Composite Sheet Stock for Hydrogen-Resistant Pressure Vessel Cores
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Solution Overview
Problem
Existing sealed vessels, particularly those used for hydrogen storage, face challenges in long-term durability due to hydrogen permeation, which can compromise the structural integrity of the core material, leading to potential leakage and structural failure, and existing materials like HDPE have uncertain mechanical properties under prolonged hydrogen exposure.
Innovation Solution
A composite sheet stock comprising a base layer, a permeation-resistant layer, and an optional sacrificial/protective layer is designed to minimize hydrogen permeation by positioning the permeation-resistant layer interiorly, with the sacrificial layer absorbing potential damage from gas flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layer HDPE structure is used, then manufacturing simplicity is maintained, but hydrogen permeation resistance deteriorates over time
Solution Approach 1:
The patent employs a multi-layer composite structure consisting of an outer HDPE layer, an intermediate barrier layer (alumina-coated steel or nylon 6,10), and an inner HDPE layer. This composite design combines the advantages of each material: HDPE provides mechanical strength and ease of manufacture, while the intermediate barrier layer provides superior hydrogen permeation resistance. The synergistic combination resolves the contradiction by maintaining manufacturing feasibility while dramatically improving long-term hydrogen barrier performance.
Solution Approach 2:
The vessel wall is segmented into multiple functional layers, each performing a specific function. The outer and inner HDPE layers provide structural integrity and ease of manufacture, while the intermediate barrier layer specifically addresses hydrogen permeation. This segmentation allows each layer to be optimized for its specific function, resolving the contradiction between manufacturing simplicity and permeation resistance.
2Strength
If an interior core material is used, then structural strength is improved, but hydrogen diffusion into the core material compromises its integrity over time
Solution Approach 1:
The intermediate barrier layer acts as an intermediary between the hydrogen environment and the core HDPE material. This barrier layer prevents hydrogen from diffusing into the core material, thereby protecting the core material's structural integrity while still allowing the core to provide its structural strength function. The intermediary layer resolves the contradiction by blocking hydrogen diffusion pathways.
Solution Approach 2:
The multi-layer composite structure protects the core HDPE material from hydrogen degradation while maintaining its structural strength. The intermediate barrier layer (alumina-coated steel or nylon 6,10) serves as a protective shield, allowing the core material to fulfill its structural role without compromising integrity due to hydrogen diffusion.
3Reliability
If the permeation-resistant layer is positioned exteriorly, then hydrogen permeation is blocked, but the structural base layer remains exposed to hydrogen and susceptible to degradation
Solution Approach 1:
Instead of placing the permeation-resistant layer on the exterior, the patent inverts the conventional approach by positioning the barrier layer in the intermediate position between the hydrogen environment and the core material. This inverted arrangement ensures that the base layer is protected from hydrogen exposure while the barrier layer effectively blocks permeation. The inversion resolves the contradiction by protecting the base layer from harmful hydrogen exposure.
Solution Approach 2:
The intermediate barrier layer serves as a mediator that blocks hydrogen from reaching the structural base layer. By positioning this protective layer between the hydrogen environment and the base material, the design prevents hydrogen degradation of the base layer while maintaining effective permeation resistance.
4Reliability
If a thick single-layer structure is used, then permeation resistance is improved, but manufacturing complexity and material usage increase
Solution Approach 1:
The patent uses a multi-layer composite structure where each layer has optimized thickness for its specific function. The intermediate barrier layer, though thin, provides superior hydrogen permeation resistance compared to thick single-layer structures. This composite approach reduces overall material usage and manufacturing complexity while achieving superior permeation resistance.
Solution Approach 2:
The patent changes the material parameters by selecting specific materials with high hydrogen barrier properties (alumina-coated steel, nylon 6,10) for the intermediate layer. This parameter change allows for thinner overall wall thickness while maintaining or improving permeation resistance, thereby reducing manufacturing complexity and material usage.
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 composite structure significantly prolongs the vessel's service life by preventing hydrogen permeation into the structural base layer, enhancing durability and reducing the risk of damage from rapid depressurization.
Implementation Method 1
a permeation resistant layer comprising a permeation resistant material for providing resistance to permeation by hydrogen
Implementation Method 2
an optional sacrificial/protective layer comprising a sacrificial/protective material, wherein the sacrificial/protective layer is oriented on an interior surface of the composite sheet stock
Data Source
AI summary
Sealed vessels for the storage and/or transmission of gases, including hydrogen, over prolonged periods of time with minimal loss due to escape of gas. A Iso provided herein are related methods of manufacture and methods of storage of gas. A Iso provided herein are related methods of manufacture and methods of transmission of gas.