High-Pressure Tank Liner Thickening via Cap Recess
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Solution Overview
Problem
The existing manufacturing method for high-pressure tanks, where a reinforcing layer is formed first and then a liner is poured with resin, faces challenges in increasing the thickness of specific parts adjacent to the cap due to differences in material elongation between the reinforcing layer and the cap, affecting the liner's integrity.
Innovation Solution
A method where two or more split bodies are joined to form the reinforcing layer, and the cap is attached to create a depressed portion for resin collection, allowing the resin to solidify and form a thicker portion adjacent to the cap, reducing the influence of material elongation differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the liner is formed by pouring resin material inside the reinforcing layer, then the manufacturing process is simplified and weight is reduced, but it becomes difficult to increase the thickness of specific parts of the liner
Solution Approach 1:
The cap is attached to the reinforcing layer before pouring the resin material, creating a depressed portion that serves as a mold for the thick portion. This preliminary action enables local thickness control without complicating the overall pouring process
Solution Approach 2:
The depressed portion is created only at the specific location where thickness increase is needed (adjacent to the cap). When resin is poured, it accumulates in this depressed portion, forming a thick portion only where required, while other areas maintain normal thickness
2Reliability
If the thickness of the liner portion adjacent to the cap is increased to reduce the influence of material elongation differences, then the liner's structural integrity is improved, but the manufacturing complexity increases
Solution Approach 1:
The cap is attached to the reinforcing layer in advance, creating the depressed portion that will form the thick portion. This preliminary setup enables the thick portion formation during the normal resin pouring and solidification process, avoiding additional manufacturing steps
Solution Approach 2:
The resin material itself forms the thick portion by accumulating in the depressed portion created by the cap. The process uses the resin's natural flow and solidification characteristics to create the desired thick portion, rather than requiring separate forming operations
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 the formation of a thicker liner portion adjacent to the cap, enhancing the tank's structural integrity and reducing the impact of material elongation differences between the reinforcing layer and the cap.
Implementation Method 1
the resin material is solidified so that the liner is formed
Implementation Method 2
after a resin material is poured inside the reinforcing layer formed in the first step, the reinforcing layer is rotated so that the resin material covers an inner surface of the reinforcing layer
Data Source
AI summary
A manufacturing method for a high-pressure tank includes joining a cylindrical member and dome members to each other so that a first reinforcing layer and a second reinforcing layer to which a cap is attached are formed, and after a resin material is poured inside the first reinforcing layer, rotating the first reinforcing layer so that the resin material covers an inner surface of the first reinforcing layer, and solidifying the resin material so that the liner is formed. The cap is attached to the first reinforcing layer so that a recessed portion in which the resin material is collected is formed between the cap and the first reinforcing layer. After the first reinforcing layer is rotated, the resin material is solidified in a state where the cap side is positioned on a lower side.