Cryogenic Container Sandwich Partition Polymer Foam Insulation
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Solution Overview
Problem
Current containers for cryogenic fluids, such as those used in upper stages of launch vehicles, face challenges in efficiently managing mechanical and thermal loads, leading to hydrogen evaporation and reduced payload capacity due to inadequate insulation and structural design, which increases weight and production costs.
Innovation Solution
A container design featuring a sandwich construction with two cover layers and an intermediate layer of polymer foam that transmits mechanical forces and provides thermal insulation, completely filling the gap between the layers to ensure efficient force transmission and minimize heat flow, thus maintaining structural integrity and reducing weight and production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an additional skin layer made of fiber-reinforced laminate is used to attach the honeycomb structure, then the mechanical strength is improved, but the weight increases and production becomes labor-intensive and cost-intensive
Solution Approach 1:
The patent removes the additional fiber-reinforced laminate skin layer from the design, retaining only the essential honeycomb structure for mechanical strength. This extraction eliminates the extra weight and production complexity while maintaining sufficient structural integrity through the optimized honeycomb core alone.
Solution Approach 2:
The honeycomb structure is designed to perform multiple functions simultaneously: providing mechanical strength, enabling gap formation for thermal insulation, and serving as the primary structural element without requiring additional reinforcement layers. This multi-functionality eliminates the need for separate fiber-reinforced laminate layers.
2Temperature
If a gap is formed between the additional cover layer and the other cover layer, then thermal insulation is improved, but mechanical force transmission is ruled out
Solution Approach 1:
The honeycomb structure serves as an intermediary element that simultaneously provides mechanical support and creates the insulating gap. The cells within the honeycomb structure allow for gap formation for thermal insulation while the overall structure maintains mechanical integrity and force transmission capabilities between the cover layers.
Solution Approach 2:
The partition wall uses a composite sandwich construction combining two cover layers with a honeycomb core structure. This composite design allows the honeycomb material to provide both mechanical strength and thermal insulation properties, with the gap between cover layers filled by the honeycomb cells creating effective thermal barrier while maintaining structural integrity.
3Ease of manufacture
If the honeycomb structure is attached exclusively via an additional skin layer, then manufacturing flexibility is improved, but production becomes labor-intensive and cost-intensive
Solution Approach 1:
The patent eliminates the additional fiber-reinforced laminate skin layer that caused production complexity, retaining only the essential honeycomb structure. This extraction simplifies the manufacturing process, reducing labor intensity and production costs while maintaining manufacturing flexibility through the inherent adaptability of the honeycomb structure.
4Temperature
If the gap between cover layers is increased for thermal insulation, then heat flow reduction is improved, but structural stability deteriorates
Solution Approach 1:
The sandwich construction with honeycomb core creates an optimal balance between gap size for insulation and structural stability. The honeycomb cells provide sufficient gap volume for thermal insulation while the interconnected cellular structure maintains rigidity and structural integrity, preventing excessive deformation under mechanical loads.
Solution Approach 2:
The honeycomb structure utilizes a porous cellular configuration that provides effective thermal insulation through the air gaps within the cells and between cells, while the solid cell walls maintain structural strength. This porous design achieves heat flow reduction without compromising structural stability.
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 container achieves high strength, rigidity, and efficient thermal insulation, minimizing hydrogen evaporation and reducing structural mass, while being cost-effective and simple to manufacture, thereby enhancing payload capacity and operational efficiency.
Implementation Method 1
an intermediate layer made of polymer foam, which is arranged in a space between the two cover layers and transmits mechanical forces and/or moments
Implementation Method 2
is heat-insulating or reduces heat flow
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to containers for receiving and storing cryogenic fluids, especially cryogenic liquids and viscous substances, said containers comprising a casing (12) and at least one partition (14) that divides the inside (16) of the container (10) into at least two adjacent chambers (18, 18'). The invention is characterised in that the at least one partition (14) has a sandwich-type structure and comprises two covering layers (20, 20') respectively facing one of the at least two adjacent chambers (18, 18'), and an intermediate layer (22) that is arranged in a space (24) between the two covering layers (20, 20'), transmits mechanical forces and/or torques, is heat-insulating or reduces a heat flux, and consists of a polymer foam. Said intermediate layer (22), which transmits mechanical forces and/or torques, is heat-insulating or reduces a heat flow, and consists of a polymer foam, completely or essentially completely fills the space (24) between the two covering layers (20, 20') and adheres to the two covering layers (20, 20') by means of an adhesive (67), especially an intumescent adhesive, preferably a paste-like glue, a film cement or an epoxy resin. The invention also relates to methods for producing said containers, and to a use thereof.