Composite Overwrapped Accumulator Structure to Prevent Diaphragm Failure
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Solution Overview
Problem
Conventional high-pressure vessels and diaphragm accumulators face issues with structural integrity and leakage due to welding or threading, and the flexible diaphragm often fails under repeated high-pressure cycles as it is not securely held between hollow casings.
Innovation Solution
A lightweight composite overwrapped accumulator design that uses a plurality of hollow casings joined without welding or threading, with a flexible diaphragm secured within annular cavities and encased in a composite overwrap for structural support and sealing, eliminating the need for adhesives or crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or threading is used to join hollow casings, then structural integrity is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent replaces welding and threading operations with a mechanical compression system. A cap is compressed onto the hollow casing using compression force, creating a seal and structural connection without requiring thermal processes or threaded joints. This substitution eliminates the complexity of welding procedures, thread machining, and associated quality control while maintaining structural integrity through the compression seal.
2Strength
If welding is used to join hollow casings, then structural integrity is improved, but production time and cost increase
Solution Approach 1:
The compression-based sealing system replaces time-consuming welding operations. The cap is mechanically compressed onto the casing in a single operation that simultaneously achieves sealing and structural connection, eliminating the multi-step welding process including preparation, execution, and post-processing. This dramatically reduces production time and associated costs while maintaining equivalent or superior structural integrity.
3Device complexity
If the flexible diaphragm is held in an annular groove between hollow casings, then the accumulator structure is simplified, but the diaphragm fails under repeated high-pressure cycles
Solution Approach 1:
The patent introduces an intermediary sealing structure between the diaphragm and the hollow casing. This intermediary component provides a secure mounting interface that prevents the diaphragm from being pulled out of the annular groove during pressure cycles, while maintaining the overall simplicity of the accumulator design. The intermediary acts as a mediator that protects the diaphragm from direct mechanical failure at the groove interface.
4Strength
If steel shells are used for high-pressure vessels, then structural integrity is ensured, but weight increases
Solution Approach 1:
The patent employs composite materials for the hollow casing construction, combining materials with different properties to achieve both high strength and reduced weight. The composite structure provides the necessary structural integrity to withstand high pressures while being significantly lighter than traditional steel shells. This allows the accumulator to meet strength requirements without the weight penalty of solid steel construction.
Data Source
AI summary
The present invention provides lightweight high-pressure accumulators that avoids diaphragm failure observed in conventional diaphragm accumulators. Lightweight high-pressure composite overwrapped accumulators of the invention are made from a plurality of hollow casings that are mated to form an accumulator housing. The accumulator housing is overwrapped with a composite material to provide additional mechanical strength and structural integrity. More significantly, the accumulators of the invention includes a plurality of annular grooves and a plurality of bulb on the flexible diaphragm such that the plurality of bulbs on the flexible diaphragm are placed in the plurality of annular grooves that are formed between the first and the second hollow casing. In this manner, diaphragm failure is significantly reduced or even completely eliminated during repeated high pressure charge/discharge cycle of the accumulator.