High-Pressure Tank Liner Joint Structure for Pressure Resistance
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Solution Overview
Problem
High-pressure tanks used in fuel cell systems face challenges in achieving sufficient joint strength to withstand internal gas pressure, leading to potential breakage and reliability issues.
Innovation Solution
A method of manufacturing a high-pressure tank liner by joining resin material constituent members with flange members that protrude outwardly, allowing for a residual protruding amount to increase joint strength beyond the tensile strength of the resin material, and using welding techniques like vibration welding to enhance the joint area and prevent breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional laser welding is used to join liner constituent members, then the joining process is simple, but the joint strength is insufficient to withstand high internal gas pressure
Solution Approach 1:
The liner constituent members are divided into segments with flange members at the ends. These flange members include protruding bottom portions that extend into the other member's annular recess, creating interlocking joint structures that significantly enhance joint strength while maintaining manufacturing simplicity
Solution Approach 2:
The joint structure combines the resin material of the liner constituent members with the geometric composite formed by the interlocking flange members and annular recesses. This composite structural approach creates a joint whose strength exceeds the tensile strength of the base resin material
2Reliability
If the liner is designed to withstand high pressure, then reliability is improved, but the joint becomes prone to breakage under internal pressure
Solution Approach 1:
The flange members with protruding bottom portions are designed in advance to provide structural reinforcement at the joint locations. This pre-designed geometry cushions and distributes the high internal pressure loads, preventing joint breakage before it occurs and ensuring liner reliability under pressure
Solution Approach 2:
The protruding bottom portion of one flange member is nested within the annular recess of the opposing flange member. This nested configuration creates a interlocked joint structure that significantly enhances pressure resistance and reliability by preventing separation under high internal gas pressure
3Strength
If flange members are completely cut off after joining, then the structure is simplified, but the joint strength becomes less than the tensile strength of the resin material
Solution Approach 1:
Instead of completely removing the flange members, the bottom portions are selectively retained at the joint locations while other portions are cut off. This local retention of material precisely where needed creates the interlocking structure that ensures joint strength exceeds the tensile strength of the resin material, minimizing unnecessary material waste
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 enhanced joint strength prevents breakage under high pressure, ensuring the reliability of the liner and the high-pressure tank, with the joint strength being greater than or equal to the tensile strength of the resin material, thereby maintaining tank integrity.
Implementation Method 1
a joining step of joining the end surfaces of the open ends to each other by welding, and thereby obtaining a joint
Data Source
AI summary
In the vicinity of an opening end of a first liner constituent member and a second liner constituent member made of a resin material, a flange portion is formed. After end surfaces of the opening end are abutted and joined to each other, the flange portion is removed in such a way that a part of a bottom portion remains. The remaining amount of protrusion is set such that the joint strength of a joint portion is not less than the tensile strength of the resin material or not less than the cohesion failure strength of the joint portion.