Double-Wall FRP Tank Assembly for Cryogenic Hydrogen Storage
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Solution Overview
Problem
Existing hydrogen storage systems for aircraft face challenges in achieving lightweight, high-energy density, and efficient thermal insulation while addressing issues like hydrogen embrittlement, vacuum tightness, and system integration, particularly in cryogenic conditions.
Innovation Solution
A method for manufacturing a vessel using partially cured Fiber Reinforced Polymer (FRP) structures that are coupled and then wrapped with an FRP layer, allowing for flexible integration of internal systems and structural elements, and a double-wall tank design with an insulating gap for thermal protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic pressure vessels are used for hydrogen storage, then reliability and ease of manufacture are improved, but weight increases significantly
Solution Approach 1:
The patent employs Fiber Reinforced Polymer (FRP) composite materials to manufacture the pressure vessel, replacing traditional metallic materials. This composite structure maintains the necessary strength and reliability for hydrogen storage while significantly reducing the overall weight of the tank system
Solution Approach 2:
The manufacturing process divides the vessel production into separate stages: first forming the FRP structure, then applying metallic reinforcement layers selectively. This segmentation allows optimization of each layer's properties - the FRP provides lightweight structural support while metallic layers provide targeted reinforcement and hydrogen embrittlement resistance
2Strength
If complete curing cycle is applied to FRP structures before assembly, then structural strength is improved, but manufacturing time and energy consumption increase
Solution Approach 1:
The patent applies a preliminary curing cycle to the FRP structures before final assembly, rather than waiting for complete curing. This preliminary action provides sufficient initial strength for handling and assembly operations, while the final curing is completed after assembly, thereby reducing total manufacturing time and energy consumption without compromising final structural integrity
Solution Approach 2:
The curing process is applied in two stages: a partial curing cycle before assembly that provides adequate strength for manufacturing operations, and a final curing cycle after assembly to achieve complete structural properties. This partial action approach optimizes the balance between strength development and manufacturing efficiency
3Reliability
If metallic materials are used for pressure vessels, then resistance to hydrogen embrittlement is improved, but weight and manufacturing complexity increase
Solution Approach 1:
The patent creates a composite structure combining FRP materials with selective metallic reinforcement layers. The FRP provides the primary lightweight structural support, while metallic layers are applied only in specific regions where hydrogen embrittlement resistance is critical, thereby minimizing weight while maintaining reliability
Solution Approach 2:
Instead of using metallic materials throughout the entire pressure vessel, the patent applies metallic reinforcement layers selectively in specific local regions where hydrogen embrittlement resistance is most needed. This local quality approach provides targeted protection against hydrogen embrittlement while keeping the overall vessel weight minimal
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 results in a lightweight, high-energy density vessel with improved thermal insulation and reduced manufacturing costs, enhancing the efficiency and flexibility of system integration and reducing the risk of hydrogen embrittlement.
Implementation Method 1
winding at least one layer of FRP material onto at least a portion of the at least partially cured FRP structures
Implementation Method 2
curing the assembly resulting from step c)
Data Source
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AI summary
The present invention provides a method for manufacturing a vessel (10) configured for housing a fluid within, said method comprising: providing at least two at least partially cured fiber reinforced polymer (FRP) structures (21,22) with complementary shapes (22.1,21.1)configured for matching with each other such that an interior volume is defined when the at least partially cured FRP structures are coupled to each other; coupling the at least partially cured FRP structures to each other such that the interior volume is defined; winding at least one layer (23) of FRP material onto at least a portion of the at least partially cured FRP structures once coupled to each other; and applying a curing cycle to cure the resulting assembly.