Laser Adhesion for Composite Cryogenic Tube Manufacturing
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Solution Overview
Problem
Conventional processes for manufacturing composite material tubes or vessels are limited by slow processing speed, restricted tube length, and the use of thin tapes, which hinder efficiency and output in forming fluid-tight laminates for cryogenic applications.
Innovation Solution
A process utilizing a laser beam to adhere composite material tapes to a cylindrical object, allowing for winding at specific angles and pitches, with overlapping layers to form a fluid-tight laminate, using a composite material with a thermoplastic matrix and oriented thermoplastic reinforcement, enabling the production of longer tubes and enhancing manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional heat techniques (convection or infra-red) are used to adhere composite material tapes, then the tapes can be adhered to the mandrel or tube liner, but a considerable amount of heat is stored in the bulk of the composite material requiring cooling between successive windings, which limits processing speed
Solution Approach 1:
The patent replaces conventional convection or infra-red heating systems with a laser beam heating system. The laser provides concentrated, controlled thermal energy that heats only the immediate bonding area rather than the bulk material, eliminating the need for cooling between windings and enabling continuous high-speed manufacturing.
Solution Approach 2:
The laser beam applies heat locally and precisely at the bonding interface between tapes, rather than heating the entire bulk of the composite material. This localized heating approach allows rapid bonding without storing excessive heat in the material, thus eliminating cooling requirements and increasing processing speed.
2Length of moving object
If conventional heat techniques are used, then tapes can be adhered, but the process only allows manufacturing of tubes of limited lengths due to heat management constraints
Solution Approach 1:
By replacing conventional heating systems with a laser beam, the process can maintain precise temperature control over extended lengths. The laser's localized heating capability allows continuous winding and bonding operations without the heat accumulation that previously limited tube length, enabling production of tubes of unlimited length.
3Productivity
If thin tapes with small width are used in conventional processes, then the tapes can be wound and adhered, but the output of the winding cell during the manufacturing process is reduced
Solution Approach 1:
The laser heating system enables the use of wider tapes by providing precise, controlled heating that prevents excessive heat storage even with larger material cross-sections. This allows the winding cell to process wider tapes at higher speeds, significantly increasing productivity and output.
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 process significantly increases processing speed, allows for the production of endless tube lengths, and enhances the output of winding cells by using wider tapes, while maintaining a high level of fluid-tightness and thermal stability suitable for cryogenic applications.
Implementation Method 1
under the application of a laser beam to heat and adhere the tape to the outer surface of the cylindrical object
Implementation Method 2
heat and adhere the tape to the outer surface of the cylindrical object
Data Source
AI summary
A process for manufacturing a tube or a vessel of composite material; a tube or vessel obtainable with the present process; the use of the tube of composite material in transport or transfer of a cryogenic fluid; and the use of the vessel of composite material for storage of a cryogenic fluid.