Method for manufacturing pressure container having opposite dome ends with different opening diameters

A method for manufacturing a pressure container having a dome end with a first opening diameter and an opposite dome end with a second opening diameter, said second opening diameter larger than said first opening diameter, said method comprising the steps of:

• (a) preparing a mandrel having a shape identical to the shape of an inner surface of the pressure container and having opposite ends thereof, said mandrel being provided at each respective opposite end with a first and second boss, said first and second bosses having respective smaller and larger outer diameters such that first boss is mounted to said mandrel end corresponding to said container dome end having said first opening diameter and said second boss is mounted to said opposite mandrel end corresponding to said container dome end having said second opening diameter;
• (b) fitting a first metal insert within said second boss, said first metal insert having a portion protruding axially outwardly of said second boss and having an outer diameter equal to or larger than said diameter of said first boss and smaller than said outer diameter of said second boss;
• (c) winding a first band of fibers on said mandrel in a polar winding manner to form a primary layer of a first predetermined thickness on said mandrel, said first band of fibers contained in a liquid phase thermosetting resin;
• (d) heating said primary layer to thereby thermally set said first band of fibers;
• (e) removing an end portion of said primary layer formed on said second boss to enable removal of said first metal insert;
• (f) removing said first metal insert from said second boss;
• (g) mounting a second insert externally of said first boss and fitting a third insert within said second boss, said second and third inserts each having respective outer diameters substantially similar to said second opening diameter of said dome end of said pressure container, said second insert having a portion protruding axially outwardly of said first boss;
• (h) winding a second band of fibers on said primary layer in a helical winding manner to form a secondary layer of a second predetermined thickness on said primary layer, said second band of fibers contained in a liquid phase thermosetting resin;
• (i) heating said secondary layer to thereby thermally set said second band of fibers;
• and,
• (j) removing said second and third inserts from said respective first and second bosses.