Multi-Material High-Pressure Tank Structure for Lighter Vehicle Storage
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Solution Overview
Problem
Existing high-pressure tanks for vehicles face challenges in balancing weight, cost, and manufacturing complexity due to the use of single materials like steel, aluminum, or composite materials, which are heavy, costly, or difficult to manufacture.
Innovation Solution
A high-pressure tank design utilizing a composite tank body, plastic end caps, and a fiber-reinforced bolster, where the end caps and liner are integrally formed from a common plastic material, and the bolster is wound about the tank body to enhance strength and inhibit deflection, reducing the need for complex manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a single metallic material (steel or aluminum) is used for the tank, then the tank is economical and simple to manufacture, but the weight is heavy
Solution Approach 1:
The patent employs a composite construction combining plastic material for the tank body and end caps, with a fiber-reinforced bolster (containing glass fibers, Kevlar®, or carbon fibers) wrapped around the midsection. This composite structure reduces weight by up to 60% compared to steel tanks while maintaining structural integrity and simplifying manufacturing through integration of multiple functions into unified components.
2Weight of moving object
If composite material is used for the tank body, then the weight is reduced, but the manufacturing cost increases
Solution Approach 1:
The patent uses a hybrid composite approach where a plastic tank body provides the basic lightweight structure, and a fiber-reinforced bolster (using glass fibers, Kevlar®, or carbon fibers) is wrapped around the midsection to provide additional strength. This combination achieves weight reduction while controlling manufacturing costs by selecting appropriate fiber types for specific performance requirements.
Solution Approach 2:
The tank is divided into distinct functional zones: the plastic tank body for containment, the fiber-reinforced bolster for structural reinforcement at the midsection, and integrated end caps for closure and connection. This segmentation allows each component to be optimized independently for its specific function, reducing overall manufacturing complexity and cost.
3Weight of moving object
If composite material is used for the tank, then weight is reduced, but the manufacturing complexity increases
Solution Approach 1:
The patent integrates multiple functions into unified components: the end caps are formed as integral pieces that simultaneously serve as closures, connection interfaces, and mounting points for accessories. The fiber-reinforced bolster is wrapped around the midsection to provide both structural reinforcement and load distribution. This merging of functions reduces the number of separate parts and assembly steps, simplifying manufacturing despite using composite materials.
Solution Approach 2:
The tank structure is segmented into the plastic body, fiber-reinforced bolster, and integrated end caps, allowing each component to be manufactured separately using optimized processes and then assembled. This segmentation reduces manufacturing complexity by enabling specialized production methods for each component while maintaining overall system integration.
4Weight of moving object
If the end caps are made from composite material, then weight is reduced, but the manufacturing difficulty increases
Solution Approach 1:
The end caps are formed as integral pieces that combine multiple functions (closure, connection, mounting) into a single molded component. This integration eliminates the need for separate machining or assembly operations that would be required with traditional composite construction, significantly simplifying manufacturing while maintaining weight reduction benefits.
Solution Approach 2:
The patent transitions from traditional composite end caps requiring complex winding and curing processes to plastic-molded end caps that can be produced using conventional injection or rotational molding techniques. This parameter change in material processing method dramatically reduces manufacturing difficulty while achieving the desired weight reduction and functional requirements.
Data Source
AI summary
A high-pressure tank for a vehicle that includes a tank body and a pair of end caps that are positioned at opposite ends of the tank body. The tank body includes (i.e., is formed from) a first material, and the pair of end caps include (i.e., are formed from) a second material that is different than the first material.