Deformable Mandrel Outer Surface for High-Pressure Tank Winding

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing methods for manufacturing high-pressure tanks with fiber-reinforced resin reinforcement layers face challenges in preventing scratches on the inner surface of tubular members during the mandrel extraction process due to relative slipping between the mandrel and the tubular member.

Innovation Solution

A manufacturing device is designed with a mandrel having a deformable outer peripheral surface and a regulation member that allows the surface to change between a winding shape for fiber bundle winding and a separable shape for easy mandrel and tubular member separation, minimizing contact and thus preventing scratches.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the fiber bundle is wound around the mandrel with tension applied, then the tubular member is pressed against the outer peripheral surface of the mandrel ensuring proper shaping, but relative slipping occurs between the mandrel and tubular member during extraction causing scratches on the inner peripheral surface

Engineering Contradiction:

Improveshaping precisionVSAvoidscratch on inner surface

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The mandrel employs an outer peripheral member with a deformable outer peripheral surface that can dynamically change its shape. During the winding process, the surface is in a first shape that allows proper pressing and shaping of the tubular member. During extraction, the surface deforms to a second shape that creates separation between the mandrel and tubular member, preventing scratches.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The outer peripheral surface of the mandrel changes its geometric parameters between two states: a first shape during winding that ensures contact and shaping precision, and a second shape during extraction that reduces contact to prevent scratching. This parameter change is achieved through the deformable structure of the outer peripheral member.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If the outer peripheral surface of the mandrel is made rigid for stable winding, then shaping precision is maintained, but the mandrel cannot be easily separated from the cured tubular member without causing damage

Engineering Contradiction:

Improvewinding precisionVSAvoidextraction ease

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The outer peripheral member is designed with a deformable outer peripheral surface that transitions between a rigid first shape during winding for precision, and a deformed second shape during extraction for ease of separation. This dynamic shape change allows the mandrel to provide both stability during manufacturing and ease of removal afterward.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The mandrel's outer peripheral surface is segmented into multiple deformable sections that can independently change shape. This segmentation allows the surface to maintain its form during winding while enabling controlled deformation during extraction to create separation between the mandrel and tubular member.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If the mandrel maintains constant contact with the tubular member during extraction, then shaping accuracy is preserved, but scratches occur on the inner surface due to relative slipping

Engineering Contradiction:

Improveshaping accuracyVSAvoidsurface scratching

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The deformable outer peripheral surface of the mandrel dynamically adjusts its contact with the tubular member. During the winding process, the surface maintains constant contact for shaping accuracy. During extraction, the surface deforms to reduce contact, creating separation that prevents scratching while allowing the tubular member to be removed intact.

Inventive Principle:

Principle #15Dynamics

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

The device effectively suppresses the occurrence of scratches on the inner surface of the tubular member by maintaining a gap between the mandrel and the tubular member during separation, ensuring a smooth and scratch-free process.

Implementation Method 1

a solidification device configured to shape the tubular member by solidifying the resin with which the fiber bundle wound around the mandrel is impregnated

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS11602906B2Manufacturing device for manufacturing tubular member constituting high-pressure tank

Publication Date: 2023.03.14 TOYOTA JIDOSHA KK

AI summary

A mandrel has an outer peripheral member that shapes an outer peripheral surface of a mandrel, and a regulation member that regulates movement of the outer peripheral surface toward the radially inner side. A manufacturing device for a tubular member includes a radial movement mechanism that deforms the outer peripheral surface by actuating the regulation member into the outer peripheral surface in a winding shape and the outer peripheral surface in a separable shape, the separable shape being obtained by moving the outer peripheral surface in the winding shape toward the radially inner side and allowing the mandrel and the tubular member to be separated in the axial direction of the mandrel.