Pressure Vessel Liner Composite Impregnation
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Solution Overview
Problem
Existing methods for producing pressure vessels with composite construction struggle to achieve high structural strength while maintaining low material costs and weight, particularly over long-term operation.
Innovation Solution
The method involves increasing the internal pressure of the support structure during the introduction of a solvent-containing matrix, using a heatable molding device to impregnate fibers, and applying the fiber material dry through winding or braiding, followed by a resin transfer molding process with reactive matrix systems to create a high-strength, low-weight fiber composite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a matrix is introduced to impregnate fiber material in conventional methods, then fiber composite structure is formed, but the reaction time is long and production efficiency is low
Solution Approach 1:
The patent applies parameter changes by heating the mold device to elevated temperatures (typically 50-150°C) during matrix introduction. This thermal parameter change accelerates the chemical reaction and impregnation process of the matrix into the fiber material, reducing reaction time from conventional hours to minutes while maintaining complete fiber saturation and composite structural integrity.
2Ease of manufacture
If fiber material is applied wet to the support structure, then impregnation is achieved, but the application process becomes complex and difficult
Solution Approach 1:
The patent applies preliminary action by applying the fiber material in a dry state to the support structure before matrix introduction. The fiber reinforcement is laid up or wound onto the liner without pre-impregnation, simplifying the application process. The matrix impregnation is then achieved in a subsequent controlled step through the heated mold, separating the complex tasks into manageable sequential operations.
Solution Approach 2:
The heated mold device serves as an intermediary that facilitates matrix impregnation without requiring pre-wetting of fibers. The thermal energy from the heated mold acts as a mediator to accelerate matrix flow and penetration into the dry fiber material, enabling complete impregnation through controlled thermal and pressure conditions rather than requiring complex pre-impregnation equipment.
3Manufacturing precision
If the matrix is introduced without increasing internal pressure of the support structure, then the process is simpler, but the matrix penetration into fiber material is insufficient
Solution Approach 1:
The patent replaces complex mechanical impregnation systems with a combined thermal-chemical approach. Instead of using high-pressure injection equipment or complex vacuum systems, the method uses a heated mold to accelerate the chemical reactivity and flow characteristics of the matrix, enabling sufficient penetration into the fiber material through controlled thermal conditions and moderate pressure application.
Solution Approach 2:
The patent applies parameter changes by controlling the temperature of the mold device and the viscosity of the matrix material. By heating the mold to specific temperature ranges and adjusting matrix composition (including solvent content), the impregnation quality is optimized through thermal and rheological parameter control rather than relying solely on mechanical pressure application.
4Strength
If high material quality is used to achieve high structural strength, then compressive strength improves, but material costs increase
Solution Approach 1:
The patent applies composite materials by combining the support structure (liner) with fiber reinforcement and matrix material to create a composite pressure vessel. This composite construction achieves high structural strength and compressive strength through the synergistic combination of materials - the liner provides structural integrity, the fiber reinforcement adds tensile strength, and the matrix binds them together - while using cost-effective material combinations rather than requiring expensive high-grade materials throughout.
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 enables the efficient and cost-effective production of pressure vessels with high compressive strength and low structural weight, allowing for quick reaction times and a non-porous, protective matrix that prevents air from entering under high pressure loads.
Implementation Method 1
introducing a matrix between the forming device and the basic structure, which matrix at least partially penetrates into the fibrous material
Implementation Method 2
the matrix saturates the fiber material on the support structure
Implementation Method 3
the internal pressure of the support structure is increased during the introduction of the solvent-containing matrix
Implementation Method 4
reactive matrix systems, reactive resin systems, reactive polyamides, preferably caprolactam, or polyurethane systems (PU) are used as the matrix
Data Source
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AI summary
A method for manufacturing a pressure vessel (2), which is preferably provided for use in bladder accumulators, comprising the following manufacturing steps: - providing a support structure (22), more particularly in the form of a liner; - applying a fibrous material (24) to the support structure (22) to form a base structure (20); - placing the base structure (20) in a heatable mould apparatus (4, 6, 10); and - introducing a matrix between the mould apparatus (4, 6, 10) and the base structure (20), which partially penetrates the fibrous material (24).