is made from foam resin which begins to foam at about 110° C. and Trapezoid Foam Resin (51) continues foaming until being completely cooled. Flat Board Prepreg (52) and Trapezoid Prepreg (53) are made from carbon or glass fiber thermoplastic prepreg. The shape of Flat Board Prepreg (52) is equal to a trapezoid bottom of Trapezoid Foam Resin (51). Trapezoid Prepreg (53) is a shell made of carbon fiber or glass fiber thermoplastic prepreg whose shape is equal to a trapezoid upper shape of Trapezoid Foam Resin (51). Flat Board Prepreg (52) and Trapezoid Prepreg (53) are attached to Trapezoid Foam Resin (51) with the pressure sensitive adhesive double-coated tape. As for the base material of the double-coated tape, a cotton cloth is preferable.

[0115] FIG. 6(B) shows a concept chart of a Trapezoid Filler (54). Trapezoid Filler (54) is composed of Trapezoid Foam Resin (51), Flat Board Prepreg (52) and Trapezoid Prepreg (53). Trapezoid Filler (54) is a part to correct irregularities or voids, which are created at the surrounding portions of the honeycomb structure. The lengths of Trapezoid Foam Resin (51), Flat Board Prepreg (52) and Trapezoid Prepreg (53) are equal to the length of the honeycomb structure to be manufactured.

[0116] FIG. 7 shows an image chart of a Honeycomb Set Tank (59). The external shape of Honeycomb Set Tank (59) is a hexahedron. Honeycomb Set Tank (59) is composed of pluralities of Pentagon Cell Tanks (56), Hexagon Cell Tanks (57) and Trapezoid Fillers (58). Internal Tanks (55) are stored in Pentagon Cell Tanks (56) and Hexagon Cell Tanks (57). Pentagon Cell Tanks (56) are placed surrounding the Honeycomb Set Tanks (59). Hexagon Cell Tanks (57) are positioned centrally relative to the Honeycomb Set Tanks (59). Trapezoid Filler Assemblies (58) are used to correct the irregularities and voids, which is formed along the surrounding portions of the honeycomb structure.

[0117] Internal Tank (55) is heated and pressurized by the compressed air at high temperature from the inside. The entire Honeycomb Set Tank (59) is heated from outside in a large-scale heat oven. The heat foam resin included in Pentagon Cell Tanks (56), Hexagon Cell Tanks (57) and Trapezoid Fillers (58) foams and expands when heated to a high temperature.

[0118] When the outside wall of Honeycomb Set Tank (59) is restrained with an external frame, the pluralities of Pentagon Cell Tanks (56), Hexagon Cell Tanks (57) and Trapezoid Fillers (58) are mutually jostled. The thermoplastic carbon fiber or glass fiber prepreg shells are attached on the surfaces of Pentagon Cell Tanks (56), Hexagon Cell Tanks (57) and Trapezoid Fillers (58). The thermoplastic carbon fiber or glass fiber prepreg shells are divided into two parts. So, the thermoplastic carbon fiber or glass fiber prepreg shells, which are structural material of the honeycomb structure, can freely expand. The thermoplastic carbon fiber or glass fiber prepreg shell melts when Honeycomb Set Tank (59) is heated to about 130° C. Then, pluralities of Pentagon Cell Tank (56), Hexagon Cell Tank (57) and Trapezoid Filler (58) are merged mutually.

[0119] During heating, Internal Tanks (55) that are stored in Pentagon Cell Tanks (56) and Hexagon Cell Tanks (57) are strongly pressurized by the heat foam resin. The surface of Internal Tank (55) is reinforced by accumulated carbon fiber thermosetting prepregs. When the accumulated carbon fiber thermosetting prepregs are heated to about 130° C., carbon fiber prepregs are strongly pressurized with the heat foam resin and internal pressure of Internal Tank (55). Then, the accumulated carbon fiber thermosetting prepregs of Internal Tank (55) are merged mutually.

