Pull-Wound Composite Pressure Tanks With Thinner Fiber Shells
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Solution Overview
Problem
Existing methods for manufacturing high-pressure tanks and pipes are complex, time-consuming, and costly due to the intricate weaving of individual fibre strands, making it difficult to achieve a thin shell thickness while ensuring pressure safety.
Innovation Solution
A method utilizing pullwinding technology to fabricate fibre filament reinforced tubes, which are then wrapped onto a liner, allowing for a continuous or semi-continuous production process, and incorporating longitudinal and hoop wound fibres at specific angles to absorb forces, with optional heat shrinking or gluing for attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual fibre strands are woven manually around the liner, then the tank can withstand high pressure, but the construction becomes complex and time-consuming
Solution Approach 1:
The fibre reinforcement is divided into separate functional layers: longitudinal fibres providing axial strength and hoop fibres providing circumferential strength. This segmentation allows each layer to be optimized independently and applied through different methods (pullwinding for longitudinal, winding for hoop), simplifying the overall construction process while maintaining pressure resistance
Solution Approach 2:
A pullwinding device acts as an intermediary mechanism that automatically positions and secures longitudinal fibres along the liner. This intermediary device eliminates the need for manual fibre placement, reducing construction complexity while ensuring proper fibre positioning for pressure containment
2Strength
If individual fibre strands are woven manually around the liner, then the tank structure is strengthened, but the production time increases
Solution Approach 1:
The pullwinding method enables continuous fabrication of longitudinal fibre reinforcement as the device moves along the liner, eliminating stop-and-go manual operations. Similarly, hoop fibres are applied continuously through winding. This continuity dramatically increases production speed while maintaining structural strength through consistent fibre placement and spacing
Solution Approach 2:
Manual mechanical fibre placement is replaced with automated pullwinding and winding mechanisms. These mechanical systems precisely control fibre tension, spacing, and positioning, ensuring structural strength requirements are met while operating at much higher speeds than manual weaving
3Reliability
If thick fibre shell is used to ensure pressure safety, then the tank can withstand high pressure, but the manufacturing cost increases
Solution Approach 1:
Different fibre layers are applied with different local qualities optimized for their specific functions: longitudinal fibres with high tensile strength for axial loading, and hoop fibres arranged at optimal angles for circumferential stress. This localized optimization ensures pressure safety is achieved with minimum material thickness, reducing manufacturing cost
Solution Approach 2:
The tank employs composite construction combining liner material with multiple fibre reinforcement layers held together by matrix material. This composite structure maximizes strength-to-thickness ratio, achieving pressure safety with thinner shells and lower material costs compared to homogeneous construction
4Strength
If complex fibre weaving is performed, then the tank structure is reinforced, but the process becomes less efficient
Solution Approach 1:
Longitudinal fibres are pre-positioned and secured along the liner using the pullwinding method before hoop fibres are applied. This preliminary action establishes the primary structural framework, allowing subsequent hoop fibre application to proceed quickly without requiring complex real-time coordination, thus reducing total manufacturing time while maintaining reinforcement effectiveness
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
Enables efficient, low-cost production of high-pressure tanks and pipes with reduced shell thickness, capable of withstanding high pressures, and accommodating thermal expansion through elastic intermediates.
Implementation Method 1
The tube of fibre filament reinforced material may be affixed to the liner by means of heat shrinking the fibre filament reinforced material onto the liner
Implementation Method 2
an intermediate layer of an elastic material, such as of a foam material, an elastomeric polymer or of a rubber, is provided between the liner and the fibre filament reinforced material, for example to compensate dilatation differences between metal core (which expands when heated) and composite shell
Data Source
AI summary
The present invention relates to a method for manufacturing tanks for storing or containing a fluid under pressure and to a method for manufacturing pipes for containing or channeling a fluid under pressure, such as for storing, containing or channeling hydrogen, natural gas or a hydraulic fluid. The method of the invention is less complex than the known procedures, can be employed in a continuous or semi-continuous manner and allows for a lower thickness of the shell made from the fibres. The method comprising the steps of providing a liner having a cylindrical portion with two ends and two dome portions at the respective ends of the cylindrical portions or a liner having a cylindrical portion and one or two open ends; fabricating a tube of fibre filaments by means of the pull-winding method; and wrapping the tube of fibre filaments onto the liner such that at least the cylindrical portion of the liner is enclosed by the tube of fibre filaments.