Sectioned Liner Composite Pressure Vessel Weld-Free Assembly
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Solution Overview
Problem
Conventional high pressure vessels, particularly diaphragm accumulators, face challenges with weight, complexity, and production time due to the need for welding or threading, which introduces points of failure and increases manufacturing costs.
Innovation Solution
The development of lightweight composite overwrapped high pressure vessels that utilize a liner housing made from multiple sections joined without welding or threading, with a composite overwrap providing structural and mechanical strength, and an elastomeric seal to prevent leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding or threading is used to join high pressure vessel sections, then structural strength and integrity are improved, but weight increases, manufacturing complexity increases, and production time increases
Solution Approach 1:
The patent replaces welding and threading (mechanical joining systems) with a compression-fit assembly system. The liner housing sections are joined through direct compression and friction fit, eliminating the need for welds or threads. This substitution reduces weight while maintaining structural integrity through the composite overwrap and precise dimensional control of the compression-fit joints.
2Strength
If welding or threading is used to join high pressure vessel sections, then structural strength is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent eliminates welding and threading processes by using a compression-fit assembly system. The liner housing sections are designed with precise dimensions to create friction-fit joints that require no additional manufacturing processes. This simplifies the manufacturing workflow, reduces the number of process steps, and lowers overall device complexity while maintaining structural integrity.
3Strength
If welding or threading is used to join high pressure vessel sections, then structural integrity is improved, but production time increases
Solution Approach 1:
The liner housing sections are pre-formed with precise dimensional tolerances that enable direct compression-fit assembly. The compression-fit joints are designed to achieve structural integrity through controlled compression during assembly, eliminating the need for time-consuming welding or threading operations. This preliminary preparation of sections with precise dimensions enables rapid assembly while maintaining strength.
4Strength
If welding or threading is used to join high pressure vessel sections, then structural integrity is improved, but reliability decreases due to points of failure
Solution Approach 1:
The patent extracts and eliminates welding and threading operations from the assembly process. By removing these joining methods, the patent removes the associated points of failure such as weld defects, thread stripping, and heat-affected zone vulnerabilities. The compression-fit system provides a more reliable joint that distributes stress evenly without creating localized weak points.
5Weight of moving object
If composite overwrap is used instead of welding, then weight is reduced and manufacturing complexity is reduced, but structural integrity must be maintained through alternative means
Solution Approach 1:
The patent employs a composite overwrap consisting of fiber reinforcement (such as carbon fiber, glass fiber, or aramid) embedded in a polymer matrix. This composite material provides high strength-to-weight ratio, enabling the vessel to achieve structural integrity while significantly reducing weight compared to traditional steel or aluminum construction with welding. The composite overwrap is wound or laid in specific patterns to optimize strength distribution.
Solution Approach 2:
The elastomeric seal acts as an intermediary element between the liner housing sections. It provides sealing functionality while also contributing to the structural assembly through compression. The seal ensures fluid containment and works in conjunction with the composite overwrap to maintain overall structural integrity of the pressure vessel.
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
This solution results in vessels that are significantly lighter, with improved power and energy densities, reduced manufacturing complexity and cost, and a 'leak-before-burst' failure mode, making them suitable for various applications including robotics and aircrafts.
Implementation Method 1
a composite overwrap over the liner that provides mechanical strength and structural support
Implementation Method 2
The joint between two or more liner sections includes an elastomeric seal to prevent fluid leakage within the joint
Data Source
AI summary
The present invention provides a lightweight high pressure vessels that are made from a liner or a liner housing that is overwrapped with a composite material. Unlike conventional high pressure vessels, the lightweight high pressure vessel of the invention includes a liner that comprises a plurality of liner sections without using welding or crimping. In particular, the lightweight high pressure vessels of the invention include a plurality of elements that are combined to form a liner housing and a composite overwrap that provides structural and mechanical strength to maintain integrity of the high pressure vessel. In one particular embodiment, the high pressure vessel of the invention is a diaphragm accumulator.