Induction Heating for Hydrogen Tank Liner Bonding
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Solution Overview
Problem
Existing methods for forming hydrogen tanks face challenges in achieving a strong bond between a plastic liner and a sealless aluminum nozzle, leading to potential hydrogen leaks and increased production costs due to manual assembly and high cycle times.
Innovation Solution
An injection mold system with a change core module and induction heating unit that heats the sealless aluminum nozzle to 160°C or higher, allowing for in-mold bonding and molding of the plastic liner, thereby enhancing the bonding strength and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate highly elastic O-ring or annular special seal is applied to seal hydrogen at the interface, then sealing performance is improved, but manufacturing cost increases and assembly complexity increases due to manual assembly requirements
Solution Approach 1:
The patent removes the separate sealing components (O-rings or annular special seals) from the interface assembly and extracts only the essential sealing function, which is achieved through the integrated molding of the plastic liner with the aluminum nozzle. This eliminates the need for additional sealing parts and manual assembly while maintaining hydrogen sealing capability.
Solution Approach 2:
The patent combines the sealing function with the structural components by integrating the plastic liner and aluminum nozzle into a single molded assembly. The sealing interface is formed directly during the injection molding process, merging the sealing function with the mechanical connection function, thereby eliminating separate sealing components and reducing assembly complexity.
2Reliability
If a separate highly elastic O-ring or annular special seal is applied to seal hydrogen at the interface, then sealing performance is improved, but device complexity increases due to additional components
Solution Approach 1:
The patent removes the separate sealing components (O-rings or annular special seals) from the interface assembly and extracts only the essential sealing function, which is achieved through the integrated molding of the plastic liner with the aluminum nozzle. This eliminates the need for additional sealing parts and manual assembly while maintaining hydrogen sealing capability.
Solution Approach 2:
The patent combines the sealing function with the structural components by integrating the plastic liner and aluminum nozzle into a single molded assembly. The sealing interface is formed directly during the injection molding process, merging the sealing function with the mechanical connection function, thereby eliminating separate sealing components and reducing assembly complexity.
3Strength
If the sealless aluminum nozzle is heated to 170°C in an oven and then manually carried and inserted into the injection molding machine, then bonding strength is improved, but productivity decreases due to excessive cycle time
Solution Approach 1:
The patent combines the heating function and injection molding process into a single integrated operation. The induction heating unit is built into the injection molding machine, allowing the aluminum nozzle to be heated to the required temperature (160°C or higher) directly within the molding machine before injection, eliminating separate heating and manual handling steps, thereby reducing cycle time while maintaining bonding strength.
Solution Approach 2:
The patent introduces an induction heating unit as an intermediary device that enables rapid and precise heating of the aluminum nozzle directly within the injection molding machine. This intermediary heating mechanism eliminates the need for external oven heating and manual handling, allowing continuous automated processing and significantly reducing production cycle time.
4Strength
If workers manually transport the heated aluminum nozzle from the oven to the injection molding machine, then bonding strength is improved, but safety risks increase due to exposure to hot surfaces
Solution Approach 1:
The patent combines the heating function and injection molding process into a single integrated operation. The induction heating unit is built into the injection molding machine, allowing the aluminum nozzle to be heated to the required temperature (160°C or higher) directly within the molding machine before injection, eliminating separate heating and manual handling steps, thereby reducing cycle time while maintaining bonding strength.
Solution Approach 2:
The patent introduces an induction heating unit as an intermediary device that enables rapid and precise heating of the aluminum nozzle directly within the injection molding machine. This intermediary heating mechanism eliminates the need for external oven heating and manual handling, allowing continuous automated processing and significantly reducing production cycle time.
5Adaptability or versatility
If change cores are replaced manually for different nozzle designs, then adaptability is improved, but productivity decreases due to at least one hour replacement time per design change
Solution Approach 1:
The patent makes the change core system dynamic and adjustable by designing the change core as a removable and replaceable component that can be quickly swapped without stopping injection work. The new design allows change cores to be exchanged in a much shorter time (less than one hour) through a simplified replacement mechanism, enabling rapid adaptation to different nozzle designs while maintaining high production efficiency.
Solution Approach 2:
The patent segments the change core into modular components that can be independently replaced. The change core is designed as a separate, standardized module that can be quickly exchanged without affecting the rest of the injection molding system, enabling rapid design changes while minimizing disruption to production flow.
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 proposed solution effectively seals hydrogen at the interface between the plastic liner and the aluminum nozzle, reducing hydrogen leaks and production costs while improving work efficiency and productivity by automating the assembly process.
Implementation Method 1
an induction heating unit that heats the sealless aluminum nozzle to 160° C. or higher
Data Source
AI summary
An embodiment change core module of an injection mold for a hydrogen tank liner that is injection molded is provided. The change core module includes upper and lower change cores configured to hold a sealless nozzle inside the injection mold, wherein the injection mold comprises upper and lower molds, and wherein the sealless nozzle has a first temperature, and an induction heating device configured to inductively heat the sealless nozzle to a second temperature.