Prismatic Composite Hydrogen Tank for Vehicle Integration
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Solution Overview
Problem
Existing gas storage tanks, particularly for hydrogen, are inefficient in terms of size and integration into vehicles due to their cylindrical or spherical shape, which compromises vehicle habitability and are not suitable for larger capacity applications.
Innovation Solution
A prismatic composite tank with continuous fiber reinforcement, featuring a polymer matrix and an internal cavity with fibers extending between non-contiguous faces, is manufactured using a process involving a prismatic fibrous preform, impregnation of an outer layer, and creation of an impermeable internal lining, allowing for efficient gas storage and structural integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cylindrical or spherical tanks are used for pressurized gas storage, then storage capacity and pressure resistance are improved, but integration into vehicles becomes difficult and vehicle habitability is compromised
Solution Approach 1:
The patent applies the opposite principle by using flat planar surfaces instead of curved surfaces. The tank is constructed as a prism with flat faces formed by assembling multiple planar panels, fundamentally departing from the traditional cylindrical or spherical curved geometries. This allows the tank to fit into angular vehicle spaces without compromising structural integrity under pressure.
Solution Approach 2:
The tank is divided into multiple planar panels that are assembled together to form the complete prismatic structure. Each panel can be manufactured separately and then joined to create the final tank, enabling modular construction that adapts to vehicle space constraints while maintaining pressure containment capabilities.
2Adaptability or versatility
If prismatic tank shape is used for better vehicle integration, then adaptability is improved, but manufacturing complexity increases for larger capacities
Solution Approach 1:
The tank is segmented into multiple standardized planar panels with regular geometries (rectangles, triangles, or trapezoids). These panels can be manufactured using conventional flat-panel fabrication techniques and then assembled using standardized joining methods, significantly reducing manufacturing complexity compared to forming large custom-prismatic structures.
Solution Approach 2:
The planar panels are designed as universal components that can be used across different tank sizes and configurations. The same basic panel types can be combined in various arrangements to create tanks of different capacities, all with prismatic shapes suitable for vehicle integration, thereby simplifying manufacturing through component standardization.
3Adaptability or versatility
If small capacity prismatic tanks are used, then vehicle integration is improved, but storage capacity is insufficient
Solution Approach 1:
The tank capacity is increased by assembling multiple planar panels to create larger prismatic structures. The segmented panel construction allows scalable capacity expansion while maintaining the prismatic geometry needed for vehicle integration, overcoming the limitation of small-capacity tanks.
Solution Approach 2:
The tank employs composite material construction with fiber-reinforced panels that provide high strength-to-weight ratios. This enables the creation of larger capacity tanks with prismatic shapes without excessive weight, allowing increased storage capacity while maintaining vehicle integration benefits.
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 prismatic composite tank effectively stores pressurized gas while providing structural integrity, enabling easier integration into vehicles and aircraft, and is adaptable for both custom and mass production.
Implementation Method 1
impregnate an outer layer of said preform with a polymer to a thickness less than 1/4 of the thickness e so as to form a composite outer envelope
Implementation Method 2
produce an impermeable layer constituting an internal lining by polymerization of a liquid introduced into the internal cavity
Implementation Method 3
produce an impermeable layer constituting an internal lining by polymerization of a liquid introduced into the internal cavity
Data Source
Figure 1~2
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Figure 6
AI summary
The invention relates to a method for manufacturing a continuous fiber-reinforced composite tank, prismatic in shape and of thickness e, for storing a gas under pressure in an internal cavity of said tank, which tank comprises fibers extending between two non-contiguous faces of said tank through the internal cavity, comprising the steps of: i. obtaining (720) a prismatic fibrous preform of thickness e comprising continuous three-dimensional reinforcements throughout its thickness; ii. impregnating (760) an outer layer of said preform with a polymer to a thickness less than 1/4 of the thickness e so as to constitute a composite outer shell extending over all faces of the prism; iii. producing (790) a watertight layer constituting an inner lining, with a thickness less than 1/10th of the thickness e between the outer shell and the fibrous network contained in the cavity of the tank.