Composite Pressure Vessel With Integrated Permeation Barrier
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Solution Overview
Problem
Existing pressure vessels for high-pressure gas storage are heavy, costly to manufacture, and suffer from structural integrity issues due to the use of metal or polymeric liners, which also reduce usable volume and lead to cyclical fatigue.
Innovation Solution
A pressure vessel made with a carbon fiber reinforced plastic that integrates a metal-free impermeable film as its innermost layer, eliminating the need for a separate liner and incorporating a sorbent mandrel for adsorbed natural gas storage, allowing for a lighter, more efficient, and cost-effective design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal or polymeric liner is used as the innermost layer, then gas impermeability is achieved, but the vessel weight increases and usable volume decreases
Solution Approach 1:
The patent removes the separate metal or polymeric liner from the pressure vessel structure and integrates the gas barrier function directly into the composite shell through impermeable film layers, eliminating unnecessary components while maintaining gas impermeability
Solution Approach 2:
The patent combines the gas barrier function with the composite shell structure by integrating impermeable film layers into the resin matrix, merging previously separate functions (structural support and gas barrier) into a unified composite system
2Reliability
If a separate liner is used, then gas barrier properties are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the gas barrier function with the composite shell manufacturing process by applying impermeable film layers during the same fabrication sequence, eliminating separate manufacturing steps for liner installation and reducing overall complexity
Solution Approach 2:
The patent applies impermeable film layers to the mandrel or tooling before composite winding begins, preparing the gas barrier in advance so that it is already in place when the structural composite layers are applied, streamlining the manufacturing process
3Reliability
If a separate liner is used, then gas impermeability is achieved, but the vessel volume is reduced
Solution Approach 1:
The patent removes the separate liner component and replaces it with thin impermeable film layers integrated into the composite shell, eliminating the volume occupied by thick-walled rigid liners while maintaining gas barrier functionality
Solution Approach 2:
The patent uses thin film impermeable layers instead of thick-walled rigid liners, achieving gas impermeability with minimal thickness and maximum usable volume while maintaining structural integrity
4Weight of moving object
If carbon fiber reinforced plastic is used without a liner, then weight is reduced, but gas permeability increases
Solution Approach 1:
The patent creates a multi-layer composite structure combining carbon fiber reinforced plastic with impermeable film layers, where each material contributes its superior properties (structural strength from carbon fiber, gas barrier from impermeable film) to achieve both weight reduction and gas impermeability
Solution Approach 2:
The patent merges the structural composite material with the gas barrier film into a unified multi-layer system, where the impermeable film is integrated within the composite structure to provide gas barrier properties without compromising the lightweight advantage
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 solution results in a pressure vessel that is lighter, more volumetrically efficient, and cost-effective, with improved structural integrity and gas barrier properties, capable of withstanding high pressures while reducing the need for additional liners.
Implementation Method 1
a permeation barrier is sprayed on and integrated into the composite
Implementation Method 2
The sorbent, which is typically an active carbon with a high surface area, adsorbs the natural gas
Data Source
AI summary
A pressure vessel includes a carbon fiber reinforced plastic with an integrated permeation barrier as its innermost layer. Alternating layers of permeation barrier and carbon fiber reinforced plastic may also be used. During manufacturing, the permeation barrier is sprayed on and integrated into the composite. The vessel, which is well-suited for high pressure gas storage is lighter weight than prior art vessels and has more usable volume than same-dimensioned prior art vessel. The permeation barrier encapsulates one or more ports or fittings of the vessel to reduce or eliminate the potential for gaps through which gas can escape. In one embodiment, a removable tooling process is employed in the manufacture of the vessel. In another embodiment, a permanent tooling process is employed and the tooling serves as a sorbent material for the vessel.