Thermoplastic Composite Pressure Tank Preform for Conformable Hydrogen Storage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current hydrogen storage tanks face challenges such as high weight, complexity, slow manufacturing processes, residual stresses leading to deformation, and difficulty in producing conformable tanks suitable for complex shapes like battery packs, with existing methods being inefficient and costly.
Innovation Solution
A method involving the continuous manufacturing of an unconsolidated textile preform using thermoplastic composite tapes, followed by consolidation under pressure, to create an elongate and consolidated textile element suitable for hydrogen storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal or composite tanks are used for hydrogen storage, then mechanical strength and pressure resistance are improved, but weight and complexity increase
Solution Approach 1:
The patent employs a composite structure consisting of a polymer liner (for leak-tightness) combined with a reinforcing layer made of thermoplastic composite tapes (for mechanical strength and pressure resistance). This composite approach allows achieving the required mechanical properties while reducing weight compared to traditional metal tanks, as the polymer-composite combination is lighter than steel or aluminum while maintaining strength through the fibrous reinforcement.
Solution Approach 2:
The tank is divided into distinct functional layers: an inner polymer liner layer responsible for hydrogen containment and leak-tightness, and an outer thermoplastic composite reinforcement layer responsible for mechanical strength and pressure resistance. This segmentation allows each layer to be optimized for its specific function, reducing overall weight while maintaining required performance.
2Strength
If conventional manufacturing methods are used for tank production, then structural integrity is improved, but manufacturing time and cost increase
Solution Approach 1:
The patent employs a continuous manufacturing process where thermoplastic composite tapes are continuously wound around a mandrel in overlapping layers to form the reinforcing shell. This continuous winding process, followed by in-situ thermocompression consolidation, eliminates the need for discrete assembly steps and lengthy curing cycles associated with conventional methods, significantly reducing manufacturing time while maintaining structural integrity through controlled consolidation.
Solution Approach 2:
The manufacturing process utilizes controlled parameter changes, specifically temperature and pressure, during the thermocompression consolidation stage. By heating the thermoplastic composite tapes to their melting point and applying compression, the material transitions from a loose wound state to a densely consolidated structure with high structural integrity. This controlled parameter change enables rapid manufacturing without compromising strength.
3Strength
If thermosetting composite materials are used for tank construction, then mechanical resistance is improved, but residual stresses and deformation increase
Solution Approach 1:
The patent uses thermoplastic composite materials instead of thermosetting materials. The key advantage is that thermoplastics can be heated above their melting point and then cooled to consolidate the structure. During cooling, the material contracts uniformly, minimizing residual stresses. The process parameters (heating temperature, cooling rate, compression pressure) are controlled to ensure uniform consolidation and stress distribution, preventing deformation while achieving high mechanical resistance.
4Productivity
If standard tank manufacturing processes are used, then production capability is improved, but adaptability to complex shapes decreases
Solution Approach 1:
The patent employs a dynamic manufacturing approach where the mandrel can be shaped to match the desired final tank geometry, including complex conformable shapes. The thermoplastic composite tapes are wound dynamically around this shaped mandrel, and during thermocompression consolidation, the material flows and conforms to the mandrel's surface. This allows production of tanks with complex shapes (such as conformable tanks for battery packs) while maintaining high productivity through the continuous winding and consolidation process.
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 method enables rapid, cost-effective production of high-strength, recyclable, and conformable tanks with low residual porosity, suitable for complex shapes, improving mechanical resistance and leak-tightness.
Implementation Method 1
Consolidation of the textile preform obtained in the preceding step, by heating and cooling the thermoplastic composite tapes
Implementation Method 2
consolidation of the preform under pressure... by heating and cooling the thermoplastic composite tapes
Data Source
AI summary
The invention relates to a method for manufacturing a tank, said method comprising #: (i) manufacturing an elongate and unconsolidated textile preform comprising several layers of the thermoplastic composite tapes, each layer comprising at least one tape wound at a given angle, said preform being manufactured by means of a specific device, said preform being manufactured according to a method comprising: implementing feed means on each of the modules, said feed means comprising selected tapes, said selected tapes comprising at least thermoplastic composite tapes, setting the speed of advance VI and the speed of rotation V2 of each of the modules and switching each module on, cutting the elongate element and/or exhausting the supply of tapes, and recovering the unconsolidated elongate textile preform obtained: step i) comprising no step of braiding the tapes, (ii) consolidating the textile preform obtained in the preceding step by heating and cooling the thermoplastic composite tapes.