Composite Pressure Vessel Liner Interface Part
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Solution Overview
Problem
Existing composite pressure vessels for hydrogen storage in vehicles face challenges with expensive metallic boss parts that require multiple process steps and inadequate sealing, necessitating a cost-effective and simple connection solution.
Innovation Solution
A composite pressure vessel design featuring a connection assembly with a plastic liner interface part that is gas-tightly connected using a joining process, such as welding, eliminating the need for metallic boss parts by integrating a non-metallic material with a multi-component injection molded part for both interface and sealing functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic boss parts are used for connection assembly, then gas-tight sealing to the liner can be achieved, but manufacturing cost increases and production complexity increases
Solution Approach 1:
The patent merges the sealing function and connection function into a single integrated connection assembly made of polyamide material. The connection assembly includes an integrated sealing surface that directly contacts the liner, eliminating the need for separate metal boss parts and multiple assembly steps. This integration reduces production complexity while maintaining gas-tight sealing through the unified design.
Solution Approach 2:
The patent replaces metallic boss parts with a polyamide-based connection assembly that copies the essential functions of the metal component. The polyamide material is molded with integrated sealing features that replicate the sealing capability of metal bosses, while being more cost-effective and simpler to manufacture through injection molding processes.
2Adaptability or versatility
If metallic boss parts are used for connection assembly, then suitable transition between liner and valve can be provided, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive metallic boss parts with a cost-effective polyamide connection assembly. The polyamide material is cheaper than metal and can be manufactured through efficient injection molding processes. The connection assembly provides the necessary transition capability between the liner and valve while being more economical in both material and manufacturing costs.
Solution Approach 2:
The patent changes the material parameter from metal to polyamide for the connection assembly. This material substitution maintains the functional capability of providing a suitable transition between liner and valve, while significantly reducing manufacturing cost. The polyamide material can be directly molded into the required shape with integrated sealing features, simplifying the manufacturing process.
3Reliability
If multiple process steps are used for integrating boss part, then suitable connection can be achieved, but production time increases and productivity decreases
Solution Approach 1:
The patent combines multiple separate components (metal boss part, sealing ring, connection features) into a single integrated polyamide connection assembly. This integration eliminates multiple assembly steps and reduces production time, thereby increasing productivity. The connection reliability is maintained through the integrated design that ensures proper alignment and sealing in a single molded component.
Solution Approach 2:
The patent incorporates all necessary connection and sealing features directly into the molded polyamide connection assembly during the injection molding process. This preliminary formation of all required features eliminates the need for subsequent assembly operations, reducing production time and increasing productivity while ensuring reliable connections.
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 provides a cost-effective and simple method for producing composite pressure vessels with a reliable gas-tight connection, reducing production complexity and costs while ensuring a secure seal, thereby enhancing the efficiency and affordability of hydrogen storage solutions.
Implementation Method 1
the first and second plastics are selected such that the first plastic melts into the second plastic during overmolding
Implementation Method 2
The gas-tight connection of the liner interface part to the liner by a joining process is preferably carried out by fusing or welding
Data Source
Figure 1
Figure 2
AI summary
A composite pressure vessel comprising an inner liner (1) for receiving a medium, in particular hydrogen, and a shell surrounding the liner (1) made of a fiber-reinforced material, further comprising a connection assembly (2), in particular a valve assembly or distributor assembly, wherein on the one hand the connection assembly (2) is gas-tightly connected to the liner (1) and on the other hand the connection assembly (2) has at least one screw, plug or weld connection (3), wherein the connection assembly (2), in addition to a base body (4) of the connection assembly (2), has a liner interface part (5), wherein the liner interface part (5) is designed as a gas-tight overmolding of the base body (4) with a first plastic, wherein the liner interface part (5) is gas-tightly connected to the liner (1) by a joining process, and a method for manufacturing such a composite pressure vessel.