High-Pressure Tank Reinforcing Layer Resin Usage Reduction
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Solution Overview
Problem
Conventional methods for manufacturing high-pressure tanks result in excessive usage of fiber-reinforced resin due to helical winding across both ends of the liner, leading to increased fiber-reinforced resin usage and potential damage during removal from the mandrel, as well as surface roughness issues affecting subsequent molding or insertion of the liner.
Innovation Solution
A method involving forming a cylinder member and dome members using fiber-reinforced resin, where a release material is wound around the mandrel to prevent bonding and facilitate easy removal, and these components are then joined to form a reinforcing layer, reducing resin usage and ensuring smooth surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If helical winding is applied across both ends of the liner to provide strength to dome sections, then the strength of dome sections is improved, but the usage of fiber-reinforced resin is excessively increased
Solution Approach 1:
The tank is divided into separate components: a cylinder member formed by winding fiber bundle around a liner, and dome sections formed separately. This segmentation allows the fiber bundle to be wound only where structurally necessary, eliminating unnecessary helical winding across the cylinder section while maintaining dome section strength through proper helical winding configuration.
Solution Approach 2:
The invention extracts the helical winding from the cylinder section entirely, applying it only to the dome sections where it provides structural benefit. The fiber bundle winding is optimized to start from the dome-cylinder junction, removing the redundant portion that caused excessive resin usage.
2Strength
If fiber-reinforced resin is wound directly around the mandrel without release agent, then the bonding strength is improved, but the cylinder member cannot be easily removed from the mandrel and surface smoothness is lost
Solution Approach 1:
A release agent is introduced as an intermediary layer between the mandrel and the fiber-reinforced resin. This release agent prevents direct bonding while allowing easy removal of the cylinder member from the mandrel after curing, solving the contradiction between bonding strength and ease of removal.
3Strength
If fiber-reinforced resin is wound directly around the mandrel without release agent, then the bonding strength is improved, but the inner layer surface becomes rough and subsequent molding or insertion is difficult
Solution Approach 1:
The release agent serves as a mediator that prevents direct adhesion between the mandrel and resin, preserving the smoothness of the inner layer surface. This ensures subsequent molding or insertion operations can be performed without difficulty while still achieving adequate bonding strength through the release agent interface.
Data Source
AI summary
A method for manufacturing a high-pressure tank including a liner that stores gas and a reinforcing layer made of a fiber-reinforced resin and covering an outer surface of the liner includes: a first step of forming a cylinder member made of the fiber-reinforced resin; a second step of forming two dome members made of the fiber-reinforced resin; and a third step of forming a reinforcing body that is the reinforcing layer by joining both end portions of the cylinder member and end portions of the two dome members, respectively. The first step includes forming the cylinder member by winding a release material around a mandrel and winding the fiber-reinforced resin on the release material.