Fiber Winding Method for Reinforcement Layer Boundary Control

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Solution Overview

Problem

Conventional reinforcement layers in tanks require processing of fiber ends to reduce level differences, increasing manufacturing time and cost, and risking strength reduction due to meandering fibers at boundaries.

Innovation Solution

A method of manufacturing a fiber-reinforced resin reinforcement layer where the to-be-wound fiber has a width reduced stepwise or continuously, with lateral portions closer to the opposite end, allowing it to be wound such that outer layer end portions are between inner layer end portions, eliminating the need for processing to conform to the liner's surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If sheet-like fiber is wound on the straight section of the liner to form a sheet layer, then the reinforcement layer is formed, but a level difference is caused at the boundary between the part with wound fiber and the part without wound fiber

Engineering Contradiction:

Improveease of forming sheet layerVSAvoidlevel difference at boundary

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The fiber sheet is designed with locally varying width, where the width is reduced stepwise or continuously from one end portion toward the opposite end portion. This local variation in geometry allows the fiber sheet to adapt to the boundary region, eliminating level differences without requiring additional processing steps.

Inventive Principle:

Principle #3Local quality

2Shape

If the wound fiber is processed at opposite end portions to reduce level difference, then the boundary shape is improved, but time and cost for manufacturing increase

Engineering Contradiction:

Improveboundary shape conformityVSAvoidmanufacturing time

Core Design Contradiction:

ShapeVSLoss of time

Solution Approach 1:

The fiber sheet is pre-formed with a width that is reduced stepwise or continuously before being wound onto the liner. This preliminary shaping action eliminates the need for subsequent processing at the boundaries, reducing manufacturing time and cost while ensuring proper shape conformity.

Inventive Principle:

Principle #10Preliminary action

3Shape

If the wound fiber is processed at opposite end portions to reduce level difference, then the boundary shape is improved, but cost for manufacturing increases

Engineering Contradiction:

Improveboundary shape conformityVSAvoidmanufacturing cost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

4Shape

If new fiber is wound on the sheet layer to cover the boundary, then the boundary is covered, but the fiber may be subject to meandering which reduces tank strength

Engineering Contradiction:

Improveboundary coverageVSAvoidtank strength

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10625478B2Method of manufacturing reinforcement layer

Publication Date: 2020.04.21 TOYOTA JIDOSHA KK

AI summary

A method of manufacturing a reinforcement layer comprises a preparatory step of preparing to-be-wound fiber, and a formation step of forming an uncured sheet layer including multiple layers of the to-be-wound fiber stacked on an outer circumferential surface. In the formation step, the to-be-wound fiber is wound on the outer circumferential surface in such a manner that, regarding an outer layer of the uncured sheet layer and an inner layer of the uncured sheet layer closer to the outer circumferential surface than the outer layer and adjacent to the outer layer in a stacking direction of the to-be-wound fiber, two end portions of the outer layer are located between two end portions of the inner layer in an axis direction extending along a center axis of a winding target member.