Recycled Composite Pressure Structures With Low Gas Permeation
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Solution Overview
Problem
Current pressure-containing structures for transporting gases like hydrogen and carbon dioxide, such as steel pipe liners, are prone to corrosion and fragmentation, and composite materials used as alternatives are costly and energy-intensive to produce, with manufacturing processes generating pollutants.
Innovation Solution
Recycled carbon fiber composite materials are mechanically processed into fragments with random fiber distributions, forming low permeability structures through processes like extrusion or 3D printing, creating a tortuous path to reduce gas permeability and prevent corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steel pipe liners are used to contain pressurized fluids, then the structure can effectively contain pressure, but the liners are prone to corrosion and fragmentation due to reaction with hydrogen
Solution Approach 1:
The patent changes the material composition parameters by using composite materials with specific fiber types (carbon fiber, glass fiber, aramid fiber) and matrix materials (thermoplastics, thermosets) to achieve corrosion resistance while maintaining pressure containment capabilities
Solution Approach 2:
The patent employs composite materials consisting of reinforcement fibers embedded in a matrix material to create pressure containing structures that are resistant to corrosion and fragmentation, replacing traditional steel liners with multi-phase composite systems
2Reliability
If composite materials are used in place of metals within hydrogen transport pressure containing structures, then corrosion resistance is improved, but the cost becomes prohibitive and manufacturing processes become energy intensive
Solution Approach 1:
The patent recovers and reuses composite material fragments from scrap parts, transforming waste material into reusable components for new pressure containing structures, thereby reducing the need for virgin material production and associated energy consumption
Solution Approach 2:
The patent changes the manufacturing approach by using mechanical recycling processes that operate at lower energy levels compared to traditional composite manufacturing, while maintaining the functional properties of the composite materials through controlled fragmentation and reprocessing
3Reliability
If composite materials are used in place of metals within hydrogen transport pressure containing structures, then corrosion resistance is improved, but the cost becomes prohibitive
Solution Approach 1:
The patent recovers and reuses composite material fragments from scrap parts, transforming waste material into reusable components for new pressure containing structures, thereby reducing the need for virgin material production and associated costs
Solution Approach 2:
The patent uses short fiber fragments instead of expensive continuous fiber composites, achieving acceptable performance at lower cost by utilizing discontinuous fiber reinforcement that is more economical to produce and process
4Ease of manufacture
If the composite material is mechanically processed into fragments, then the cost and energy consumption are reduced, but the fiber distribution becomes random which may affect structural performance
Solution Approach 1:
The patent changes the fiber distribution parameters by controlling the degree of randomness and fragment size distribution to achieve optimal balance between manufacturing ease and structural performance, using statistical uniformity rather than precise alignment
Solution Approach 2:
The patent uses extrusion processes with controlled flow dynamics to distribute fragments uniformly during forming, leveraging fluid mechanical principles to achieve homogeneous material distribution without requiring precise pre-positioning of fibers
5Reliability
If the fragments are formed into a pressure containing structure, then the tortuous path effect decreases gas permeability, but the structure must maintain sufficient strength to contain pressure
Solution Approach 1:
The patent employs composite materials with reinforcement fibers embedded in a matrix material to create pressure containing structures that are resistant to corrosion and fragmentation, replacing traditional steel liners with multi-phase composite systems
Solution Approach 2:
The patent utilizes the tortuous path effect created by random fiber distribution and curved fragment geometries to impede gas permeation, where the curved and irregular shapes of fragments create a more complex diffusion path for gases
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 method reduces production costs and energy consumption while minimizing pollutant generation, providing effective, corrosion-resistant pressure-containing structures for gases like hydrogen and carbon dioxide.
Implementation Method 1
the random fiber distribution of the plurality of fragments generates a tortuous effect thereby producing a low gas permeability for the pressure containing structure for substantially containing a fluid within the pressure containing structure
Data Source
AI summary
Systems, methods, and devices for providing a low permeability pressure containing structure from high performance recycled composite material, such as polymer carbon fiber composite. One or more recycled scrap composite parts are mechanically processed to form a plurality of fragments based on protected carbon fiber, which are then formed into the pressure containing structure. The distribution of the plurality of fragments and fibers included therein generate a tortuous effect that decreases the permeability of the pressure containing structure, such that the pressure containing structure is suitable for transporting and storing gases and other fluids that may corrode traditional steel pressure structures.