Parallel FRP Honeycomb Core for Hydrogen Tank Strength
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Solution Overview
Problem
The existing honeycomb sandwich panels face a peel-off problem due to the vertical arrangement of the honeycomb core, which is insufficient to support panel loads, and the manufacturing process of arranging the core parallel to the surface is complex and inefficient, leading to distorted shapes and reduced productivity.
Innovation Solution
A honeycomb core assembly made from soft FRP prepreg with a double structural wall, manufactured by processes of stiffening through heat and pressure, where the honeycomb core is arranged parallel to the surface, and internal and external walls are reinforced to maintain pressure and withstand external shocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the honeycomb core is arranged vertically to the panel surface, then the manufacturing process is simple, but the core cannot support panel loads and causes peel-off between hull and core
Solution Approach 1:
The patent inverts the conventional vertical arrangement of honeycomb core to a horizontal arrangement parallel to the panel surface. This inversion allows the core to effectively support panel loads while preventing peel-off between hull and core, resolving the strength issue without requiring complex manufacturing modifications
Solution Approach 2:
The patent changes the orientation parameter of the honeycomb core from vertical to horizontal arrangement. This parameter change fundamentally alters the load-bearing characteristics, enabling the core to support panel loads effectively while maintaining manufacturing simplicity
2Strength
If the honeycomb core is arranged parallel to the panel surface, then the load support capability is improved, but the manufacturing process becomes complex and productivity decreases
Solution Approach 1:
By inverting the core arrangement from vertical to horizontal, the patent achieves both improved load support and maintained productivity. The horizontal arrangement naturally aligns with the panel surface, simplifying the manufacturing process rather than complicating it
Solution Approach 2:
The patent segments the honeycomb core into multiple layers arranged horizontally, with each layer consisting of multiple cells. This segmentation allows for standardized manufacturing of individual layers that can be efficiently assembled, maintaining high productivity while achieving superior load support
3Reliability
If the honeycomb core is arranged parallel to the panel surface, then the peel-off problem is solved, but the manufacturing precision is reduced due to distorted shapes
Solution Approach 1:
The horizontal arrangement inversion eliminates the peel-off problem by distributing bonding stress across the entire panel surface rather than concentrating it at discrete vertical attachment points, thereby improving bonding reliability without compromising shape accuracy
Solution Approach 2:
The patent employs flexible FRP prepreg materials that can conform to the honeycomb core structure during manufacturing. This flexibility allows the material to adapt to slight shape variations while maintaining precise bonding, ensuring both high reliability and manufacturing precision
4Quantity of substance
If internal tanks are gathered into honeycomb core assembly, then the hydrogen storage capacity is improved, but the structural strength becomes insufficient to withstand external shocks
Solution Approach 1:
The patent uses FRP (fiber-reinforced plastic) composite materials for the honeycomb core structure, combining multiple materials with complementary properties. The FRP provides both the structural strength needed to withstand external shocks and the lightweight characteristics necessary for high hydrogen storage capacity
Solution Approach 2:
By segmenting the hydrogen storage system into multiple internal tanks arranged within the honeycomb structure, the patent increases total storage capacity while the distributed arrangement reduces the impact of external shocks on any single tank, thereby maintaining structural integrity
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
This solution prevents the honeycomb core from collapsing under vertical loads, enhances structural strength, and allows for the efficient manufacturing of high-capacity hydrogen tanks that can maintain internal pressure and withstand external shocks, improving safety and reducing costs.
Implementation Method 1
stiffening by heat and pressure, where the pressure is generated from the reaction force between the heat expansion pressure by internal pressurizing devices
Implementation Method 2
manufactured by the processes of stiffening by heat and pressure
Data Source
AI summary
The present invention is directed to a new manufacturing process for a FRP honeycomb structure where the honeycomb core assembly is arranged parallel to the surface. The honeycomb core is made from FRP prepreg with double structural walls and is manufactured by stiffening using heat and pressure. In a honeycomb core assembly set tank, a plurality of internal tanks are gathered in honeycomb core assembly. An internal tank FRP wall maintains the pressure of the internal tank, while an external FRP wall, heat foamed plastic resin and rigid FRP hull of set tank endure the external shock loading. A honeycomb core structure of six-corner cell can be infinitely arranged, and its structural position is unique. A set tank in which a plurality of internal tanks are gathered into a honeycomb core assembly can be arranged in infinite combinations, such that the total capacity can be extremely large.