Type IV Pressure Vessel Boss With Spike-Anchored Composite Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming bosses in Type IV pressure vessels lack mechanical engagement between the boss and the outer composite shell, leading to potential leakage and failure under stress, as they rely on molding processes or ferrule crimping for sealing and coupling.
Innovation Solution
A Type IV pressure vessel design featuring a boss with a shank extending between the liner and the outer composite shell, where spikes are embedded into the composite shell to mechanically fasten the boss to both the liner and the outer composite shell, providing a direct and secure mechanical coupling without relying on molding or ferrule crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If injection molding process is used to mold the liner around the boss, then the sealing between the liner and the boss is improved, but the mechanical engagement between the boss and the outer composite shell deteriorates
Solution Approach 1:
The boss is divided into distinct functional segments: a sealing portion that interfaces with the liner, a shank portion that extends through the composite shell, and spike portions that provide mechanical anchoring. This segmentation allows each segment to independently fulfill its specific function without compromising the others.
Solution Approach 2:
The boss structure implements a nested configuration where the sealing portion is positioned inside the composite shell, the shank portion extends through the shell thickness, and the spike portions embed into the shell. This nested arrangement enables simultaneous achievement of sealing and mechanical engagement.
2Strength
If ferrule crimping is used to couple the boss to the outer composite shell, then the mechanical coupling is improved, but the complexity of the device deteriorates
Solution Approach 1:
The ferrule component is completely removed from the design. Instead of using a separate ferrule for mechanical coupling, the boss itself is designed with integrated spike portions that directly engage with the outer composite shell, eliminating the need for additional coupling components.
Solution Approach 2:
The mechanical coupling function previously performed by a separate ferrule is merged into the boss structure itself. The spike portions of the boss directly provide the mechanical anchoring to the composite shell, combining the boss and coupling elements into a single integrated component.
3Ease of operation
If the boss is allowed to rotate or slide axially within the outer composite shell, then the ease of installation is improved, but the reliability under stress deteriorates
Solution Approach 1:
The spike portions are pre-configured on the boss before assembly, positioned to engage with the outer composite shell in a way that automatically prevents rotation and axial sliding once installed. This preliminary configuration ensures that the anti-rotation and anti-sliding functions are built-in from the start.
Solution Approach 2:
The spike portions automatically perform the function of preventing boss rotation and axial movement without requiring additional components or complex assembly steps. The spikes self-anchor into the composite shell, providing inherent stability and preventing movement under operational stresses.
Data Source
AI summary
A type IV conformable pressure vessel has improved mechanical coupling between an outer composite shell and a boss. The pressure vessel comprises an inner polymeric liner having a flare edge fixedly coupled to the boss. The boss has a bore in fluid communication with an interior of the pressure vessel. In addition, the boss has a shank extending between the liner and the outer composite shell. The shank includes a plurality of spikes projecting radially away from the boss. The outer composite shell of resin and fiber surrounds an outer periphery of the liner and an outer periphery of the shank. The spikes are embedded into the outer composite shell to mechanically fasten the outer composite shell to the boss.