Fiber-Reinforced Container Winding Method for Cost Reduction
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Solution Overview
Problem
The high manufacturing costs of fiber-reinforced pressure vessels, particularly for hydrogen-powered vehicles, are due to the expensive carbon fiber material, necessitating a cost-effective production method without compromising mechanical properties.
Innovation Solution
A manufacturing method involving the sequential winding of two roving sections with different mechanical properties onto an inner shell, where one section with lower tensile strength is wound as a cross layer and the other with higher tensile strength as a peripheral layer, allowing for continuous winding without interruptions, thereby reducing material costs and maintaining mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-strength carbon fiber is used throughout the entire pressure vessel, then mechanical strength and pressure resistance are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent applies different fiber types to different locations on the pressure vessel based on local stress requirements. High-strength carbon fiber is used only in the cylindrical central section where hoop stress is highest, while lower-strength glass fiber is used in the end sections where stress is lower. This local differentiation maintains pressure resistance while significantly reducing overall material cost.
Solution Approach 2:
The pressure vessel is divided into distinct zones (cylindrical central section and end sections) with different fiber reinforcement requirements. The winding process is segmented to apply different fiber types to different zones, allowing optimization of material usage based on structural needs rather than using expensive carbon fiber uniformly throughout.
2Strength
If circumferential winding is used to maximize pressure resistance, then strength is improved, but fiber end effects and manufacturing complexity increase
Solution Approach 1:
Instead of applying circumferential winding throughout the entire vessel, the patent applies it only partially to the cylindrical central section where it is most effective. The end sections use cross-layer winding at smaller angles, reducing the need for complex winding angle transitions and minimizing fiber end effects while maintaining sufficient strength.
3Stability of the object's composition
If multiple fiber layers with different winding angles are applied alternately, then mechanical stability is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The patent applies different winding patterns to different locations: circumferential winding (0° angle) is applied only to the cylindrical central section where hoop stress dominates, while cross-layer winding (smaller angles) is applied to the end sections. This local differentiation achieves mechanical stability where needed without the complexity of alternating layers throughout the entire vessel.
Data Source
Figure 1~5
Figure 6~7
AI summary
A manufacturing process for a fiber-reinforced container (1), comprising at least the steps of: - providing an inner shell (2) of the container (1), - feeding and winding at least one roving (3) onto the inner shell (2), wherein at least two roving sections (4, 5) with different mechanical properties are wound successively, and - bonding the at least one roving (3) to the inner shell (2) to produce an outer shell (6) made of fiber composite material. In order to enable cost-effective production of a fiber-reinforced container, it is provided that at least two roving sections (4, 5) are wound as successive, interconnected parts of a roving (3).