Composite Hydrogen Tank With Polyamide Liner For Gradual Pressure Release
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Solution Overview
Problem
The challenge in mass-producing high-pressure hydrogen tanks for vehicles is the need for cost-effective designs that meet stringent safety requirements, including gradual pressure release in case of accidents or fires, without exploding or tearing.
Innovation Solution
A cylindrical tank design featuring metal end pieces with a polyamide liner, a carbon fibre structural layer, and a glass fibre protective layer, along with elastomer seals and hooping to maintain radial clamping, allowing for industrial-scale production at a reasonable cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal tanks are used for high-pressure hydrogen storage, then strength and pressure containment are improved, but weight and cost increase significantly
Solution Approach 1:
The patent employs a composite structure consisting of a polyamide liner for pressure containment, carbon fibre reinforcement layers for structural strength, and glass fibre protective layers for external protection. This composite construction achieves the required strength for 700 bar hydrogen storage while significantly reducing weight compared to traditional all-metal tanks. The carbon fibre provides high tensile strength to withstand internal pressure, the polyamide liner ensures pressure containment and gradual pressure release in accident scenarios, and the glass fibre protective layer protects the structural components from external damage.
2Reliability
If thicker liner material is used to prevent pressure release in accidents, then safety is improved, but weight and cost increase
Solution Approach 1:
The patent specifies a polyamide liner with a thickness of 1.5 mm or less, which is optimized to provide adequate safety for gradual pressure release in accident scenarios without excessive weight. The liner's material properties and thickness are carefully selected to ensure that in the event of tank damage, pressure is released gradually rather than explosively, while keeping the overall tank weight acceptable for vehicle applications.
Solution Approach 2:
The patent employs different materials and thicknesses for different functional requirements: a thin polyamide liner (≤1.5 mm) for pressure containment and controlled pressure release, carbon fibre reinforcement layers for structural strength, and glass fibre protective layers for external protection. This localized optimization ensures safety without unnecessary weight increase throughout the entire tank structure.
3Reliability
If complex safety features are added to prevent explosions, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The polyamide liner inherently provides safety functionality through its material properties. In the event of tank damage or fire, the polyamide material melts and closes off the pressure containment, automatically preventing explosive pressure release without requiring additional active safety systems. This self-service approach to safety reduces device complexity while maintaining high reliability.
Solution Approach 2:
The polyamide liner acts as an intermediary between the high-pressure hydrogen and the external environment. It provides a controlled failure mode where the liner's melting and deformation characteristics ensure gradual pressure release, mediating the transition from high-pressure containment to safe pressure dissipation without requiring complex safety mechanisms.
4Strength
If multiple fibre layers and protective structures are added, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the tank wall into distinct functional layers: a polyamide liner layer for pressure containment, carbon fibre reinforcement layers for structural strength, and glass fibre protective layers for external protection. Each layer is manufactured and applied separately, allowing for specialized processing of each material type and simplifying quality control and manufacturing procedures compared to a monolithic structure.
Solution Approach 2:
The patent employs a preform construction method where the polyamide liner and fibre reinforcement layers are prepared and positioned before final resin impregnation and curing. This preliminary arrangement of layers simplifies the manufacturing process by allowing each layer to be independently prepared and positioned, then consolidated in a single subsequent operation, reducing overall manufacturing complexity.
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
The design ensures safe and cost-effective production of high-pressure fluid storage tanks that can gradually release pressure in accidents or fires, preventing explosions and maintaining structural integrity.
Implementation Method 1
the bearing surface comprising a non-cylindrical part, the internal pressure of the tank having a tendency to clamp the end pieces against the liner
Implementation Method 2
each end piece further comprises an elastomer seal placed in an annular groove of the non-cylindrical part of the exterior surface of the end piece, the internal pressure of the tank having a tendency to clamp the end piece against the liner, compressing the seal
Implementation Method 3
a structural layer of fibre impregnated with thermosetting resin enveloping the liner
Data Source
AI summary
A tank (1) for storing fluid under high pressure, of cylindrical overall shape and round cross section comprising at each of its ends along its axis (2), a metal end piece (3, 4), a liner (6) enveloping the said end pieces, and a structural layer (7) of fiber impregnated with thermosetting resin enveloping the said liner.