Metal Composite Cylinder Neck Flange Deformation Management
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Solution Overview
Problem
Current metal composite high-pressure cylinders face challenges in achieving reliability under heavy cyclic loading, minimizing weight, and reducing manufacturing costs while ensuring a long lifetime, as existing designs often result in high weight and cost due to mismatched deformation limits between metal liners and composite overwraps, leading to premature destruction.
Innovation Solution
A metal composite cylinder design with a cylindrical metal liner and profiled bottoms, featuring a neck flange with a choke fixed in a pole hole of the pressure overwrap, utilizing a composite material with spiral and circumferential reinforcing filaments, and an annular band with non-circular grooves to manage deformation intensity, ensuring compatibility and reducing weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the liner wall thickness and composite overwrap thickness are selected based on the assumption that the cylinder main bearing element is a composite overwrap and the metal liner is in elastic range, then the cylinder can withstand high pressure cyclic loading, but the weight and cost of the construction become very high
Solution Approach 1:
The patent changes the design parameters by allowing the metal liner to operate in the plastic deformation range rather than limiting it to elastic range. This is achieved by carefully selecting the thickness ratio between liner and composite overwrap, and by designing the composite overwrap with specific winding patterns (helical and circumferential layers) that can accommodate and distribute plastic deformations, thereby reducing material quantities while maintaining reliability
Solution Approach 2:
The patent uses a composite structure combining metal liner with composite overwrap made of high-strength fibers (such as carbon, glass, or aramid fibers) in a polymer matrix. The composite overwrap is designed with specific layer configurations (helical layers at 45-60 degrees and circumferential layers) that work synergistically with the metal liner to withstand high pressure cyclic loading, allowing weight reduction while maintaining or improving reliability
2Reliability
If the liner wall thickness and composite overwrap thickness are selected based on the assumption that the cylinder main bearing element is a composite overwrap and the metal liner is in elastic range, then the cylinder can withstand high pressure cyclic loading, but the cost of the construction becomes very high
Solution Approach 1:
The patent changes the design parameters by allowing the metal liner to operate in the plastic deformation range rather than limiting it to elastic range. This is achieved by carefully selecting the thickness ratio between liner and composite overwrap, and by designing the composite overwrap with specific winding patterns (helical and circumferential layers) that can accommodate and distribute plastic deformations, thereby reducing material quantities while maintaining reliability
Solution Approach 2:
The patent uses a composite structure combining metal liner with composite overwrap made of high-strength fibers (such as carbon, glass, or aramid fibers) in a polymer matrix. The composite overwrap is designed with specific layer configurations (helical layers at 45-60 degrees and circumferential layers) that work synergistically with the metal liner to withstand high pressure cyclic loading, allowing weight reduction while maintaining or improving reliability
3Weight of moving object
If a thin metal liner is used to reduce weight compared to all-metal cylinders, then the weight is lower, but the cylinder may not provide sufficient reliability under heavy high pressure cyclic loading
Solution Approach 1:
The patent uses a composite structure combining metal liner with composite overwrap made of high-strength fibers (such as carbon, glass, or aramid fibers) in a polymer matrix. The composite overwrap is designed with specific layer configurations (helical layers at 45-60 degrees and circumferential layers) that work synergistically with the metal liner to withstand high pressure cyclic loading, allowing weight reduction while maintaining or improving reliability
Solution Approach 2:
The patent applies different material properties and structural characteristics to different parts of the cylinder. The composite overwrap has varying thickness and fiber orientation in different zones (helical layers at 45-60 degrees in critical zones, circumferential layers in other zones) to optimize stress distribution and accommodate local deformation requirements, enabling thin liner design while maintaining overall reliability
4Adaptability or versatility
If the cylinder design uses materials with different deformation limits (composite overwrap up to 2% and metal liner 0.2% elastic deformation), then the cylinder can accommodate different material properties, but the weight and cost become very high
Solution Approach 1:
The patent changes the design parameters by allowing the metal liner to operate in the plastic deformation range rather than limiting it to elastic range. This is achieved by carefully selecting the thickness ratio between liner and composite overwrap, and by designing the composite overwrap with specific winding patterns (helical and circumferential layers) that can accommodate and distribute plastic deformations, thereby reducing material quantities while maintaining reliability
Solution Approach 2:
The patent introduces dynamic deformation accommodation by designing the composite overwrap structure to flexibly adapt to the different deformation characteristics of the metal liner. The helical and circumferential layers can dynamically redistribute stresses during cyclic loading, accommodating the large deformation of composite material (up to 2%) while protecting the metal liner from excessive stress, enabling the system to utilize the full deformation potential of each material
Data Source
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AI summary
The technical result of the invention is that the proposed cylinder construction provides high performance at any given level of cyclic high-pressure and torsional loading with minimum weight and manufacturing cost. The technical result is achieved by the following: metal composite cylinder contains a cylindrical metal liner with profiled bottoms and neck flange with a choke fixed in a pole hole of the pressure overwrap, made of composite material formed by a group of layers of reinforcing filaments orientated in spiral and circumferential directions, with different reinforcing capacity; at that, neck flange, of the liner is equipped with a collar on the side of the open end of the choke, with an outer diameter greater than the sum of the pole hole diameter of the composite overwrap and two widths of wound filaments of reinforcing material, so that concentric annular cavity is formed between the outer surface of the composite overwrap and the flange, where a annular band is located filling the entire volume of the cavity; the band is made of the material of the composite overwrap, and the choke of neck flange is fixed in the annular band with grooves of non-circular shape.