Composite Tank Surface Profiling for Secure Protective Member Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing high-pressure tanks with a protective member result in a rough surface due to irregular resin bleeding, making it difficult to securely bond the protective member, which is unstable and labor-intensive, especially when the surface is not flat and transparent, requiring manual shaving and visual inspection.
Innovation Solution
The method involves winding fiber bundles in multiple layers around the liner with a first pitch width, forming gaps in a second wider pitch width to create a sharpened surface for secure bonding of the protective member, and optionally applying a light reflecting layer for precise laser-based shaving and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fiber bundles are wound around the liner to form a fiber reinforced resin layer, then the tank structure is strengthened, but the surface becomes rough with irregular projections due to resin bleeding
Solution Approach 1:
The patent applies a release agent to the liner surface before winding the fiber bundles. This preliminary action prevents excessive resin bleeding and projections from forming on the outer surface, creating a smoother surface that facilitates subsequent protective member bonding while maintaining the structural strength benefits of the fiber reinforced layer
2Ease of manufacture
If the protective member is bonded directly to the rough surface with projections, then the bonding process is simplified, but the bonding state becomes unstable
Solution Approach 1:
The release agent is applied in advance to prevent the formation of surface projections, creating a smooth bonding surface. This eliminates the need for subsequent shaving operations and ensures stable protective member bonding from the outset, resolving the contradiction between process simplicity and bonding reliability
3Reliability
If manual shaving of projections is performed to create a flat surface, then the protective member can be bonded stably, but the work load and time consumption increase significantly
Solution Approach 1:
The release agent treatment is performed during the winding process itself, preventing projection formation before it occurs. This eliminates the need for separate manual shaving operations, maintaining bonding stability while dramatically improving production efficiency by removing the time-consuming post-processing step
4Shape
If the surface resin layer is transparent with high light transmission, then the tank appearance is improved, but it becomes difficult to accurately identify surface shape and projection positions
Solution Approach 1:
The release agent prevents excessive resin bleeding and projection formation in the first place, maintaining a smooth surface that is easy to detect and process. This approach preserves the aesthetic benefits of a uniform surface while eliminating the detection difficulties that would arise from irregular projections
Solution Approach 2:
The patent mentions that a light reflecting layer may be applied to the surface. This layer changes the optical properties of the transparent resin, making surface features visible to laser detection systems while maintaining the aesthetic appearance of the tank
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 approach facilitates stable and secure bonding of the protective member, reducing manual labor and ensuring accurate positioning, as the protective member is bonded to a sharpened surface, enhancing operational efficiency and stability.
Implementation Method 1
winding fiber bundles containing an uncured resin component around the outer surface of a liner in a predetermined pitch width so as to form an uncured fiber reinforced resin layer
Implementation Method 2
curing the resin so as to form a fiber reinforced resin layer
Implementation Method 3
applying a solvent to an uncured surface resin layer, which has been formed through bleeding of the uncured resin component of the uncured fiber reinforced resin layer to the outside, to allow the solvent to infiltrate the uncured surface resin layer
Implementation Method 4
performing heating treatment for foaming the surface resin layer to make it porous through removal of the solvent by evaporation
Implementation Method 5
performing heating treatment for foaming the surface resin layer to make it porous
Implementation Method 6
securely bonding an elastic protective member to the portion left unshaved as a base
Data Source
AI summary
Provided are a method for producing a tank with an outer surface profile that allows an elastic protective member to be easily and firmly attached to a surface thereof, and also such a tank with a protective member. The method for producing the tank, which includes winding fiber bundles containing an uncured resin component in multiple layers around the outer surface of a liner in a first pitch width so as to form a fiber reinforced resin layer and securely bonding the protective member to a portion of the outer surface thereof, further includes: winding the fiber bundles in a second pitch width wider than the first pitch width so as to form a gap with a required width where no fiber bundle is present between adjacent fiber bundles in winding the fiber bundles to form an outermost fiber bundle layer; shaving off a tip end portion of a projection made of a resin that has cured after bleeding into the gap, with a portion thereof left unshaved so as to form a sharpened portion; and securely bonding the protective member to the sharpened portion while pressing it from above.