Type IV Pressure Vessel Filament Winding with Low-Viscosity Thermoplastic Matrix
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Solution Overview
Problem
The production of Type IV pressure vessels with thermoplastic matrices faces challenges such as high costs and inefficiencies due to the complexity of impregnating filaments uniformly, leading to frequent downtimes and difficulties in recycling, while thermosetting matrices result in environmental issues and high processing temperatures.
Innovation Solution
A method involving winding a hollow body with continuous filaments and impregnating them with a polymerizable mixture of low viscosity (<500 mPa·s) within a mold, followed by polymerization to form a thermoplastic matrix, ensuring complete impregnation and reducing processing temperatures and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If thermoplastic matrices are used with continuous filament winding, then weight reduction and recyclability are improved, but uniform impregnation becomes difficult and production costs increase
Solution Approach 1:
The patent applies preliminary action by pre-impregnating the continuous filaments with thermoplastic material before winding them onto the hollow body. This preliminary impregnation ensures uniform distribution of the matrix material along the filament length, eliminating the difficulty of achieving uniform impregnation during or after the winding process. The filaments are prepared in advance with the exact amount of matrix material needed, which then cures or solidifies to form a uniformly impregnated composite structure.
Solution Approach 2:
The patent uses an intermediary substance (such as a coupling agent or surface treatment) on the filament surface to facilitate better bonding and more uniform impregnation with the thermoplastic matrix. This intermediary layer enhances the interaction between the filament and matrix materials, ensuring complete and uniform penetration of the matrix into the filament structure during the winding and curing process.
2Ease of manufacture
If thermosetting matrices are used for filament winding, then manufacturing process is simpler, but environmental harm and high processing temperatures increase
Solution Approach 1:
The patent applies parameter changes by switching from thermosetting matrices to thermoplastic matrices, which fundamentally changes the processing parameters. Thermoplastics can be processed at lower temperatures without the need for high-temperature curing ovens, and they can be melted and reprocessed multiple times. This parameter change eliminates the environmental harms associated with thermosetting resins while maintaining manufacturing simplicity through conventional molding and shaping processes.
Solution Approach 2:
The patent utilizes phase transitions of thermoplastic materials, which transition from solid to melt and back to solid through controlled heating and cooling. This phase transition mechanism allows for simpler processing compared to the chemical curing required for thermosetting materials. The thermoplastic matrix is heated to melt state for impregnation and shaping, then cooled to solidify, eliminating the need for high-temperature curing and reducing environmental impact.
3Manufacturing precision
If wet-winding process with thermosetting resins is used, then filament impregnation is achieved, but production downtime and cleaning requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-impregnating the filaments with thermoplastic material before winding. This eliminates the need for subsequent curing processes and cleaning operations required in wet-winding with thermosetting resins. The pre-impregnated filaments are ready for immediate winding and shaping, significantly reducing production downtime and eliminating the need for frequent cleaning of equipment from resin drips and splashes.
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 enables efficient and cost-effective production of Type IV pressure vessels with reliable impregnation, minimizing downtime and environmental concerns, while allowing for material recovery and recycling.
Implementation Method 1
impregnating the filament winding with a polymerizable mixture while the wound body is inside a mold that surrounds the wound body; and polymerizing the polymerizable mixture so as to form a plastic matrix that embeds the filament winding
Data Source
AI summary
A pressure vessel having a hollow body wound with a continuous filament, whereby the filament is embedded in a thermoplastic matrix, is provided, as well as a method for producing such a vessel. The method involves: (i) wrapping a hollow body with at least one continuous filament; (ii) impregnating the filament winding with a polymerizable mixture, whereby the wound body is inside a mold that surrounds the wound body; and (iii) polymerizing the polymerizable mixture in order to form a plastic matrix that embeds the filament winding.