Composite Pressure Vessel Barrier Layer for Low Permeation
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Solution Overview
Problem
Type IV pressure vessels made from non-metallic materials have a shorter service life due to higher permeation through their layered structure, limiting their effectiveness in applications requiring high structural integrity and impermeability.
Innovation Solution
A pressure vessel design featuring a base layer, reinforcement layer, and an impermeable barrier layer, where the barrier layer is softened during high-temperature curing to ensure it is supported by the base and reinforcement layers, maintaining its geometrical form and impermeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the barrier layer is made from a material with low melting temperature to ensure it remains deformable during curing, then the ease of manufacture is improved, but the strength and structural integrity deteriorate
Solution Approach 1:
The pressure vessel is divided into three distinct layers: a base layer for structural support, a barrier layer for impermeability, and a reinforcement layer for strength. This segmentation allows each layer to be optimized independently - the base layer provides mechanical support during curing, the barrier layer can be made from low-melting-point material for ease of manufacture, and the reinforcement layer adds structural integrity
Solution Approach 2:
The pressure vessel uses a composite structure combining three different material layers with distinct functions. The base layer (structural polymer), barrier layer (low-melting-point impermeable material), and reinforcement layer (fibrous material) work together to resolve the contradiction between ease of manufacture and strength
2Strength
If high curing temperature is used to maximise the strength of the fibre reinforced polymer, then the strength is improved, but the barrier layer material may deform and lose its geometrical form
Solution Approach 1:
The base layer is formed beforehand to provide structural support and maintain the geometrical form of the barrier layer before the reinforcement layer is applied and cured. This pre-formed structural foundation prevents deformation of the barrier layer during high-temperature curing of the reinforcement layer
Solution Approach 2:
The barrier layer is separated into its own distinct layer between the base layer and reinforcement layer, allowing it to be made from low-melting-point material that remains deformable during curing while being protected by the structural base layer from losing its geometrical form
3Ease of manufacture
If the barrier layer is made from a material that is soft at curing temperature to allow deformation, then the ease of manufacture is improved, but the reliability deteriorates due to potential loss of barrier function
Solution Approach 1:
The barrier layer is segmented as a distinct layer between the base layer and reinforcement layer, allowing it to be made from low-melting-point material for ease of manufacture while being protected by the surrounding structural layers from deformation that would compromise its barrier function
Solution Approach 2:
The barrier layer is given local quality with low-melting-point material specifically at the regions where it needs to deform during manufacturing, while being constrained by the base layer and reinforcement layer to maintain its barrier function in service
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 design enhances the structural strength and impermeability of the pressure vessel, allowing it to withstand higher temperatures and pressures while maintaining low permeation rates, suitable for long-term use in applications like aircraft emergency oxygen supply.
Implementation Method 1
The heat curable polymer has been cured at a first temperature
Implementation Method 2
the barrier layer is formed from a material that is in a softened state at the first temperature
Data Source
AI summary
A pressure vessel, and a method of manufacturing a pressure vessel. The pressure vessel includes: a base layer formed from a polymer material; a reinforcement layer formed from a fibre reinforced polymer material wherein the polymer is a heat curable polymer; and an impermeable barrier layer, the barrier layer located between the base layer and the reinforcement layer; wherein the heat curable polymer has been cured at a first temperature, and wherein the barrier layer is formed from a material that is in a softened state at the first temperature.