Pressure Vessel Protector Assembly for Dome Impact Rigidity
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Solution Overview
Problem
The structural rigidity of the side parts of TYPE 4 pressure vessels used in hydrogen vehicles is compromised due to difficulties in winding a sufficient thickness of carbon fiber composite material, leading to increased risk of damage and hydrogen leaks during impacts.
Innovation Solution
A pressure vessel assembly and protector system that includes a first and second protector surrounding the outer surfaces of the side domes, connected by a connector, which enhances structural rigidity without the need for additional reinforcing layers like fiberglass, thereby simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a sufficient thickness of carbon fiber composite material is wound around the side part of the pressure vessel, then the structural rigidity is improved, but it becomes difficult to wind the material around the dome-shaped side parts
Solution Approach 1:
The side part protection is divided into multiple carbon fiber layers with different winding directions (first layer: first winding direction, second layer: second winding direction different from the first). This segmentation allows each layer to be wound more easily around the dome-shaped surface while collectively providing sufficient structural rigidity.
Solution Approach 2:
The solution adds a dimensional aspect by using multiple layers with different winding directions rather than relying on a single thick layer. This multi-layer approach with varying orientations enables the material to conform to the curved dome surface more effectively while maintaining rigidity.
2Reliability
If a fiberglass layer is added around the periphery of the carbon fiber layer to ensure structural rigidity, then the reliability is improved, but the manufacturing process becomes complicated and costs increase
Solution Approach 1:
The protective function is merged into the existing carbon fiber layer structure itself, rather than adding a separate fiberglass layer. The multi-layer carbon fiber configuration with different winding directions provides both the structural rigidity and impact protection that would otherwise require an additional fiberglass layer, thereby simplifying the manufacturing process and reducing costs.
Solution Approach 2:
Instead of using a different material (fiberglass) to provide structural rigidity, the solution uses additional layers of the same carbon fiber material with different winding directions. This copying approach with the same material eliminates the need for separate material handling, bonding processes, and heat treatment chambers required for fiberglass.
3Strength
If different materials (carbon fiber and fiberglass) are used for the layers, then the structural rigidity is improved, but abnormal noise occurs due to different expansion amounts
Solution Approach 1:
The solution uses the same material (carbon fiber composite) for all layers instead of mixing different materials like carbon fiber and fiberglass. This homogeneity ensures uniform thermal expansion characteristics across all layers, preventing the close-contact separation that causes abnormal noise during pressure vessel expansion, while still achieving the required structural rigidity through multi-layer configuration.
Data Source
AI summary
A pressure vessel assembly includes a pressure vessel including a cylinder, a first side dome provided at one end of the cylinder, and a second side dome provided at the other end of the cylinder, a first protector that surrounds an outer surface of the first side dome, a second protector that surrounds an outer surface of the second side dome, and a connector that connects the first protector and the second protector such that the pressure vessel is interposed between the first protector and the second protector. The pressure vessel assembly can help to prevent damage and breakage of the pressure vessel caused by external impact and improve safety and reliability of the pressure vessel.