Breather Layer Gas Management for Type IV Pressure Vessels
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Solution Overview
Problem
Elongated conformable pressure vessels face challenges in managing gas permeation due to the susceptibility of polymeric liners to gas migration, leading to issues like buckling and dynamic gas release, and existing methods are less desirable as they require complex layer formations or direct contact with the liner, which can entrap air bubbles or require specific fiber materials.
Innovation Solution
A Type IV conformable pressure vessel design featuring a gas-permeable, liquid-impermeable breather layer between the polymeric liner and the outer composite shell, which allows gas to escape through a predetermined exit location, and uses braided dry fibers or a polymeric film to enhance porosity and prevent resin intrusion, accommodating varying liner diameters and preventing resin absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a porous layer is wrapped about the inner polymeric layer to manage gas permeation, then gas migration is reduced, but the device complexity increases due to multiple layered structures
Solution Approach 1:
The patent extracts the gas permeation management function from the complex multi-layer structure and concentrates it in a single breather layer disposed directly on the polymeric liner. This breather layer alone provides gas permeability and porosity to manage gas migration, eliminating the need for separate porous layers, inner polymeric layers, and outer polymeric layers that were previously required.
Solution Approach 2:
The breather layer performs multiple functions simultaneously: it provides gas permeability to allow gas migration, maintains porosity to prevent resin intrusion, and serves as the primary gas management component. This multi-functional design replaces what previously required multiple specialized layers working together.
2Ease of manufacture
If continuous wrapped fibers forming overlapping helical patterns are used to form each layer, then manufacturing is simplified, but adaptability to varying liner diameters in conformable pressure vessels is reduced
Solution Approach 1:
The patent transitions from static helical wrapping to dynamic braiding, where fiber strands are braided around the liner in a flexible manner that naturally adapts to varying diameters. The braided structure can conform to the changing geometry of conformable pressure vessels while maintaining structural integrity and gas permeability.
Solution Approach 2:
The patent changes the structural parameter of the fiber reinforcement from helical wrapping to braiding. This parameter change allows the structure to adapt to varying diameters while maintaining the necessary mechanical properties and gas permeability characteristics.
3Reliability
If an inner composite structure is applied in direct contact with the liner, then gas permeation is managed, but air bubbles may be entrapped and manufacturing precision is compromised
Solution Approach 1:
The patent uses a porous breather layer made of porous material that allows gas to pass through while maintaining structural integrity. The porosity of this material enables gas permeation management without requiring direct contact composite structures that would trap air bubbles during manufacturing.
Solution Approach 2:
The breather layer acts as an intermediary between the polymeric liner and the outer composite shell. It provides the necessary gas permeability and porosity functions without requiring the inner composite structure to be in direct contact with the liner, thereby preventing air bubble entrapment while still managing gas permeation.
4Reliability
If the breather layer has high porosity to allow gas escape, then gas venting is improved, but resin may be absorbed by the porous structure
Solution Approach 1:
The patent converts the potential harm of resin absorption by porous materials into a benefit by carefully controlling the porosity characteristics of the breather layer. The porosity is optimized to allow gas permeation while minimizing resin absorption, effectively using the porous structure's natural properties for the desired gas venting function without the detrimental resin absorption effect.
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 design effectively manages gas permeation by reducing gas absorption in the composite shell and liner, preventing buckling, and maintaining porosity while preventing resin intrusion, thus ensuring reliable operation and efficient gas venting.
Implementation Method 1
Gas permeating through the liner wall collected by the breather layer
Implementation Method 2
maintaining porosity while preventing resin intrusion
Data Source
AI summary
A type IV pressure vessel has improved permeate gas management. The pressure vessel comprises an inner polymeric liner, a breather layer disposed on the liner, and an outer composite shell structure disposed on the breather layer. The breather layer is gas permeable, impermeable to liquids, and provides a flow passageway for gas permeating through the liner wall collected by the breather layer. The outer composite shell is formed by one or more layers of fiber of a first fiber type and resin. Gas permeating from an interior space of the liner is received by the breather layer and directed to a predetermined exit location on the pressure vessel.