A high-pressure tank in a method of manufacturing a high-pressure tank includes a liner and a fiber. The manufacturing method includes: preparing a dome and a pipe each having a general portion and a joining end portion formed to be thicker than the general portion such that an outer diameter at least at an end face is larger than an outer diameter of the general portion by an estimated level difference amount; joining the joining end portion of the dome and the joining end portion of the pipe together in an axial direction; cutting off portions on the further outer side in a radial direction than a reference plane, with an outer peripheral surface of the general portion of the dome having a large outer diameter at the joined surface as the reference plane; and winding a carbon fiber around the outer peripheral surface of the liner in helical winding.

A high-pressure tank in a method of manufacturing a high-pressure tank includes a liner and a fiber. The manufacturing method includes: preparing a dome and a pipe each having a general portion and a joining end portion formed to be thicker than the general portion such that an outer diameter at least at an end face is larger than an outer diameter of the general portion by an estimated level difference amount; joining the joining end portion of the dome and the joining end portion of the pipe together in an axial direction; cutting off portions on the further outer side in a radial direction than a reference plane, with an outer peripheral surface of the general portion of the dome having a large outer diameter at the joined surface as the reference plane; and winding a carbon fiber around the outer peripheral surface of the liner in helical winding.

Methods of making a composite article, such as a motor housing, are provided herein. The method can include applying a resin-fiber material to a shaped surface to form an intermediate article. The resin-fiber material includes an uncured resin composition and a fiber substrate material. The method further includes solidifying the uncured resin composition present in the intermediate article to form the composite article. Solidifying can be accomplished by applying heat to the intermediate article to initiate an exothermic reaction comprising polymerization, cross-linking, or both of the uncured resin composition. Application of the heat from the heat source can be ceased after initiation of the exothermic reaction, but polymerization, cross-linking or both of remaining uncured resin composition can continue in one or more of a radial, circumferential, or axial direction through a thickness of the resin-fiber material in the absence of heat from the heat source to form the composite article.

Methods of making a composite article, such as a motor housing, are provided herein. The method can include applying a resin-fiber material to a shaped surface to form an intermediate article. The resin-fiber material includes an uncured resin composition and a fiber substrate material. The method further includes solidifying the uncured resin composition present in the intermediate article to form the composite article. Solidifying can be accomplished by applying heat to the intermediate article to initiate an exothermic reaction comprising polymerization, cross-linking, or both of the uncured resin composition. Application of the heat from the heat source can be ceased after initiation of the exothermic reaction, but polymerization, cross-linking or both of remaining uncured resin composition can continue in one or more of a radial, circumferential, or axial direction through a thickness of the resin-fiber material in the absence of heat from the heat source to form the composite article.

A filament winding assembly includes a rotating mandrel coupled to a shaft that rotates the rotating mandrel. The rotating mandrel includes a first perforated sleeve that defines holes and includes a winding surface. The rotating mandrel also includes a second perforated sleeve disposed inside the first perforated sleeve. The second perforated sleeve defines an interior volume and holes configured to form fluid pathways with the holes of the first perforated sleeve. The fluid pathways extend from the interior volume to the winding surface of the first perforated sleeve. The filament winding assembly includes a filament that is wound, under tension, around the winding surface of the first perforated sleeve. The filament winding assembly also includes a fluid source fluidically coupled to the interior volume of the second perforated sleeve. The fluid source exhausts fluid, through the fluid pathways, from the wound filament to reduce manufacturing defects of the wound filament.

A filament winding assembly includes a rotating mandrel coupled to a shaft that rotates the rotating mandrel. The rotating mandrel includes a first perforated sleeve that defines holes and includes a winding surface. The rotating mandrel also includes a second perforated sleeve disposed inside the first perforated sleeve. The second perforated sleeve defines an interior volume and holes configured to form fluid pathways with the holes of the first perforated sleeve. The fluid pathways extend from the interior volume to the winding surface of the first perforated sleeve. The filament winding assembly includes a filament that is wound, under tension, around the winding surface of the first perforated sleeve. The filament winding assembly also includes a fluid source fluidically coupled to the interior volume of the second perforated sleeve. The fluid source exhausts fluid, through the fluid pathways, from the wound filament to reduce manufacturing defects of the wound filament.

A dynamic correction system of a manufacturing process using wire is provided. The dynamic correction system includes a driving device, a path sensor, and a controller. The driving device is configured to: drive a carrier with a motion parameter and encapsulate the carrier with a wire. The path sensor is configured to obtain an actual path information of the wire encapsulating the carrier. The controller is configured to: obtain an actual path of the wire encapsulating the carrier according to the actual path information; obtain an actual path difference between a target path and the actual path; determine whether the actual path difference is greater than a predetermined error; and, when the actual path difference is greater than the predetermined error, control the driving device to change the motion parameter to cause the actual path of the wire encapsulating the carrier to approach the target path.

A method of determining a void volume during manufacture of a composite pipe formed of concentric layers of adjacently positioned, helical windings of composite tape has the steps of: (a) scanning the surface of a layer of adjacently positioned, helical windings to generate scanning information; (b) using the scanning information to locate gap(s) between adjacent windings and to determine the number of gaps and characteristic dimensions of each gap in the layer; and (c) generating a calculated void volume of the layer, using the number of gaps and the characteristic dimensions of each gap for the layer. The invention also relates to a corresponding apparatus for determining a void volume during manufacture of a composite pipe formed of concentric layers of helically wound composite tape.

A method for producing wound hollow profiles having variable curvatures and cross-sections. In this case, a core having at least one curvature or cross-sectional change is moved in a translatory manner relative to a system having at least a first and a second fibre feed which cause the formation of an axial fibre reinforcement and at least one first wound layer.

Method of manufacturing an integral thermoset infused fibre reinforced composite, structural stator vane ring for a core inlet, a bypass duct, or an air intake of a gas turbine engine. The method comprises winding fibre reinforcement material around a mandrel to form an inner annulus preform; providing a plurality of vane preforms comprising fibre reinforcement material, arranging the plurality of vane preforms around the inner annulus preform, and connecting each of the plurality of vane preforms to the inner annulus preform using a fibre jointing method; winding fibre reinforcement material around the plurality of vane preforms to form an outer annulus preform and connecting the outer annulus preform to each of the plurality of vane preforms using a fibre jointing method to produce a stator vane ring preform; and infusing a thermoset resin into the stator vane ring preform and curing the resin to form the integral stator vane ring.