High-Pressure Gas Tank Bubble Removal During Thermal Curing
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Solution Overview
Problem
The filament winding method for manufacturing high-pressure gas tanks results in air bubbles forming in the fiber-reinforced resin layer, leading to dimension errors and poor aesthetic appearance due to irregularities on the surface.
Innovation Solution
A manufacturing method that includes multiple stages of thermal curing with a bubble removal process, where the process is adjusted based on the viscosity of the thermosetting resin, using techniques such as rotational speed control, fluid application, and antifoam application to prevent air bubble formation, thereby reducing the amount of thermosetting resin on the surface and breaking air bubbles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the filament winding method is used to manufacture high-pressure gas tanks, then the weight of the tank is reduced, but air bubbles form in the fiber-reinforced resin layer causing surface irregularities
Solution Approach 1:
The patent applies preliminary action by performing bubble removal processes at multiple predetermined stages during the thermal curing process, before the resin fully cures and before surface irregularities are formed. This includes removing air bubbles during the resin application stage and during the curing stage, preventing bubble formation rather than addressing it after occurrence.
Solution Approach 2:
The patent implements continuity of useful action by maintaining multiple bubble removal processes throughout the entire thermal curing process. Instead of a single removal attempt, the system continuously monitors and removes air bubbles at multiple stages (resin application, early curing, late curing), ensuring uninterrupted prevention of surface defects throughout the manufacturing process.
2Manufacturing precision
If air bubbles are removed at multiple stages during thermal curing, then air bubble formation is prevented, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies segmentation by dividing the thermal curing process into multiple distinct stages (resin application stage, early curing stage, late curing stage) and implementing separate bubble removal processes for each stage. This segmentation allows targeted bubble removal strategies for different process phases, making the complex bubble removal task manageable through systematic stage-based approach.
Solution Approach 2:
The patent implements feedback mechanisms by monitoring the thermal curing process parameters (temperature, resin viscosity, bubble formation) and adjusting the bubble removal processes accordingly. The system detects bubble formation at each stage and triggers appropriate removal actions based on real-time process conditions, optimizing the complex multi-stage process through continuous feedback control.
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 method effectively prevents air bubble formation in the fiber-reinforced resin layer, improving the surface smoothness and reducing irregularities, which enhances the assembly and aesthetic quality of the high-pressure gas tank.
Implementation Method 1
performing a thermal curing process that heats the tank vessel to thermally cure the thermosetting resin
Implementation Method 2
when viscosity of the thermosetting resin changes to a specified viscosity level
Implementation Method 3
a first process that causes the thermosetting resin located on outer surface of the fiber layer to be removed by an external force from the tank vessel
Implementation Method 4
a second process that sprays a fluid to break air bubble formed in the thermosetting resin located on outer surface of the fiber layer
Implementation Method 5
a third process that applies a resin solution serving as antifoam onto surface of the fiber layer
Data Source
AI summary
A thermal curing device is used to manufacture a high-pressure gas tank by FW method. In the thermal curing device, a tank vessel configured to have a fiber layer formed on its outer surface by winding carbon fibers impregnated with a thermosetting resin is held to be rotatable about a virtual central axis of the tank vessel. In the thermal curing device, the tank vessel is heated by a heating unit during rotation, so as to thermally cure the thermosetting resin in the fiber layer and thereby form a fiber-reinforced resin layer. A bubble removal process for preventing formation of air bubble in the fiber-reinforced resin layer is performed at multiple different stages during such heating.