Composite Pressure Vessel Localized Reinforcement
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Solution Overview
Problem
High-pressure storage vessels face challenges in manufacturing cost and weight efficiency, as increased material usage for supporting high pressures results in higher material costs and weight penalties.
Innovation Solution
The use of a composite pressure vessel design with alternating layers of filament wrap and slit tapes or tows, applied at specific angles to address non-homogeneous stress distribution profiles, combined with automated fiber placement for localized reinforcement, to optimize material distribution and reduce unnecessary material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If increased material usage is used to support high pressures, then structural strength is improved, but material cost and weight increase
Solution Approach 1:
The patent applies different material configurations to different regions of the pressure vessel based on local stress requirements. The dome regions receive slit tapes or tows applied at specific angles to address non-homogeneous stress distribution, while cylindrical regions use alternating layers of filament wrap. This localized quality approach ensures strength is provided exactly where needed without adding unnecessary weight to low-stress areas.
Solution Approach 2:
The patent employs composite material structures combining multiple fiber types and resin systems. The shell comprises alternating layers of filament wrap and slit tapes or tows, with each layer potentially using different fiber materials (carbon, glass, basalt, boron, aramid, Kevlar, HDPE, nylon) and resin types (thermoset or thermoplastic). This composite approach optimizes the strength-to-weight ratio by selecting materials with specific properties for specific structural requirements.
2Strength
If increased material usage is used to support high pressures, then structural strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent reduces manufacturing cost by applying materials only where structurally necessary. The automated fiber placement system deposits slit tapes or tows at specific angles in dome regions where stress concentration occurs, and applies filament wrap in cylindrical regions. This eliminates waste of material in low-stress areas and reduces overall material procurement and processing costs.
Solution Approach 2:
The patent optimizes manufacturing parameters including the angle of slit tape application (determined by the ratio of meridional to parallel stress components), the alternation pattern of filament wrap layers, and the automated placement parameters. These parameter optimizations enable efficient material deposition that minimizes material usage while maintaining structural integrity, thereby reducing manufacturing cost.
3Strength
If alternating layers of filament wrap and slit tapes are used, then stress distribution is improved, but device complexity increases
Solution Approach 1:
The automated fiber placement system incorporates intelligence to automatically determine and execute the complex alternating layer pattern. The system calculates the required slit tape angles based on stress distribution analysis and autonomously places materials in the correct locations and orientations. This automation transforms a potentially complex manual process into a self-managing system that consistently produces the optimized stress distribution pattern.
Solution Approach 2:
The patent manages the complexity of alternating composite layers through systematic design principles. The shell structure alternates between filament wrap layers (providing general hoop strength) and slit tape or tow layers (providing targeted reinforcement at specific angles in dome regions). This structured composite approach, while multi-layered, follows a predictable pattern that simplifies manufacturing planning and quality control.
Data Source
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AI summary
A composite pressure vessel, comprising: a liner assembly, further comprising: a liner; at least one of a polar boss and a blind boss; and a shell, further comprising: at least one layer of a filament wrap continuously disposed around at least a substantial portion of the liner assembly, wherein the liner assembly and the filament wrap combined have a non-homogenous support profile; and at least one fiber segment locally disposed on an area of the liner assembly and the at least one layer of a filament wrap that may be more susceptible to rupture than other areas of the liner assembly, according to the non-homogenous support profile. Complementary pairs of fiber segments and/or hoops may be configured to address a non-homogenous stress distribution profile of the composite pressure vessel.