Composite Vessel Monolithic Wall Structure
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Solution Overview
Problem
Current composite pressure vessels are inadequate for environments with extreme temperature variations, physical impact, and chemical corrosion due to non-optimized structural design and high material costs, as they struggle to maintain leak-tightness over long periods without increasing weight and cost.
Innovation Solution
A method for producing leak-tight vessels with multiple functional layers, including a heat-sealable thermoplastic inner barrier layer and fibre-reinforced thermoplastic material layers, where the thermoplastic materials have compatible melting points, allowing for a unified monolithic structure that prevents layer detachment and reduces weight and cost by varying fibre and thermoplastic ratios along the vessel's thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the barrier layer thickness is increased to decrease permeation, then the leak-tightness is improved, but the weight and cost of the composite vessel increase
Solution Approach 1:
The patent applies composite materials by combining a thermoplastic barrier layer with fibre-reinforced thermoplastic layers. The barrier layer provides leak-tightness while the fibre-reinforced layers provide mechanical strength, allowing the vessel to achieve both low permeation and adequate structural performance without excessively thickening the barrier layer alone.
Solution Approach 2:
The patent changes material parameters by selecting thermoplastic materials with specific melting points (within 40°C of each other) to ensure proper consolidation. By optimizing the barrier layer thickness in combination with fibre-reinforced layers and controlling consolidation temperature and pressure, the patent achieves low permeation without excessive weight gain.
2Adaptability or versatility
If multiple functional layers are added to resist environmental constraints, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The patent implements multi-functionality by designing a composite structure where the barrier layer provides leak-tightness, fibre-reinforced layers provide mechanical strength and impact resistance, and the thermoplastic matrix provides thermal and chemical resistance. Multiple environmental constraints are addressed through a unified multi-functional structure rather than separate specialized layers.
Solution Approach 2:
The patent applies local quality by varying the fibre reinforcement distribution and composition in different layers. The barrier layer has specific thermoplastic properties for sealing, while outer layers have enhanced fibre reinforcement for impact and pressure resistance, optimizing each layer's properties for its specific functional requirements.
3Strength
If fibre-reinforced polymer material is used to confer pressure resistance, then the strength is improved, but the cost increases due to high fibre content
Solution Approach 1:
The patent changes material parameters by optimizing the fibre-to-thermoplastic ratio in the composite layers. By carefully controlling fibre content and distribution, the patent achieves adequate pressure resistance while reducing excessive fibre usage that would increase cost. The thermoplastic matrix content is optimized to provide proper consolidation and bonding.
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 vessel that withstands high pressures, resists environmental constraints, and maintains low porosity, making it suitable for diverse applications while minimizing weight and cost, with a monolithic structure that prevents layer detachment and ensures long-term leak-tightness.
Implementation Method 1
the thermoplastic material of the at least one inner barrier layer and the thermoplastic materials of the functional layers have melting points situated in a 40°C temperature range
Implementation Method 2
forming a monolithic consolidated wall structure with a continuity between the thermoplastic materials of the at least one barrier layer and the fibre-reinforced heat-sealable thermoplastic materials of the functional layers
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
Method for producing a leak-tight vessel (1) for holding a gas and/or liquid, comprising a leak tight inner barrier layer (3) comprising a heat-sealable thermoplastic material (60) and a plurality of functional layers (41, 42) each comprising a fibre-reinforced heat-sealable thermoplastic material (61, 62), and vessel (1) obtained thereof.