Two-Step Induction Heating for High-Pressure Tank Liners
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Solution Overview
Problem
The existing manufacturing methods for high-pressure tanks with fiber reinforced resin layers, which use induction heating to harden the resin, result in increased volume fraction of fibers and void formation due to resin seepage and gas entrapment, leading to reduced strength and quality.
Innovation Solution
A two-step heating process using low-frequency induction heating to soften the resin and then high-frequency induction heating to harden it, allowing for controlled release of air and gas and prevention of resin seepage, thereby maintaining a stable fiber volume fraction and preventing void formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-frequency induction heating is used to harden the fiber reinforced resin layer, then the hardening speed is improved, but voids are formed inside the layer due to gas entrapment
Solution Approach 1:
The heating process is divided into two distinct stages: first low-frequency induction heating to soften the resin and release trapped gas, then high-frequency induction heating to rapidly harden the layer. This segmentation of the heating process resolves the contradiction by performing gas release before rapid hardening, eliminating void formation while maintaining high productivity.
Solution Approach 2:
Low-frequency induction heating is applied as a preliminary action before high-frequency heating. This preliminary step softens the thermosetting resin and allows gas to escape, creating favorable conditions for the subsequent rapid hardening step to proceed without void formation.
2Strength
If the fiber reinforced resin layer is heated to harden it, then the structural integrity is improved, but resin seepage increases causing fiber volume fraction variations
Solution Approach 1:
The heating process is segmented into two stages with different frequencies. The first stage at low frequency controls resin softening and gas release, while the second stage at high frequency achieves rapid hardening. This segmentation prevents resin seepage during hardening while ensuring complete structural integrity.
Solution Approach 2:
The heating frequency parameter is changed between two distinct values: low frequency for controlled softening and gas release, then high frequency for rapid hardening. This parameter change allows precise control over the resin's physical state during processing, preventing both void formation and resin seepage while maintaining fiber volume fraction consistency.
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 method effectively prevents voids and resin seepage, ensuring a consistent fiber volume fraction and maintaining the structural integrity and quality of the high-pressure tank.
Implementation Method 1
a first heating step of heating the uncured fiber reinforced resin layer by low-frequency induction heating so that the thermosetting resin is softened
Implementation Method 2
a second heating step of, after the first heating step, heating the softened fiber reinforced resin layer by high-frequency induction heating so that the fiber reinforced resin layer is hardened
Data Source
AI summary
A manufacturing method for a high-pressure tank is a manufacturing method for a high-pressure tank including a reinforced layer formed such that an electrically conductive fiber bundle impregnated with thermosetting resin is wound around a liner. The manufacturing method includes: a step of preparing the tank in which the uncured reinforced layer is formed on the liner; a first heating step of heating the uncured reinforced layer by low-frequency induction heating so the thermosetting resin is softened; and a second heating step of, after the first heating step, heating the softened reinforced layer by high-frequency induction heating so that the softened reinforced layer is hardened.