[0120] FIG. 8(A) and FIG. 8(B) shows a concept chart of a Container Wall Assembly (66). The manufacturing process for a Honeycomb Set Tank will be explained with an example of a ten-foot container.

[0121] FIG. 8(A) shows a plan chart of a Container Wall Assembly (66). FIG. 8(B) shows a front chart of a Container Wall Assembly (66). Container Wall Assembly (66) is composed of Bottom Wall (60), Top Wall (61), Rear Wall (62), Front Wall (63), Left Side Wall (64) and Right Side Wall (65). Bottom Wall (60), Top Wall (61), Rear Wall (62), Front Wall (63), Left Side Wall (64) and Right Side Wall (65) are manufactured from steel and they are boards with a flat inside wall, and the outside wall is a corrugated plate.

[0122] FIG. 9(A) and FIG. 9(B) show processing charts of a Container Honeycomb Cell. FIG. 9(A) shows a plan chart and FIG. 9(B) shows a front chart. The Container Honeycomb Cell is composed of Bottom Wall (67), Rear Wall (68), Left Side Wall (69), Rear Cushion Wall (70), Left Side Cushion Wall (71), Pentagon Honeycomb Cell (72), Hexagon Honeycomb Cell (73) and Trapezoid Filler (74). Bottom Wall (67), Rear Wall (68) and Left Side Wall (69) are manufactured from steel and they are boards with a flat inside wall, and the outside wall is a corrugated plate. Rear Cushion Wall (70) and Left Side Cushion Wall (71) are manufactured from heat foam resin and they protect the honeycomb set tank from external shock loading. Pentagon Honeycomb Cell (72) is composed of a pentagon heat form resin and a pentagon shell made of carbon fiber or glass fiber thermoplastic prepreg. Hexagon Honeycomb Cell (73) is composed of a hexagon heat form resin and a hexagon shell made of carbon fiber or glass fiber thermoplastic prepreg. Trapezoid Filler (74) is composed of a trapezoid hexagon heat form resin and a trapezoid shell made of carbon fiber or glass fiber thermoplastic prepreg.

[0123] The Manufacturing process for the Container Honeycomb Cell is composed of three steps: [0124] (1) Three container walls, Bottom Wall (67), Rear Wall (68), Left Side Wall (69), are assembled into a triangular configuration. [0125] (2) Rear Cushion Wall (70) and Left Side Cushion Wall (71) are squarely assembled on Bottom Wall (67) [0126] (3) A plurality of Pentagon Honeycomb Cells (72), Hexagon Honeycomb Cells (73) and Trapezoid Fillers (74) are set up for shaping the honeycomb structure. A plurality of Pentagon Honeycomb Cells (72), Hexagon Honeycomb Cells (73) and Trapezoid Fillers (74) are assembled together with the outer shell.

[0127] Pentagon Honeycomb Cells (72) are placed surrounding the outer portions of the Container Honeycomb Cell. Hexagon Honeycomb Cells (73) are placed at the central part. Trapezoid Fillers (74) are filled in to correct the irregularities and voids which result along the outer surrounding periphery of the honeycomb structure. The outer shells of Pentagon Honeycomb Cells (72), Hexagon Honeycomb Cells (73) and Trapezoid Fillers (74) are manufactured from thermoplastic carbon fiber or glass fiber prepreg. Thermoplastic carbon fiber or glass fiber prepreg is not cohesive at the room temperature, so the assembly operation of the honeycomb structure is not difficult.

[0128] FIG. 10(A) and FIG. 10(B) show a concept chart of a Container Honeycomb Cell (87). FIG. 10(A) shows a plan concept chart of Container Honeycomb Cell (87). FIG. 10(B) shows a front concept chart.

