Polymeric Pressure Vessel Injection Molding System
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Solution Overview
Problem
Current pressure vessels used in vehicle systems are made of metallic materials, which are heavy and inefficient, leading to increased weight and reduced fuel efficiency.
Innovation Solution
An injection molding system is developed to form pressure vessels using a polymeric material, which includes a mold body with a cavity configured to receive and solidify the polymeric material, forming a lightweight yet structurally robust pressure vessel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic materials are used to form pressure vessels, then the pressure vessels can hold fuel at elevated pressures, but the weight of the pressure vessel increases
Solution Approach 1:
The patent changes the material parameter from metallic to polymeric composite material, which has lower density while maintaining sufficient mechanical strength through reinforcement fibers and optimized molecular structure, thereby reducing weight while preserving pressure holding capability
Solution Approach 2:
The patent employs composite polymeric materials consisting of polymer matrix combined with reinforcement fibers (such as glass, carbon, or aramid fibers), creating a material that combines the lightweight advantage of polymers with the high strength characteristics of fibers, enabling weight reduction without sacrificing structural integrity and pressure resistance
2Weight of moving object
If polymeric material is used to form pressure vessels, then the weight is reduced, but the manufacturing process complexity increases
Solution Approach 1:
The patent divides the molding process into distinct stages: material preparation (compounding polymer with fibers), injection molding (filling the mold cavity), cooling and solidification, and ejection. This segmentation allows each stage to be optimized independently and facilitates automation, reducing overall process complexity despite the advanced material system
Solution Approach 2:
The patent replaces traditional mechanical assembly processes (such as welding or fastening metal components) with injection molding, where the polymeric material is injected into a pre-formed mold cavity that defines the final shape. This substitution eliminates complex assembly operations and enables monolithic production of the pressure vessel, reducing manufacturing complexity
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 use of polymeric materials in injection molding reduces the weight of pressure vessels, enhancing fuel efficiency and allowing for the distribution of stress and pressure evenly, ensuring structural integrity and safety.
Implementation Method 1
an injector configured to compress and propel a polymeric material therethrough in a liquid state
Implementation Method 2
transmit the polymeric material from the injector to the mold portion
Implementation Method 3
forming the pressure vessel as the polymeric material cools to a solid state
Implementation Method 4
as the polymeric material cools to a solid state
Implementation Method 5
The cavity includes a mold portion configured to form the pressure vessel
Data Source
AI summary
An injection molding system for forming a pressure vessel includes an injector that propels a polymeric material and a mold body in fluid communication with the injector. The mold body defines a cavity for receiving the polymeric material. The cavity includes a mold portion for forming the pressure vessel. The mold portion extends longitudinally along an axis between a first mold end and a second mold end. The cavity includes a transport portion that transmits the polymeric material from the injector to the mold portion. The transport portion includes a sprue connected to the injector and extending between the injector and the first mold end of the mold portion, runners connected to the sprue and extending radially from the axis, and gates connected to each of the runners and to the first mold end of the of the mold portion spaced around the substantially annular configuration.