Induction Heating High-Pressure Tank Resin Liner
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Solution Overview
Problem
Conventional high-pressure tank manufacturing methods face challenges in shortening the hardening time of thermosetting resin and simplifying the manufacturing process, leading to increased complexity and time requirements.
Innovation Solution
A method involving the disposition of a conductive heating material on the outer periphery of a resin liner, followed by winding a conductive fiber impregnated with thermosetting resin around it, and then using induction heating to harden the resin, ensuring uniform heating and eliminating the need to remove the heating material from inside the liner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional induction heating method heats the first fiber-reinforced resin layer before the second layer, then the increase of fiber volume content percentage is suppressed, but the hardening time of the entire thermosetting resin is extended
Solution Approach 1:
The heating process is segmented into two distinct phases: first heating the outer superficial layer to suppress resin oozing and control fiber volume content, then heating the inner layer adjacent to the container to accelerate hardening. This segmentation allows each phase to optimize for its specific goal without compromising the other.
Solution Approach 2:
The induction heating is applied periodically in two stages: initial heating of the first layer, followed by heating of the second layer after the first layer starts hardening. This periodic action enables sequential control of heating zones to achieve both precision in fiber volume content and reduced overall hardening time.
2Manufacturing precision
If conventional induction heating method is used to heat the fiber-reinforced resin layer, then the resin oozing is suppressed, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The heating material is disposed on the outer periphery of the resin liner before winding the fiber-reinforced resin layer. This preliminary placement ensures that heating can immediately begin from the outer layer, suppressing resin oozing from the start of the process and simplifying subsequent manufacturing steps.
Solution Approach 2:
A heating material acts as an intermediary between the induction heating coil and the fiber-reinforced resin layer. This intermediary material facilitates uniform heat distribution and enables controlled heating of the resin, simplifying the manufacturing process while maintaining precision in resin oozing control.
3Productivity
If the heating material is disposed on the outer periphery of the resin liner, then the hardening time is shortened and manufacturing is simplified, but the heating uniformity must be maintained
Solution Approach 1:
The heating material is strategically disposed on the outer periphery of the resin liner where heating is most needed initially. This localized placement creates optimal heating conditions for the outer layer while the induction heating coil provides overall uniform heating, achieving both shortened hardening time and maintained heating uniformity.
Solution Approach 2:
The system uses a composite approach combining the heating material (with high thermal conductivity) and the fiber-reinforced resin layer. This composite structure enables efficient heat transfer from the outer periphery throughout the entire resin layer, achieving uniform heating while maintaining shortened hardening time through the synergistic combination of materials.
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 approach significantly shortens the hardening time of the thermosetting resin, simplifies the manufacturing steps, and enhances productivity by allowing for efficient uniform heating of both superficial and deep layer portions of the fiber-reinforced resin layer.
Implementation Method 1
heating the heating material and the fiber on the outer periphery of the resin liner by induction heating to harden the thermosetting resin
Implementation Method 2
after applying a high frequency current through the induction heating coil and inducing high-frequency induction heating
Implementation Method 3
heating the heating material and the fiber on the outer periphery of the resin liner by induction heating to harden the thermosetting resin
Data Source
AI summary
There is provided a high-pressure tank manufacturing method that ensures a shorten heating period compared with a conventional one and eliminates a need for taking out a material for heating after heating. A high-pressure tank manufacturing method includes: disposing a conductive heating material on an outer periphery of a resin liner; winding a conductive fiber with which thermosetting resin is impregnated around the outer periphery of the resin liner on which the heating material is disposed; and heating the heating material and the fiber on the outer periphery of the resin liner by induction heating to harden the thermosetting resin.