[0129] Container Honeycomb Cells (87) are composed of Bottom Wall (75), Rear Wall (76), Front Wall (77), Left Side Wall (78), Right Side Wall (79), Rear Cushion Wall (80), Front Cushion Wall (81), Left Side Cushion Wall (82), Right Side Cushion Wall (83), Pentagon Honeycomb Cells (84), Hexagon Honeycomb Cells (85) and Trapezoid Fillers (86). Bottom Wall (75), Rear Wall (76), Front Wall (77), Left Side Wall (78) and Right Side Wall (79) are manufactured from steel. Rear Cushion Wall (80), Front Cushion Wall (81), Left Side Cushion Wall (82) and Right Side Cushion Wall (83) are manufactured from heat foam resin. Pentagon Honeycomb Cells (84), Hexagon Honeycomb Cells (85) and Trapezoid Fillers (86) are manufactured from heat foam resin and carbon fiber or glass fiber thermoplastic prepreg. Pentagon Honeycomb Cells (84), Hexagon Honeycomb Cells (85) and Trapezoid Fillers (86) are manufactured from heat foam resin and carbon fiber or glass fiber thermoplastic prepreg. Each Pentagon Honeycomb Cell (84) and Hexagon Honeycomb Cell (85) has a large cavity, wherein an internal tank is stored in each cavity.

[0130] FIG. 11(A) and FIG. 11(B) show a processing chart of a Container Honeycomb Cell Tank with Height Adapter (91). FIG. 11(A) shows a plan chart, and FIG. 11(B) shows a front chart.

[0131] Container Honeycomb Cell Tank with Height Adapter (91) is composed of Container Honeycomb Cell (88), internal Tank (89) and Height Adapter (90). Container Honeycomb Cell (88) is the same as Container Honeycomb Cell (87) in FIG. 10. Internal Tank (89) is the same as Internal Tank (31) in FIG. 4 and Internal Tank (43) in FIG. 5. Height Adapter (90) is the same as Height Adapter (32) in FIG. 4 and Height Adapter (44) in FIG. 5.

[0132] Container Honeycomb Cell Tank with Height Adapter (91) is assembled by inserting Internal Tank (89), to which Height Adapter (90) is attached, into the cavity of Container Honeycomb Cell (88). Internal Tank (89) is inserted into Container Honeycomb Cell (88) from above by crane. The assembling operation of a Container Honeycomb Cell Tank with Height Adapter (91) is not difficult, because the cavity diameter of each Container Honeycomb Cell (88) is larger than the diameter of Internal Tank (89).

[0133] FIG. 12(A) and FIG. 12(B) show a processing chart of a Container Honeycomb Cell Tank Top Piping (98). FIG. 12(A) shows a plan chart. FIG. 12(B) shows a front chart.

[0134] Container Honeycomb Cell Tank Top Piping (98) is composed of Internal Tanks (92), Pentagon Honeycomb Cells (93), Hexagon Honeycomb Cells (94), Height Adapters (95), Shut Off Valves (96) and Top Pipings (97). Pentagon Honeycomb Cells (93) are the same as Pentagon Cell Tanks (40). Hexagon Honeycomb Cells (94) is the same as Hexagon Cell Tank (50). Internal Tank (92) and Height Adapter (95) is the same as Internal Tank (31), Height Adapter (32) in FIG. 4 and Internal Tank (43), Height Adapter (44) in FIG. 5.

[0135] Container Honeycomb Cell Tank Top Piping (98) is assembled by attaching Shut Off Valve (96) and connecting Top Piping (97) to Internal Tank (92). Height Adapter (95) at the top of Internal Tank (92) is removed before attaching Shut Off Valve (96) and Top Piping (97).

[0136] It is easy to connect Top Piping (97) to Internal Tank (92), because Top Piping (97) only ties two Internal Tanks (92). Internal Tank (92) can be rotated freely in the cylindrical cavity of Pentagon Honeycomb Cell (93) and Hexagon Honeycomb Cell (94). Additionally, Height Adapter (95) at the bottom uniformly adjusts the height position of the connection ports. Shut Off Valve (96) is attached to Internal Tank (92). Therefore, Top Piping (97) actually connects two Shut Off Valves (96). After the Top Piping is finished, the vacant space above Internal Tank (92) is filled with the granulated powder foam resin, and Top Wall of container is installed. The Top Wall of the container is not shown in FIG. 12.

