製造工程

二重膜式ガスホルダーの製造工程

膜材性能の確認、裁断、接合、気密溶着、膨張成形、POC検収まで、二重膜式ガスホルダーの製造フローをご紹介します。

製造工程を見る検収項目を見る

02項目

主要材料確認

06工程

主要製造工程

04項目

検収確認項目

Double-membrane gas holder production process

工程管理の要点

二重膜式ガスホルダーの製造では、材料を接合するだけでなく、膜材の強度とガスバリア性能を確認し、その結果に基づいて裁断、接合、溶着、成形条件を管理します。最終的に検査とPOC確認を行い、納入可否を判定します。

01 / 材料性能

材料性能と製造条件

裁断・接合前に膜材の耐せん断性、メタン透過率、耐候性を確認し、後工程と長期運転の安全範囲を定めます。

Shear Resistance

Shear resistance determines whether the membrane can transfer loads stably around cut edges, corner transitions, and sewn paths. It is a prerequisite for preventing local tearing and boundary instability.

It affects edge integrity and cutting allowance, reducing stress concentration during later assembly.

It affects how the labyrinth sewing zone distributes loads and how the seam and membrane cooperate under tension.

It affects deformation control after node connection and inflation forming, shaping long-term fatigue risk.

Methane Permeability

Methane permeability describes the gas-barrier capability of the membrane. It is fundamental to sealing performance, pressure stability, and long-term operating efficiency.

It affects membrane selection and layer-structure confirmation, defining whether gas-tightness targets can be met.

It affects continuity after sealing weld treatment, preventing welded areas from becoming weak leakage paths.

It affects pressure retention after inflation forming and remains a key reference during acceptance and POC checks.

02 / 製造工程

膜体の主要製造工程

寸法精度、接合部の気密性、膨張成形後の圧力安定性について、各工程に管理点を設定します。

Membrane Selection and Property Confirmation

Membrane Cutting

Labyrinth Sewing

Sealing Weld Treatment

Reinforcement Welding and Node Connection

Inflation Forming and Dimensional Calibration

製造工程

Membrane Selection and Property Confirmation

作業内容

Confirm membrane structure, thickness, and node strategy against gas media, design pressure, size envelope, and site conditions.

管理ポイント

Check shear resistance, methane permeability, layer compatibility, and downstream process fit so that material selection matches the fabrication window.

品質への影響

This stage sets the manufacturing ceiling for everything that follows, including cutting accuracy, seam stability, and sealing performance.

製造工程

Membrane Cutting

作業内容

Cut the membrane according to developed dimensions, segment the material, and prepare edges for later joining and node positioning.

管理ポイント

Control edge integrity, dimensional allowance, and orientation consistency so the material enters sewing without hidden edge defects.

品質への影響

Cutting accuracy directly affects alignment, stress-transfer paths, and the final geometry after forming.

製造工程

Labyrinth Sewing

作業内容

Use labyrinth sewing to establish the primary joining path so that the connection zone has a clearer structural load distribution and assembly reference.

管理ポイント

Control sewing path, stitch spacing, corner transitions, and local stress relief to avoid accumulated deviation before sealing weld treatment.

品質への影響

This step defines the structural order of the joined membrane area and prepares the base for sealing weld quality and global stability.

製造工程

Sealing Weld Treatment

作業内容

Apply sealing weld treatment to critical joining zones and build a continuous sealed boundary with stable gas-barrier performance.

管理ポイント

Control weld continuity, thermal input consistency, and full coverage to prevent under-weld, over-weld, or local shrinkage from disturbing the membrane surface.

品質への影響

Sealing weld quality determines whether the seam truly becomes a reliable sealing face, making it a decisive factor for gas tightness and service stability.

製造工程

Reinforcement Welding and Node Connection

作業内容

Complete accessory interfaces, reinforcement at load-bearing nodes, and local welded connections so the membrane and its installation boundaries form one integrated system.

管理ポイント

Control interface position, node alignment, and reinforcement matching so the membrane can carry loads consistently under real installation conditions.

品質への影響

Node-connection quality directly affects installation fit-up, boundary sealing, and load transfer during operation.

製造工程

Inflation Forming and Dimensional Calibration

作業内容

Inflate the membrane into its target operating shape and calibrate contour, tension, and local behavior at the same time.

管理ポイント

Observe formed surfaces, load uniformity, pressure response, and rebound behavior to confirm that the geometry stays aligned with design values.

品質への影響

This stage acts as an integrated manufacturing validation and can expose dimensional drift, node imbalance, or leakage risk before delivery.

03 / 検収・POC

検収・POC確認

外観、寸法、溶着部、気密性、膨張状態を同一の納入基準で確認し、出荷または次工程へ進める状態であることを判定します。

Appearance and Dimensional Review

Review membrane flatness, contour consistency, node positions, and key dimensions to confirm that fabrication remains aligned with developed design data.

Weld and Seal Integrity Check

Check sealing-weld areas, connected boundaries, and critical nodes for continuity to identify under-weld, false weld, local shrinkage, or leakage risk.

Inflated-State Stability Confirmation

Confirm pressure response, membrane tension, and overall shape stability in the inflated state to verify balanced behavior under simulated operating conditions.

POC Acceptance and Delivery Decision

Bring appearance, dimensions, sealing, and forming results together at the POC gate to determine whether the unit is ready for dispatch or the next project stage.

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