Composite Tank Fiber Layer Density Variation
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Solution Overview
Problem
The existing methods for manufacturing high-pressure tanks using resin transfer molding (RTM) face challenges in achieving efficient resin impregnation, particularly in the deep portions of the fiber layer, leading to prolonged processing times and potential quality issues such as deformation due to uneven pressure distribution and high fiber density.
Innovation Solution
The method involves wrapping fibers around the tank liner in a manner that creates a less dense fiber layer on the dome portion and a denser layer on the straight body portion, with resin impregnation performed separately in axial and radial directions, utilizing a mold with runners and an opening/closing mechanism to optimize resin flow and reduce resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fibers are wrapped in a dense fiber layer to provide sufficient reinforcement, then the strength of the tank is improved, but the resin impregnation time increases and quality deteriorates due to difficulty in penetrating deep portions
Solution Approach 1:
The patent applies different fiber wrapping densities to different regions of the tank. The dome portion is wrapped with a less dense fiber layer to facilitate resin penetration, while the straight body portion uses a denser fiber layer for enhanced reinforcement. This local differentiation allows the tank to achieve both strong reinforcement and efficient resin impregnation without compromising either aspect.
2Strength
If a uniform dense fiber layer is used throughout the tank, then the reinforcement is maximized, but resin flow resistance increases and impregnation becomes incomplete
Solution Approach 1:
The patent implements varying fiber layer densities across different tank sections. The dome portion features a less dense fiber arrangement that reduces resin flow resistance and enables complete impregnation, while the straight body portion maintains a denser fiber structure for optimal reinforcement. This spatial variation in fiber density simultaneously satisfies both reinforcement requirements and resin impregnation quality standards.
3Manufacturing precision
If resin is poured into the deep portions of the fiber layer, then complete impregnation is achieved, but the process takes a long time and pressure distribution becomes uneven
Solution Approach 1:
By creating a less dense fiber layer in the dome portion, the patent enables resin to penetrate deep portions more quickly and efficiently. The reduced fiber density in this critical region decreases flow resistance, allowing resin to reach and impregnate the innermost layers without requiring excessively long processing times or causing uneven pressure distribution, thus improving both impregnation completeness and manufacturing efficiency.
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 facilitates faster resin impregnation, ensures uniform distribution, and reduces the risk of deformation by allowing resin to penetrate deeper into the carbon fibers, improving the tank's quality and productivity.
Implementation Method 1
a resin pouring method in which resin is poured into the fiber layer in an axial direction of the liner and resin is poured into the fiber layer in a radial direction of the liner
Data Source
AI summary
Provided is a method for manufacturing a tank and a manufacturing device thereof that can achieve resin impregnation within a short time. The method wraps fibers in an overlapping manner in a radial direction around an outer surface of a liner such that a first fiber layer (braiding layer) on an outer surface of a dome portion is less dense than a second fiber layer (helical layer) on an outer surface of a straight body portion and such that a portion of a lamina of the first fiber layer, which is less dense, is interposed continuously from the first fiber layer partially between laminae of the second fiber layer, and then impregnates the fiber layer including the first fiber layer and the second fiber layer with a resin.