[0137] All Internal Tanks (92) of Container Honeycomb Cell Tank are connected in series. The piping at the bottom is processed with the Container Honeycomb Cell Tank turned 180 degrees and the connections in reverse.

[0138] FIG. 13(A) show a plan chart of a Honeycomb Container Tank with Piping (114). FIG. 13(B) show a front chart of a Honeycomb Container Tank with Piping (114).

[0139] FIG. 13(A) and FIG. 13(B) show a concept chart of a Honeycomb Container Tank with Piping (114), Honeycomb Container Tank With Piping (114) is composed of Internal Tanks (99), Pentagon Honeycomb Cells (100), Hexagon Honeycomb Cells (101), Cushion Wall (102), Bottom Wall (103), Top Wall (104), Rear Wall (105), Front Wall (106), Left Side Wall (107), Right Side Wall (108), Shut Off Valves (109), Top Piping (110), Bottom Piping (111), Entrance Connection (112) and Exit Connection (113).

[0140] Internal Tanks (99) are the same as Internal Tanks (92) in FIG. 12. Pentagon Honeycomb Cells (100) are the same as Pentagon Cell Tanks (84) in FIG. 10. Hexagon Honeycomb Cells (101) are the same as Hexagon Cell Tanks (85) in FIG. 10. Cushion Wall (102) is made of heat foam resin and becomes the cushioning material of the honeycomb set tank. Bottom Wall (103), Top Wall (104), Rear Wall (105), Front Wall (106), Left Side Wall (107), Right Side Wall (108) are the same as Bottom Wall (60), Top Wall (61), Rear Wall (62), Front Wall (63), Left Side Wall (64), Right Side Wall (65) in FIG. 8. Shut Off Valve (109) and Top Piping (110) is the same as Shut Off Valve (96) and Top Piping (97) in FIG. 12.

[0141] Bottom Piping (111) is the piping at the bottom of Internal Tanks (99). The piping of the bottom is processed with the honeycomb container tank turned 180 degrees and in reverse. All Internal Tanks (99) are connected in series. It is a little difficult to attach Shut Off Valve (109) and to connect Bottom Piping (111) to Internal Tank (99). Internal Tank (99) cannot be rotated freely in the cylindrical cavity of Pentagon Honeycomb Cell (100) and Hexagon Honeycomb Cell (101), because the top of Internal Tank (99) is already fixed by Top Piping (110). It is necessary to note it is because the piping of Bottom Piping (111) makes a mistake easily in the connection order. The leakage inspection of piping is necessary. After the piping work has finished, the vacant space above Internal Tank (99) is filled with the granulated powder foam resin, and the container wall is installed.

[0142] All Internal Tanks (99) in Honeycomb Container Tank with Piping (114) are connected into one line as shown in FIG. 1. Entrance Connection (112) and Exit Connection (113) are the connection ports to the outside.

[0143] FIG. 14(A) shows a plan chart of a Reinforcement Frame Device (121). FIG. 14(B) shows a front chart.

[0144] FIG. 14(A) and FIG. 14(B) shows a concept chart of a Reinforcement Frame Device (121). Reinforcement Frame Device (121) is composed of Bottom Frame (115), Top Frame (116), Rear Frame (117), Front Frame (118), Left Side Frame (119) and Right Side Frame (120). These frames are manufactured from steel.

[0145] The heat foam resin of the honeycomb cell foams when the honeycomb container tank is heated. Also, the walls of the honeycomb container tank are pushed out outside. The container wall assembly can be destroyed, if there is no Reinforcement Frame Device (121). The heat of the heating oven is never interrupted, because the reinforcement frame is a bone structure.

[0146] FIG. 15(A) shows a plan chart of a High-Pressure Container Tank (134). FIG. 15(B) shows a front chart of a High-Pressure Container Tank (134).

