High-Pressure Tank Joint Overlap Margin Optimization
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Solution Overview
Problem
The existing manufacturing method for high-pressure tanks with dome-shaped side end members joined to a cylindrical tube member results in varying mechanical strength due to uneven stress distribution at the joint areas, which affects the tank's ability to withstand internal pressure.
Innovation Solution
A manufacturing method where the side end members are joined to the tube member with an overlap margin between 5% to 35% of the tube member's inside diameter, and a second reinforcing layer is applied by helical winding to stabilize the stress distribution and enhance the tank's mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If side end members are joined to tube member with overlap structure, then assembly is facilitated and structural integrity is improved, but stress distribution becomes uneven and mechanical strength varies
Solution Approach 1:
The patent applies parameter changes by optimizing the overlap margin to a specific range (5%-35% of tube inside diameter) and controlling the position of the circumferential end surface relative to the tube end surface. These parameter adjustments transform the joining structure from one with uneven stress distribution to one with uniform stress distribution, resolving the contradiction between assembly facilitation and stress uniformity.
2Strength
If overlap margin is increased to reduce stress, then mechanical strength improves, but assembly difficulty increases due to geometrical intersection
Solution Approach 1:
The patent resolves this contradiction by establishing an optimal parameter range for the overlap margin (5%-35% of tube inside diameter). This parameter optimization ensures sufficient overlap for stress reduction while preventing excessive overlap that would cause geometrical intersection and assembly difficulties. The balanced parameter range simultaneously achieves both strength enhancement and assembly ease.
3Reliability
If side end members are joined with facing wall surfaces configuration, then stress concentration is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent addresses this contradiction by specifying precise parameter ranges: the overlap margin (5%-35% of tube inside diameter) and the position of the circumferential end surface (0.5%-20% of tube inside diameter from tube end surface). These controlled parameters enable the facing wall surfaces configuration to be achieved with consistent manufacturing precision, reducing stress concentration while maintaining production feasibility.
Data Source
AI summary
This manufacturing method is a manufacturing method of a high-pressure tank that is formed by joining dome-shaped side end members to both ends of a cylindrical tube member and that has a first reinforcing layer made of fiber-reinforced resin. The manufacturing method has a joining step of joining the side end members to both ends of the tube member such that an outer wall surface of the tube member and an inner wall surface of each side end member face each other. In the joining step, a margin for overlap between each side end member and the tube member in an axial direction of the tube member is within a range of 5% or more to 35% or less relative to the inside diameter of the tube member.