High-Pressure Tank Intermediate Layer for Peeling Resistance

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Solution Overview

Problem

Conventional high-pressure tanks experience peeling off of the protective layer when repeatedly filled and emptied in high-temperature, high-humidity environments due to clearance between the helical and hoop layers, leading to crack formation and potential detachment.

Innovation Solution

Incorporating an intermediate layer with thinner fibers arranged in different directions to reduce clearance between the helical and hoop layers, filled with a resin that fixes both sets of fibers, thereby minimizing crack formation and peeling off.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an intermediate layer with thinner fibers is added between the helical and hoop layers, then the clearance between layers is reduced and peeling resistance is improved, but the device complexity increases

Engineering Contradiction:

Improvepeeling resistanceVSAvoidlayer structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The protective layer is segmented into three distinct layers: the helical layer, the intermediate layer with thinner fibers, and the hoop layer. This segmentation allows each layer to perform its specific function, with the intermediate layer specifically designed to fill clearances and prevent peeling between the outer layers.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The intermediate layer acts as an intermediary element between the helical and hoop layers. It mediates the interface between these two layers by filling the clearance with thinner fibers, thereby preventing direct contact issues and peeling between the thicker fibers of the outer layers.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If the clearance between helical and hoop layers is reduced by adding an intermediate layer, then crack formation is minimized, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveclearance controlVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The intermediate layer is designed with local quality characteristics - it uses thinner fibers specifically at the interface between the helical and hoop layers where clearance problems occur. This localized solution addresses the specific manufacturing precision issue without requiring changes to the entire structure.

Inventive Principle:

Principle #3Local quality

3Reliability

If thinner fibers are used in the intermediate layer, then the clearance filling capability is improved, but the material cost increases

Engineering Contradiction:

Improvecrack resistanceVSAvoidmaterial consumption

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

Instead of using thinner fibers throughout the entire protective layer structure, the invention applies this action partially - only in the intermediate layer where it is most needed for crack resistance. This partial application achieves the necessary reliability improvement while controlling material consumption.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS11226068B2High-pressure tank and manufacturing method of high-pressure tank

Publication Date: 2022.01.18 TOYOTA JIDOSHA KK

AI summary

Provided is a high-pressure tank including: a helical layer containing first fibers that are wound in a helical pattern and a first resin that fixes the first fibers; a hoop layer located outward of the helical layer in the high-pressure tank and containing second fibers that are wound in a hoop pattern and a second resin that fixes the second fibers; and an intermediate layer located between the helical layer and the hoop layer and containing third fibers that are thinner than at least either the first fibers or the second fibers and a third resin that fixes the third fibers, the first fibers of the helical layer, and the second fibers of the hoop layer.