High-Pressure Vessel Protective Layer Injection Molding
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Solution Overview
Problem
The manufacturing process of high-pressure vessels for natural gas and hydrogen fuel cell vehicles is inefficient due to non-uniform composite material surfaces, inadequate adhesive strength, lengthy glass fiber winding processes, and complex fire-resisting material application, leading to increased time and cost with potential loss of fire resistance upon shock.
Innovation Solution
A high-pressure vessel design featuring a composite material layer surrounded by a sequentially laminated protective layer comprising a shock-absorbing resin layer, a heat-resistant ceramic layer, and a surface protective layer, formed through injection molding or thermoforming, which simplifies the manufacturing process and enhances shock, heat, and chipping resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass fiber is wound and wetted with polymer resin to manufacture the glass fiber layer, then chipping prevention and protective pad securing are improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent extracts and eliminates the glass fiber layer from the multi-layer protective structure. Instead of using glass fiber winding with polymer resin, the invention uses a single-layer protective pad made of thermoplastic resin that provides both shock absorption and chipping prevention functions, thereby removing the time-consuming glass fiber winding process while maintaining protective performance
Solution Approach 2:
The protective pad is designed to perform multiple functions simultaneously: shock absorption, chipping prevention, and protective pad securing. This multi-functional design replaces the need for separate glass fiber layer and protective pad layer, simplifying the structure and reducing manufacturing steps
2Reliability
If fire-resisting material spray is applied to the outer surface, then fire resistance is improved, but the application process becomes very complicated and uniformity is difficult to achieve
Solution Approach 1:
The patent incorporates fire-resisting materials into the composite structure by integrating them into the protective pad layer or the inner liner layer. This approach combines the fire-resisting material with the base material to form a composite structure that provides fire resistance as an inherent property rather than requiring separate spray application, thereby simplifying the manufacturing process and ensuring uniform distribution
Solution Approach 2:
The fire-resisting function is merged with the protective pad or liner material. Instead of applying fire-resisting spray as a separate post-processing step, the fire-resisting material is combined with the structural layers during the molding process, eliminating the complicated spray application process while ensuring uniform fire protection
3Reliability
If multiple sequential processes are used to manufacture the high-pressure vessel, then comprehensive protection (shock, heat, chipping) is improved, but manufacturing time and cost increase and quality uniformity becomes difficult to obtain
Solution Approach 1:
The patent merges multiple protective functions (shock absorption, heat resistance, chipping prevention) into a single integrated protective pad layer made of thermoplastic resin. This consolidation replaces the sequential multi-layer manufacturing process with a single molding operation, maintaining comprehensive protection while dramatically improving production efficiency and quality uniformity
Solution Approach 2:
The protective pad is designed as a multi-functional component that simultaneously provides shock absorption, heat resistance, and chipping prevention. This universal design eliminates the need for separate layers for each protective function, simplifying the manufacturing process to a single molding step while ensuring all protective requirements are met
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 solution reduces manufacturing time and cost, ensures consistent quality, maintains fire resistance under shock conditions, and increases production efficiency while ensuring the safety and integrity of the high-pressure vessel.
Implementation Method 1
a protective layer surrounding an outer surface of the composite material layer and including a shock-absorbing layer, a heat-resistant layer, and a surface protective layer, which are sequentially laminated, wherein the shock-absorbing layer of the protective layer is made of a resin material
Implementation Method 2
a heat-resistant layer, and a surface protective layer, which are sequentially laminated
Data Source
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AI summary
Proposed are a high-pressure vessel and a manufacturing method thereof, the high-pressure vessel including: a liner including a cylinder portion and dome portions disposed at both ends of the cylinder portion, and storing a high-pressure fluid therein, each of the dome portions having a dome shape; a composite material layer surrounding an outer surface of the liner; and a protective layer surrounding an outer surface of the composite material layer and including a shock-absorbing layer, a heat-resistant layer, and a surface protective layer, which are sequentially laminated, wherein the shock-absorbing layer of the protective layer is made of a resin material and formed by an injection molding method on an inner surface of the heat-resistant layer.