A method for manufacturing a high-pressure tank including a liner and a reinforcing layer covering an outer surface of the liner includes: forming a cylinder member made of a fiber-reinforced resin; forming a pair of dome members made of the fiber-reinforced resin; and forming a reinforcing body that is the reinforcing layer by joining the cylinder member and the dome members. When forming the cylinder member, a resin-impregnated fiber sheet is wound around an outer peripheral surface of a mandrel to form a cylinder body, and a resin-impregnated fiber bundle is then wound so as to overlap the cylinder body.

A high-pressure tank fabrication method includes a pre-form fabrication step and a molding step. In the pre-form fabrication step a pre-form is fabricated by winding dry fiber bundles with different thicknesses (first fiber bundles and second fiber bundles) onto a liner in a state in which the dry fiber bundles with different thicknesses are made to be adjacent to one another. In the molding step, molding includes disposing the pre-form fabricated in the pre-form fabrication step in a mold and injecting resin.

A composite storage tank may include a wall structure including at least three regions including an inner region, an outer region, and at least one permeation barrier. Another region may be optionally incorporated for venting potential permeation of fluids. The at least one permeation barrier and/or the venting layer may be strategically positioned between the inner region and the outer region to reduce or at least partially prevent fluid permeation of the inner region or the outer region. A vehicle may include such a composite storage tank. Methods of forming a composite fluid storage tank may include forming an inner composite region, applying a permeation barrier to an outer surface of the inner composite region, forming an outer composite region, and curing the inner composite region and the outer composite region with the permeation barrier to form the composite fluid storage tank.

An end of a shell forming a high-pressure container is opened to form an opening. A cap is disposed partially inside the opening to close the opening. A shell reinforcing layer having a first reinforcing layer that is made of a first fiber-reinforced resin having a fiber direction oriented in a circumferential direction, and a second reinforcing layer that is integrated with the first reinforcing layer and made of a second fiber-reinforced resin having a fiber direction oriented in an axial direction, is wrapped in layers around an outer circumferential surface of the shell. The second reinforcing layer is placed over a region of the first reinforcing layer.

A method of manufacturing a composite vessel assembly (20) includes the steps of filling a first chamber defined by a first liner (28,30,32) with a first granulated material (96) through a first orifice (98) in the first liner. A vacuum is then applied to the first chamber, and the first orifice is plugged. The first liner may then be enveloped with a first layer (84) for structural rigidity followed by relief of the vacuum.

Disclosed are gas cylinder assemblies for containing pressurized gas. The gas cylinder assembly has a polymeric liner and a low-permeability barrier layer. The polymeric liner a first end portion, a second end portion and a central body. The central body comprises an outer surface and an inner surface disposed between the first end and the second end. The gas cylinder assembly comprises a reinforcement structure wound over the central body. The gas cylinder assembly further comprises a metal foil interposed between the reinforcement structure and central body. The metal foil is configured to reduce permeation of contents of the polymeric liner.

Provided are a method for producing a tank with an outer surface profile that allows a thin label to be easily and firmly attached to a surface thereof, and also such a tank. The method for producing the tank, which includes winding fiber bundles containing an uncured resin component in multiple layers around the outer surface of a liner in a first pitch width so as to form a fiber reinforced resin layer, further includes: winding fiber bundles in a second pitch width wider than the first pitch width so as to form a gap with a required width where no fiber bundle is present between adjacent fiber bundles in winding the fiber bundles to form an outermost layer; shaving off a tip end portion of a projection made of a resin that has cured after bleeding into the gap, with a portion of the projection in a predetermined height left unshaved; and attaching a label to a surface obtained through shaving off the tip end portion.

A method of manufacturing a high-pressure fluid vessel includes forming a first portion of a high-pressure fluid vessel with a molding process. The high-pressure fluid vessel includes a stack of capsules. Each capsule includes a first domed end, a second domed end, and a semicylindrical portion extending between and connecting the first domed end to the second domed end. The method further includes forming a second portion of a high-pressure fluid vessel with the molding process. The second portion of the high-pressure fluid vessel is positioned adjacent to the first portion of the high-pressure fluid vessel. The second portion of the high-pressure fluid vessel is welded to the first portion of the high-pressure fluid vessel.

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.

A pressure vessel includes curved sidewalls configured as a frame having a polygonal outline, a planar top side and a planar bottom side attached to the curved sidewalls forming a sealed pressure chamber therebetween. Each planar side includes a contoured surface having shaped pressure resistant features formed thereon. A preferred method for forming the pressure resistant features includes hydraulic pressurization to induce plastic strain. The pressure vessel also includes an array of internal support posts within the sealed pressure chamber attached to the planar sides in a geometrical pattern, such as a hexagonal array. The support posts can be solid metal cylinders, hollow tubes or tubes through which reinforcing materials, such as carbon fiber, glass fiber, or fiber/epoxy tape have been passed. A composite pressure vessel includes tubular internal support posts reinforced with reinforcing materials, as well as contoured surfaces and curved sidewalls reinforced with these same reinforcing materials.