Composite Pressure Vessel Winding Pattern for Leakage Prevention
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Solution Overview
Problem
Conventional composite materials used in pressure vessels are highly permeable to low molecular weight fluids due to the nature of the resin matrix, leading to issues with fluid leakage and the need for impermeable liners, which increase weight and create corrosion risks.
Innovation Solution
The composite material design involves offsetting crossover regions between layers to minimize unreinforced matrix material, reducing permeability by ensuring there are no continuous paths for fluid molecules to penetrate, and varying winding angles and thicknesses to enhance strength and stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional filament winding techniques are used to manufacture composite pressure vessels, then weight is reduced compared to steel alternatives, but the composite material becomes highly permeable to low molecular weight fluids due to continuous regions of unreinforced matrix material at crossover regions
Solution Approach 1:
The patent segments the continuous path of unreinforced matrix material by offsetting crossover regions between adjacent layers. Each layer's crossover regions are positioned to fall within the reinforced areas of adjacent layers, breaking the continuity of permeable paths and creating a segmented barrier to fluid penetration.
Solution Approach 2:
The patent addresses the two-dimensional winding pattern by introducing a third dimensional consideration - the vertical stacking sequence of layers. By controlling the relative positioning of crossover regions across multiple layers (z-dimension), the patent creates a three-dimensional architecture that blocks fluid penetration paths without requiring metallic liners.
2Reliability
If metallic liners are added to composite pressure vessels to reduce permeability, then fluid leakage is prevented, but the weight of the vessel increases and corrosion risks are created
Solution Approach 1:
The patent extracts and eliminates the metallic liner component from the pressure vessel structure by achieving impermeability through the composite material architecture itself. The offset winding pattern creates inherent barrier properties that replace the need for separate liner components.
Solution Approach 2:
The composite material structure serves its own impermeability function through the offset crossover region architecture, eliminating the need for separate protective liners. The material structure itself provides the fluid barrier function that would otherwise require an additional component.
3Ease of manufacture
If crossover regions are aligned between layers in conventional winding, then manufacturing is simplified, but continuous regions of unreinforced matrix material are created that increase permeability and reduce structural strength
Solution Approach 1:
The patent introduces asymmetry in the layer stacking sequence by offsetting the angular position of crossover regions between adjacent layers. Instead of identical repeating patterns, each layer is positioned at a different angular offset, creating an asymmetric three-dimensional architecture that prevents alignment of unreinforced regions.
Data Source
Figure 1a~2f
Figure 3~5
AI summary
A composite material comprises of at least first and second layers, each comprising a polymeric matrix material and wound tows (4, 8) for reinforcement. The tows (4, 8) are wound in opposite directions in each of the first and second layers such that overlapping tows form crossover regions (6, 10). The wound tows (8) in the second layer are arranged such that the crossover regions (10) are formed to be laterally offset from the crossover regions (6) in the first layer.