Molding Composite Pressure Vessel Liner to Boss
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Solution Overview
Problem
Existing composite pressure vessels face issues with the secure fastening of bosses to liners under high pressure, leading to potential detachment and leakage, which compromises the structural integrity and safety of the vessel.
Innovation Solution
A method and tool for molding a boss into the end of a composite pressure vessel liner, involving the application of pressure and heat to form an outward angle between the liner and boss necks, ensuring a secure fit and eliminating gaps for enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the boss is securely fastened to the liner through molding, then the structural integrity and reliability of the pressure vessel are enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The boss is positioned around the liner neck before the molding process begins. The liner material is then heated and molded to form an outward angle that secures the boss in place. This preliminary positioning allows the boss to be integrated into the liner structure during manufacturing, ensuring secure fastening while managing process complexity through a systematic approach.
2Reliability
If the liner neck is molded to form an outward angle to secure the boss, then the risk of detachment and leakage under high pressure is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The liner material is heated to change its physical state and increase its moldability. This allows the liner neck to be molded into the desired outward angle configuration that secures the boss. The parameter change (heating) enables precise shaping during the molding process, ensuring the correct angle is achieved while managing precision requirements through controlled material state changes.
3Reliability
If the boss is molded into the liner end section, then the structural integrity is enhanced, but the manufacturing time and cost increase
Solution Approach 1:
The boss integration is combined with the liner molding process. The liner material is heated and molded in a single operation to simultaneously form the liner structure and secure the boss in place. This merging of operations ensures structural integrity while improving manufacturing efficiency by eliminating separate boss installation steps.
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 effectively secures the boss to the liner, preventing detachment and leakage even under high pressures, while being simple and economical to manufacture, thus enhancing the structural integrity and reliability of the pressure vessel.
Implementation Method 1
applying pressure and heat to the liner end section to mold the liner neck
Implementation Method 2
applying pressure and heat to the liner end section to mold the liner neck to abut the boss neck inner surface
Data Source
AI summary
A method for molding a composite pressure vessel liner to secure a boss to the liner is described. The method comprises providing a moldable liner having an end section with a neck and a port. A boss is positioned around the neck of the liner and the liner is heated and pressure is applied to mold the liner to form to the shape of the boss. The angle of the molded liner secures the boss in place around the liner and it is able to withstand high pressures. A tool for molding the liner and a method for using the tool is also described. The tool comprises a tool body and a pipe having external threads. The tool body abuts the liner and the boss. Winding the pipe exerts pressure on the liner, which when heated, forces the liner to mold to the shape of the boss.