[0147] FIG. 15(A) and FIG. 15(B) show a concept chart of a High-Pressure Container Tank (134), High-Pressure Container Tank (134) is composed of Container Wall (122), Container Base Palette (123), Pentagon Honeycomb Cells (124), Hexagon Honeycomb Cells (125), Trapezoid Fillers (126), Cushion Wall (127), Internal Tank (128), Shut Off Valves (129), Internal Tank Piping (130), Entrance Connection (131), Exit Connection (132) and Control Board (133).

[0148] High-Pressure Container Tank (134) is an example of honeycomb structural high-pressure set tank, and is designed so that it is accommodated in an ISO ten-foot container. Container Wall (122) is the most outside protection wall of Internal Tank (128) and is hexahedron made of steel. Container Base Palette (123) is welded under High-Pressure Container Tank (134), and transports High-Pressure Container Tank (134) conveniently. Cushion Wall (127) is manufactured from the heat foam resin and is the second protection of Internal Tanks (128). Pentagon Honeycomb Cells (124), Hexagon Honeycomb Cells (125) and Trapezoid Fillers (126) are manufactured from the heat foam resin. The heat foam resin foams and expands when heated. The outer shells of Pentagon Honeycomb Cells (124), Hexagon Honeycomb Cells (125) and Trapezoid Fillers (126) are made of thermoplastic carbon fiber prepreg or thermoplastic glass fiber prepreg. These outer shells mutually merge by the heat-treatment process, and then the shape of merged shells becomes a honeycomb structure.

[0149] The strong honeycomb cell manufactured from carbon fiber or the glass fiber is the third protection of Internal Tanks (128). The honeycomb structure built with carbon fiber or the glass fiber protects Internal Tanks (128) from external shock loading. The heat form resin, which is formed by a heat-treatment process, is the fourth protection of Internal Tanks (128).

[0150] Internal Tank (128) is made from plastic and is reinforced by thermosetting carbon fiber prepreg. The reinforcement structure of Internal Tank (128) is designed to endure the high pressure in a single tank alone. All Internal Tanks (128) are enclosed in High-Pressure Container Tank (134). They are connected in series, by Internal Tank Piping (130). Two Shut Off Valves (129) are attached at the top and bottom of each Internal Tank (128). Shut Off Valve (129) is used when High-Pressure Container Tank (134) is manufactured. They need heat proofing, because the Shut Off Valves (129) are heated at heat treatment process, Shut Off Valves (129) are permanently enclosed in High-Pressure Container Tank (134). Shut Off Valve (129) is also used when High-Pressure Container Tank (134) is transported. Control Board (133) controls the opening and shutting of Shut Off Valve (129). Shut Off Valve (129) can minimize a potential disaster due to Internal Tank (128) being damaged accidentally while transporting High-Pressure Container Tank (134). There are Entrance Connection (131) and Exit Connection (132) in High-Pressure Container Tank (134). Entrance Connection (131) and Exit Connection (132) are the connecting ports to the outside.

[0151] It will be appreciated that modifications may be made in the present invention. This invention is the one invented to improve U.S. Pat. No. 8,917,809 B2. Manufacturing the large-scale container set tank is difficult by U.S. Pat. No. 8,917,809 B2, because the patent heats the honeycomb cell from the outside. The method of the new invention can be applied to the pillar of a large-scale honeycomb structure. In addition, it is difficult to make a honeycomb cell with high size accuracy by the patent of “U.S. Pat. No. 8,917,809 B2”, because the patent manufactures the honeycomb cell with thermosetting prepreg. The method of the new invention can be applied to the rapid-transit railway and the aircraft.

[0152] The spirit of this invention is a technical advancement of U.S. Pat. No. 8,917,809 B2 with new manufacturing facilities. For that purpose, this invention developed the manufacturing process for the honeycomb cell with advanced accuracy and on a large scale. Although the present invention has been fully described in connection with the preferred embodiment thereof with reference to the accompanying drawings, it is to be noted that various changes and modifications will be apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as defined by the appended claims, unless they depart therefrom.