Composite Pressure Vessel with Parallel Fiber Layers
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Solution Overview
Problem
Existing composite material reservoirs for pressurized fluids face inefficiencies in fiber usage, material excess, and process productivity due to helical winding methods and the use of thermosetting resins, which are not recyclable and require complex handling.
Innovation Solution
A composite reservoir design featuring longitudinal and circumferential layers of thermoplastic resin-impregnated fibers with parallel orientations, minimizing fiber crossings and using thermoplastic resins to optimize material usage and simplify production, while maintaining structural integrity and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If helical winding method is used to produce structural layer, then end pieces can be retained and prevented from ejection under pressure, but fiber crossings and undulations occur reducing structural efficiency
Solution Approach 1:
The structural layer is divided into two distinct functional layers: a longitudinal layer with fibers oriented parallel to the tank axis for end piece retention, and a circumferential layer with fibers oriented perpendicular to the axis for hoop strength. This segmentation eliminates fiber crossings and undulations while maintaining the ability to retain end pieces under pressure.
Solution Approach 2:
The invention transitions from a single helical winding approach to a two-dimensional fiber arrangement with longitudinal and circumferential layers. This dimensional change allows fibers to be oriented in two perpendicular directions, eliminating the need for fiber crossings while providing both end piece retention and hoop strength.
2Reliability
If multiple helical winding layers are used to retain end pieces, then end piece ejection is prevented, but material usage increases and productivity decreases
Solution Approach 1:
The structural layer is divided into two distinct functional layers: a longitudinal layer with fibers oriented parallel to the tank axis for end piece retention, and a circumferential layer with fibers oriented perpendicular to the axis for hoop strength. This segmentation eliminates fiber crossings and undulations while maintaining the ability to retain end pieces under pressure.
Solution Approach 2:
The longitudinal layer provides continuous fiber support along the tank axis, enabling end piece retention without requiring multiple overlapping helical layers. This continuous action reduces the number of winding passes needed while maintaining structural integrity.
3Strength
If thermosetting resin is used as matrix, then structural integrity is achieved, but recyclability is lost and handling complexity increases
Solution Approach 1:
The invention changes the material parameter from thermosetting resin to thermoplastic resin. This parameter change transforms the matrix material from non-recyclable and difficult to handle to recyclable and easier to process, while maintaining structural integrity through the thermoplastic resin's mechanical properties and bonding characteristics.
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 design achieves substantial material savings, enhanced performance by exploiting fiber potential, and improved recyclability, with thermoplastic resins reducing porosity risks and maintaining seal integrity under pressure cycles.
Implementation Method 1
thermoplastic resins must be heated above their melting point to be made more fluid and to facilitate their implementation and the impregnation of fibers
Implementation Method 2
thermoplastic resins must be heated above their melting point to be made more fluid and to facilitate their implementation and the impregnation of fibers
Data Source
Figure 1A~1B
Figure 2A~3D
Figure 4~5B
AI summary
A reservoir made of a composite material comprises a tubular element (15), two end fittings (11, 13; 111), each inserted into one end of the tubular element, and a circumferential layer (9) that envelops the tubular element and the end fittings. The circumferential layer is made of resin-impregnated wound fibres. At least one segment of each end fitting (11, 13; 111) has an outwardly tapering shape and the wall of the tubular element (15) has a taper at each end, and thus at each end the wall is pressed against the segment surface having a tapering shape. The tubular element (15) comprises a plastic tube (5) surrounded by a longitudinal layer (7) essentially made of parallel fibres in a resin matrix, the parallel fibres being oriented along the longitudinal axis of the plastic tube (5). Finally, the circumferential layer (9) is essentially made of fibres wound around the circumference of the tubular element (15) and end fittings (11, 13; 111) and parallel to each other.