High-Pressure Container Hoop and Helical Composite Layer Design
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Solution Overview
Problem
High-pressure containers used in fuel cell systems face challenges in durability and safety due to high internal pressures, particularly in storing hydrogen gas, where existing composite materials struggle to evenly distribute stress and may result in air pockets, compromising the container's structural integrity.
Innovation Solution
A composite layer structure is implemented on the perimeter of the high-pressure container, comprising alternately wound hoop and helical layers with varying thicknesses and angles, where hoop layers closest to the liner have the greatest thickness, decreasing as distance from the liner increases, and helical layers are wound at lower angles to enhance durability and reduce material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If composite material winds at high angle to form hoop layer around center portion, then resistance to circumferential stress is improved, but air pockets occur at interface between hoop layer and helical layer
Solution Approach 1:
The patent applies parameter changes by varying the winding angle of composite material layers. Hoop layers are wound at high angles (nearly perpendicular to axial direction) to maximize circumferential stress resistance, while helical layers are wound at lower angles to ensure proper overlap and eliminate air pockets at interfaces. This dynamic adjustment of winding angle parameters optimizes both strength and reliability.
2Ease of manufacture
If composite layer uses uniform thickness, then manufacturing is simplified, but durability against stresses from various directions cannot be guaranteed
Solution Approach 1:
The patent implements local quality by varying the thickness of composite layers at different radial positions. Inner layers (closer to the liner) have greater thickness to withstand higher circumferential stresses, while outer layers have reduced thickness. This non-uniform thickness distribution optimizes durability against multi-directional stresses while the alternating hoop-helical pattern maintains manufacturing feasibility.
3Strength
If more composite material is used to increase durability, then resistance to high pressure is improved, but weight of container increases
Solution Approach 1:
The patent optimizes the weight-strength ratio by changing the thickness parameter of composite layers. Inner layers have greater thickness to provide necessary pressure resistance, while outer layers have reduced thickness to minimize weight. This graduated thickness distribution ensures adequate strength while avoiding excessive material usage and weight increase.
Data Source
AI summary
A high-pressure container having a liner and a composite layer for reinforcing a perimeter of the liner includes: a cylinder part foiled along the axial direction of the high-pressure container; and dome parts fastened to both ends of the cylinder part to enclose the high-pressure container. The composite layer formed on the cylinder part is formed by a plurality of hoop layers and helical layers overlapped alternately. A hoop layer disposed closer to the liner has a thickness greater than that of a hoop layer disposed farther from the liner so that a thickness of the hoop layers decreases as a distance from the linear increases.