Galvanic Liner for Composite Hydrogen Tank
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Solution Overview
Problem
Cryogenic hydrogen tanks for aircraft require a manufacturing method that reduces weight while maintaining high capacity and simplifies the manufacturing process, given hydrogen's high interfuse rate and low density, which poses challenges with non-metallic materials.
Innovation Solution
A manufacturing method involving a hydrogen tank body with an inner tank wall made from fibre reinforced composite material, coated with a galvanic liner layer using electroplating, providing thermal insulation and a distribution line for filling and emptying, with a galvanic coating process that includes higher pressure and surface repressing to ensure uniformity and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If non-metallic material is used for the inner tank wall, then weight is reduced, but hydrogen interfusion occurs due to high interfuse rate
Solution Approach 1:
The invention applies composite materials by combining non-metallic fiber reinforced plastic material for the tank structure with a metallic galvanic liner layer for hydrogen barrier protection. This composite structure allows the tank to benefit from the low weight of non-metallic materials while the metallic layer provides the necessary hydrogen retention, resolving the contradiction between weight reduction and hydrogen interfusion prevention.
2Reliability
If a metal liner layer is added to prevent hydrogen interfusion, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The invention replaces traditional mechanical attachment methods (such as bonding or mechanical fastening) with a galvanic deposition process. The metallic liner layer is applied through galvanic coating, which creates a metallurgical bond with the fiber reinforced plastic substrate. This substitution simplifies the manufacturing process by eliminating the need for separate attachment steps and ensures a reliable, integrated structure.
3Weight of moving object
If fiber reinforced composite material is used for the inner tank wall, then weight is reduced, but manufacturing precision is challenged due to surface quality requirements
Solution Approach 1:
The invention applies preliminary surface treatment to the fiber reinforced composite material before applying the galvanic liner layer. The inner surface undergoes cleaning, chemical treatment, and/or blast cleaning to remove contaminants and create a suitable surface morphology. This preliminary action ensures that the subsequent galvanic coating adheres properly and achieves uniform thickness, thereby meeting manufacturing precision requirements while maintaining the weight benefits of composite materials.
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 hydrogen tank with enhanced corrosion resistance and simplified manufacturing, effectively addressing the interfuse rate issue and ensuring reliable storage for aircraft use.
Implementation Method 1
galvanic coating of an inner side of the inner tank wall in order to generate a galvanic liner layer
Data Source
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AI summary
In order to simplify manufacturing of a hydrogen tank (10) that can reliably retain H2 therein and has a low weight, the invention provides a manufacturing method for manufacturing a hydrogen tank (10) for a vehicle (12), comprising the steps of: a) providing a hydrogen tank body (56) with an inner tank wall (58) made from fibre reinforced composite material, and b) galvanic coating of an inner side (20) of the inner tank wall (58) in order to generate a galvanic liner layer (22).