Helical Winding Turnback Strategy for High Pressure Tank Weight Reduction

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

High pressure tanks for fuel gas storage face challenges in reducing weight while minimizing strain in the reinforcing layer, which increases when the amount of fibers is reduced.

Innovation Solution

A manufacturing method for high pressure tanks that includes forming a helical layer with both base turnback and distant turnback layers, where the fiber bundles are wound with gaps between them, reducing the weight and strain on the reinforcing layer, and maintaining sufficient strength by adjusting the coverage to between 50% and 80%.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If the amount of fibers forming the reinforcing layer is reduced to reduce the weight of the high pressure tank, then the weight of the high pressure tank is reduced, but the strain caused in the reinforcing layer due to swelling of the liners is increased

Engineering Contradiction:

Improveweight of the high pressure tankVSAvoidstrain in the reinforcing layer

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The helical layer is segmented into multiple layers with different turnback positions (base turnback layers and distant turnback layers). This segmentation allows the fiber bundles to be distributed more effectively, reducing strain concentration while maintaining weight reduction benefits.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the helical layer have different qualities: base turnback layers provide strong reinforcement near the caps where swelling occurs, while distant turnback layers with gaps provide weight reduction. This local differentiation optimizes both strength and weight.

Inventive Principle:

Principle #3Local quality

Solution Approach 3:

The distant turnback layers incorporate gaps between adjacent fiber bundles, creating a porous structure that reduces the amount of fiber material needed while still providing sufficient reinforcement to control strain.

Inventive Principle:

Principle #31Porous materials

2Strength

If the coverage of distant turnback layers is increased to further reduce strain, then the strain reduction is improved, but the weight reduction effect is diminished

Engineering Contradiction:

Improvestrain reduction in the reinforcing layerVSAvoidweight of the high pressure tank

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The coverage of distant turnback layers is optimized to a specific parameter range (50-80%). This parameter optimization achieves the best balance between strain reduction and weight reduction, avoiding excessive fiber usage while maintaining sufficient reinforcement.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11285658B2Manufacturing method for high pressure tank

Publication Date: 2022.03.29 TOYOTA JIDOSHA KK

AI summary

A manufacturing method for a high pressure tank, includes preparing a liner, and forming a helical layer by helical-winding fiber bundles around the liner, wherein a plurality of layers included in the helical layer include: base turnback layers formed by winding the fiber bundles while a base section of each of caps projecting outward of the liner is used as a winding turnback position where the fiber bundles are turned back in the axial direction; and distant turnback layers formed by winding the fiber bundles while a distant position distant from each base section is used as the winding turnback position, and in the distant turnback layers, the helical-winding is performed such that gaps are generated between adjacent fiber bundles of the fiber bundles.