Composite Vessel Assembly Vacuum Curing Without Rigid Molds
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Solution Overview
Problem
Traditional pressure vessels, such as spherical and cylindrical designs, inefficiently utilize space and present manufacturing challenges due to complex shapes and high internal pressures, necessitating improved methods for constructing lightweight, high-strength, and cost-effective vessels.
Innovation Solution
A mold-less curing method involving a pliable containment for composite vessel assembly, utilizing vacuum application and resin infusion to compact and cure the composite structure, which includes sealing orifices for pressure control and resin flow, and using sheets and granulates to facilitate manufacturing without molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional spherical or cylindrical pressure vessels are used, then stress distribution is even, but space utilization efficiency is low (52-70%)
Solution Approach 1:
The pressure vessel is divided into multiple separate tanks (first tank, second tank, third tank) that can be arranged in different configurations. This segmentation allows the system to achieve better space utilization (up to 90% efficiency) while each individual tank maintains its structural integrity and stress distribution characteristics.
2Volume of moving object
If non-spherical/cylindrical pressure vessels with complex shapes are designed to support high internal pressure, then space utilization improves (90% efficiency), but manufacturing complexity increases
Solution Approach 1:
Instead of manufacturing one complex high-pressure vessel, the system segments the function into multiple simpler tanks connected by junctions. Each tank can be manufactured using standard processes, and the complex rectangular arrangement is achieved through assembly rather than monolithic manufacturing.
Solution Approach 2:
The patent describes nesting tanks within tanks (e.g., second tank inside first tank, third tank inside second tank) to achieve efficient space utilization. This nested configuration allows multiple pressure-containing volumes to occupy the same external footprint, achieving 90% space efficiency without requiring complex single-vessel geometries.
3Manufacturing precision
If vacuum is applied to the pliable containment, then air is evacuated and composite assembly is compacted, but chambers need pressure control
Solution Approach 1:
The pliable containment acts as an intermediary that transmits vacuum pressure uniformly to the composite structure. The vacuum applied to the containment creates controlled compaction forces on the composite layers and resin without requiring direct contact or complex pressure control mechanisms at the composite interface.
Solution Approach 2:
The pliable containment dynamically adapts its shape and pressure distribution to conform to the composite vessel assembly during vacuum application. This dynamic response allows uniform compaction while automatically accommodating the three-dimensional geometry and internal chamber structures without rigid constraints.
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 the production of lightweight, high-energy storage density vessels with reduced porosity and enhanced mechanical properties by uniformly curing the composite under controlled pressure and temperature, minimizing the need for additional tooling and machining.
Implementation Method 1
applying a vacuum to the inside of the pliable containment and through a first orifice in the pliable containment to evacuate air and compact the composite vessel assembly
Implementation Method 2
The pliable containment may be in biased contact with the composite vessel assembly when the vacuum is applied
Data Source
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AI summary
A method of manufacturing a composite vessel assembly (20) includes the step of placing the composite vessel assembly (20) in a pliable containment (94) prior to curing of a resin of the composite vessel assembly (20). With the composite vessel assembly (20) in the pliable containment (94), a vacuum is applied through an orifice (96) in the pliable containment (94) to evacuate air and compact the composite vessel assembly (20).