High Pressure Tank Liner Ferrule Adhesion Segmentation
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Solution Overview
Problem
High pressure tanks face stress concentration and liner separation issues at the ferrule part due to differing shrinkage rates between the resin liner and the reinforcing layer, leading to potential detachment during temperature changes.
Innovation Solution
A high pressure tank design featuring a resin liner with protruding ends that slide backward with the ferrules into a CFRP reinforcing layer, combined with serrated ferrule parts for increased contact area, preventing stress concentration and separation, and utilizing filament winding for efficient CFRP layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the liner and CFRP reinforcing layer are adhered at the ferrule part, then the liner is securely fixed, but stress concentrates on the ferrule part causing liner separation during shrinkage
Solution Approach 1:
The adhesion between liner and CFRP reinforcing layer is segmented into two distinct locations: the body part adhesion provides secure fixing, while the ferrule part separation prevents stress concentration. This spatial segmentation of adhesion zones resolves the contradiction by allowing each zone to fulfill its specific function without interfering with the other.
Solution Approach 2:
Different adhesion qualities are applied to different parts of the liner. The body part has high adhesion strength for secure fixing, while the ferrule part has low or no adhesion to allow shrinkage movement. This local differentiation of adhesion properties resolves the contradiction between secure fixing and preventing separation.
2Strength
If the liner is fully adhered to the CFRP reinforcing layer, then structural integrity is improved, but stress concentration occurs during thermal shrinkage
Solution Approach 1:
The adhesion structure is segmented into adhered zones (body part) and non-adhered zones (ferrule part). This segmentation allows the structure to maintain integrity through adhesion in critical areas while avoiding stress concentration in shrinkage-prone areas, thus resolving the contradiction between structural integrity and stress distribution.
Solution Approach 2:
The CFRP reinforcing layer acts as an intermediary element that provides both structural support and controlled separation zones. By positioning the adhesion interface at the body part rather than the ferrule part, the CFRP layer mediates between the need for structural integrity and the need to accommodate thermal shrinkage without stress concentration.
3Reliability
If an interposing releasing agent layer is added between liner and CFRP layer, then liner separation is prevented, but device complexity and manufacturing steps increase
Solution Approach 1:
The releasing agent layer, which is an additional component used in conventional designs, is completely removed from the structure. Instead, the patent uses the inherent adhesion properties of the liner-CFRP interface at specific locations to achieve the same functional outcome, thereby reducing device complexity while maintaining reliability.
Solution Approach 2:
The liner-CFRP interface itself provides the necessary separation function during shrinkage without requiring an external releasing agent layer. The non-adhered ferrule part design allows the structure to self-accommodate thermal shrinkage, eliminating the need for additional releasing agents and simplifying the overall design.
4Reliability
If the liner protrudes from the CFRP reinforcing layer at ferrule ends, then shrinkage movement is accommodated, but manufacturing precision requirements increase
Solution Approach 1:
The liner end configuration is designed to be dynamic rather than fixed. The protruding liner ends that slide within the CFRP reinforcing layer during shrinkage create a dynamic adjustment mechanism that accommodates dimensional changes, reducing the impact of manufacturing tolerances while maintaining reliable shrinkage accommodation.
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
Effectively prevents stress concentration and liner separation from ferrules during shrinkage, ensuring the tank's integrity and functionality across temperature variations, including low temperatures, while allowing for cost-effective production by eliminating the need for additional interposing layers.
Implementation Method 1
When a liner is formed of a resin, a shrinkage rate with respect to a temperature change of the liner differs from that of a reinforcing layer surrounding an outer periphery of the liner
Implementation Method 2
the bottom part may be configured to include serration parts at its outer periphery. Such serration parts increase an area in which the resin liner is brought into contact with the ferrule parts, thereby making the resin liner and the ferrule be firmly integrated with each other
Data Source
AI summary
A high pressure tank includes two ferrules, a resin liner that covers outer parts of the ferrules at both end parts of the resin liner to fixedly install the ferrules, and a CFRP reinforcing layer formed on an outer surface side of the resin liner and attached to the resin liner at a center of a body part of the resin liner. Two leading end parts of the resin liner covering the outer parts of the ferrules protrude from end openings provided at both end parts of the CFRP reinforcing layer.