Filament Winding Tank Liner Deflection Control
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Solution Overview
Problem
The filament winding method for manufacturing high-pressure tanks often results in fiber sheet deflection due to insufficient tensile force, leading to inaccuracies in the reinforcement layer formation.
Innovation Solution
A manufacturing method that winds fibers in a sheet-like form on a mandrel with higher rigidity than the liner, allowing for increased tensile force and reducing deflection, followed by shaping the ends of the sheet layer to match the dome portions and applying internal pressure during helical winding to enhance accuracy and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fiber sheet is wound on the liner directly to form a reinforcement layer, then the manufacturing process is simpler, but the tensile force is insufficient causing fiber sheet deflection and reducing manufacturing precision
Solution Approach 1:
A mandrel is introduced as an intermediary object between the fiber sheet and the liner. The mandrel provides a rigid surface for winding the fiber sheet, enabling sufficient tensile force application without directly deforming the liner. After the reinforcement layer is formed, the mandrel is removed, leaving the fiber sheet properly bonded to the liner.
Solution Approach 2:
The fiber sheet is wound on the mandrel before being transferred to the liner. This preliminary winding action allows the fiber sheet to be properly tensioned and positioned on a rigid surface first, ensuring manufacturing precision is achieved during the winding process, and then the mandrel is removed and the fiber sheet is bonded to the liner.
2Manufacturing precision
If high tensile force is applied to the fiber sheet to reduce deflection, then manufacturing precision improves, but the liner rigidity is exceeded causing liner deformation
Solution Approach 1:
The mandrel serves as a mediator that absorbs the high tensile force during fiber sheet winding. By winding on the rigid mandrel instead of directly on the liner, the necessary high tensile force can be applied to reduce fiber sheet deflection without exceeding the liner's rigidity limit and causing deformation.
Solution Approach 2:
The fiber sheet is preliminarily wound on the mandrel with high tensile force to ensure manufacturing precision. This preliminary action on the rigid mandrel allows the liner to remain undeformed, and subsequent removal of the mandrel and bonding to the liner completes the process without compromising liner integrity.
3Strength
If the fiber sheet is wound on the liner with insufficient tensile force, then the liner remains undamaged, but the fiber sheet deflection increases reducing tank shape accuracy
Solution Approach 1:
The mandrel acts as an intermediary that enables high tensile force application during fiber sheet winding without damaging the liner. The rigid mandrel supports the fiber sheet tension, ensuring proper sheet layer formation and tank shape accuracy, while the liner remains undamaged. After winding, the mandrel is removed and the fiber sheet is bonded to the liner.
Solution Approach 2:
The fiber sheet is preliminarily wound on the mandrel with sufficient tensile force to ensure proper shaping and reduce deflection. This preliminary action on the mandrel achieves the required tank shape accuracy, and subsequent removal of the mandrel and bonding to the liner completes the process without compromising either shape accuracy or liner integrity.
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 improves the shape accuracy and strength of the tank by reducing deflection and irregularities, while also shortening the time required for reinforcement layer formation and enhancing production efficiency.
Implementation Method 1
heating and curing the wound fibers in the sheet-like form to form a sheet layer
Data Source
AI summary
There is provided a manufacturing method of a tank including a liner. The manufacturing method comprises (A) a process of winding fibers in a sheet-like form impregnated with a resin on a mandrel having a higher rigidity than rigidity of the liner and heating and curing the wound fibers in the sheet-like form to form a sheet layer; (B) a process of pulling out the mandrel from the sheet layer; and (C) fitting the liner into the sheet layer, after the process (B).