Composite Storage Tank Manufacturing with Rigid Cap and Helical Winding
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Solution Overview
Problem
Existing methods for producing pressurized fluid storage tanks are complex and costly, particularly due to difficulties in applying a composite ribbon around cylindrical tanks with rounded ends and mechanical stress variations between ends and the cylindrical center.
Innovation Solution
A method involving a rigid, thermoplastic polymer cap with reinforcing fibers is attached to one end of the tank, allowing the composite ribbon to be helically wound around the cap and envelope, reducing the number of layers and facilitating easier production, while also creating a leakage path for overpressure relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a composite tape is wound helically around a rigid sealed envelope with rounded ends, then the tank structure is formed, but the mechanical stress distribution becomes non-uniform between rounded ends and cylindrical center
Solution Approach 1:
The tank structure is divided into three distinct zones: a first rounded end zone, a cylindrical center zone, and a second rounded end zone. Each zone receives a different number of composite tape layers, with fewer layers at the rounded ends and more layers at the cylindrical center, creating non-uniform reinforcement that matches the stress distribution pattern.
Solution Approach 2:
Different regions of the tank are given different local properties: the cylindrical center receives maximum tape layers for high stress areas, while the rounded ends receive fewer layers since they experience lower stresses. This local differentiation optimizes both structural efficiency and manufacturing feasibility.
2Ease of manufacture
If the sealed envelope has an opening with a tip at one end, then the tank can be filled, but the tip disrupts the relative movement of the application head and envelope during tape winding
Solution Approach 1:
The opening with tip is pre-positioned at one end of the envelope before the tape winding process begins. The winding pattern is specifically designed to accommodate this feature by reducing or eliminating tape layers in the immediate vicinity of the tip, allowing the application head to complete winding operations without collision or disruption.
3Strength
If multiple layers of composite tape are applied to the entire envelope surface, then mechanical strength is increased, but production time and cost increase
Solution Approach 1:
Instead of applying uniform tape layers across the entire envelope, the method applies different numbers of layers to different zones: maximum layers at the cylindrical center where stresses are highest, and reduced layers at the rounded ends where stresses are lower. This local differentiation maintains necessary structural strength while significantly reducing total material usage and production time.
Solution Approach 2:
The method applies the minimum necessary tape layers to each zone rather than excessive uniform coverage. The cylindrical center receives sufficient layers for high stress, while rounded ends receive only the necessary minimum, avoiding over-reinforcement that would waste time and material.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the manufacturing process, reduces costs, and ensures homogeneous mechanical stress distribution and enhanced mechanical resistance by using a rigid composite cap that interpenetrates with the ribbon for strong bonding, allowing for efficient production of pressurized fluid storage tanks.
Implementation Method 1
causing the polymer material of said tape to melt
Implementation Method 2
the polymer of the ribbon and that of the cap are both melted. Consequently, the two polymers easily diffuse into each other and interpenetrate so as to ensure perfect bonding
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a process for manufacturing a fluid storage tank, comprising the following steps: a) providing a rotational rigid sealed jacket (10) having two opposite rounded ends (44, 46) and at least one opening at one of the two opposite ends (46); b) providing a composite ribbon (18) comprising a thermoplastic polymer material and a fibrous material embedded in the polymer material; c) melting the polymer material of the ribbon (18) and helically winding the ribbon around the sealed jacket (10) by making a plurality of contiguous turns and superposed turns so as to form a composite layer around the sealed jacket (10). And before step c), further providing a rigid cap (30) and covering one of the rounded opposite ends (46) of the jacket with the rigid cap (30).