Basalt-based pressure vessel for gas storage and method for its production

Abstract

A pressure vessel includes a first (base or innermost) layer composed of a resin-impregnated woven sleeve with chopped basalt fibers assembled in the voids of the sleeve and impregnated with an epoxy resin. A second and third layer is composed of continuous basalt fiber filaments arranged in a helical pattern, with the helical angle of the second layer being not equal to that of the third layer. A fourth layer is composed of continuous basalt fibers arranged in a hoop pattern. The fifth (outermost) layer is composed of randomly oriented chopped basalt fibers impregnated with a resin matrix and compacted with the subsequent wound filaments at up to ten pounds of tension.

Claims

1. A linerless pressure vessel comprising: an innermost layer including a resin-impregnated sleeve and fibers and a nano-additive in voids of the sleeve; and a second and a third layer each arranged at a helical angle, the helical angle of the second layer being different than the helical angle of the third layer.

2. A linerless pressure vessel according to claim 1 wherein the fibers in the voids of the sleeve are basalt fibers.

3. A linerless pressure vessel according to claim 1 wherein the innermost layer is at least one of carbon-fiber free and aramid-fiber free.

4. A linerless pressure vessel according to claim 1 wherein at least one of the second and third layers is carbon-fiber free, aramid-fiber free, or carbon-fiber free and aramid-fiber free.

5. A linerless pressure vessel according to claim 1 wherein the linerless pressure vessel is formed using a water-soluble tooling.

6. A linerless pressure vessel according to claim 1 wherein the linerless pressure vessel is spherical shaped.

7. A linerless pressure vessel according to claim 1 wherein the linerless pressure vessel is cylindrical shaped.

8. A linerless pressure vessel according to claim 1 further comprising a fourth layer arranged in a hoop pattern about the third layer.

9. A linerless pressure vessel according to claim 8 further comprising a fifth layer including randomly oriented fibers.

10. A linerless pressure vessel according to claim 9 further comprising a sixth layer, the sixth layer including a fiber material different than that of at least one other layer.

11. A linerless pressure vessel according to claim 1 wherein the second and third layers is impregnated with a resin matrix.

12. A linerless pressure vessel according to claim 11 wherein the resin matrix includes a nano-particle additive.

13. A linerless pressure vessel comprising an innermost layer including a resin-impregnated sleeve and material assembled in voids of the sleeve.

14. A linerless pressure vessel according to claim 13 wherein the sleeve is a woven sleeve.

15. A linerless pressure vessel according to claim 13 wherein the material assembled in the voids of the sleeve includes a nano-additive.

16. A linerless pressure vessel according to claim 15 further comprising a second layer adjacent to the innermost layer, and a third layer adjacent to the second layer, the second and third layers being arranged at different angles relative to one another.

17. A linerless pressure vessel comprising an innermost layer including a resin-impregnated sleeve and a nano-additive.

18. A linerless pressure vessel according to claim 17 further comprising the resin-impregnated sleeve including voids, the nano-additive assembled in the voids.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is an enlarged cross-section view of a composite material made according to this invention. The first, second and third layers combine to make a permeation barrier.

(2) FIG. 2 is a process flow diagram of a method of manufacturing a cylindrical-shaped pressure vessel using the composite material of FIG. 1.

(3) FIG. 3A is a front view of the first layer of the composite material, a woven or braided basalt fiber sleeve, as it is pulled over the disposable ceramic mandrel. The mandrel is preferably a water soluble mandrel.

(4) FIG. 3B is a front view of the braided basalt fiber sleeve of FIG. 3A as its ends are twisted over the mandrel.

(5) FIG. 3C is a front view of the braided basalt fiber sleeve of FIG. 3B after it is covered with a basalt fiber veil. Randomly oriented chopped basalt fibers impregnated with epoxy resin are assembled in the voids of the braided basalt fiber sleeve.

(6) FIG. 3D is a front view of the sleeve of FIG. 3C after the excess braided basalt fiber sleeve is pulled back towards the center to meet in the middle.

(7) FIG. 3E is a front view of the second layer of the composite material, a basalt fiber roving attached at about a 45 angle. Preferably, the helical angle (or wind) is below 50 and, most preferably, a polar wind (in a range of about 0 to 2).

(8) FIG. 3F is a front view of the third layer of the composite material, a basalt fiber roving attached at about a 45 angle. Preferably, the helical angle is different than that of the second layer in FIG. 3E, above 50, and can be as high as about 80.

(9) FIG. 3G is a front view composite material after its fourth and fifth layers have been applied. The fourth layer is continuous basalt fibers arranged in a hoop pattern and then cured in an oven. The fifth layer is composed of randomly oriented chopped basalt fibers impregnated with epoxy resin and compacted with the subsequent wound filaments

(10) FIG. 3H is a front view of the composite material as the mandrel is flushed with warm water in order dissolve, and therefore, remove it from the assembled pressure vessel.

(11) FIG. 4 is a front view of the assembled pressure vessel as it is plumbed for use in storing compressed natural gas in a light-duty motor vehicle application.

DETAILED DESCRIPTION OF THE INVENTION

(12) A basalt reinforced plastic material 10 made according to this invention is especially suited for use in high-pressure storage of gaseous matter such industrial and fuel gasses in compressed natural gas applications and compressed hydrogen fuel applications. A composite material made according to this invention also can be used to store other types of gasses, liquids and powders under pressure (or not under pressure).

(13) Referring first to FIGS. 1 to 3H, the structure of the material 10 and method of making it involves at least five laminate layers 11, 13, 15, 17, 19 and includes impregnated woven, braided, and chopped basalt fibers and a resin matrix. Nano-additives may be added to the resin matrix used in one or more of the layers (see e.g., Seshasai Gandikota, Selective toughening of carbon/epoxy composites using graphene oxide. Master's Thesis, Oklahoma State University (December 2011), hereby incorporated by reference).

(14) The first (base or innermost) layer 11 is composed of a resin-impregnated woven basalt fiber sleeve, preferably 13 micron chopped basalt fibers about 12 millimeters in length assembled in the voids of the sleeve and impregnated with an epoxy resin.

(15) The second and third layers 13, 15 are composed of continuous basalt fiber roving arranged in a helical pattern, preferably arranged at about a 2 helical angle, with the third layer 15 being at a 54 helical angle.

(16) The fourth layer 17 is preferably composed of continuous 1200TEX 13 micron basalt fiber roving arranged in a hoop pattern, that is, generally perpendicular to a central longitudinal axis of the mandrel on which the layer is being formed.

(17) The fifth (outermost) layer 19 is preferably composed of randomly oriented chopped 15 micron basalt fibers about 12 millimeters in length impregnated with epoxy resin and compacted.

(18) An aramid fiber, such as DUPONT KEVLAR aramid fiber, may be placed on top of the fifth layer 19 or used as part of the fifth layer 19. Carbon fiber may also be placed on top of the fifth layer 19 or used as part of the fifth layer 19.

(19) Compared to current art materials for use in high-pressure storage of gaseous matter, a basalt fiber-based composite material 10 like that made according to this invention can reduce overall production costs of a pressure vessel like that of FIG. 4, in some cases by about 20%. The basalt-based composite 10 and the resulting pressure vessel 20 are also more economical than lined tanks due to the increased manufacturing costs of metallic and polymer liners. The basalt fiber-based composite 10 also has superior gas barrier properties and mechanical properties compared to metallic- and polymer-lined vessels. Last, it permits the pressure or storage vessel 20 to be liner free, that is, not require the use of a metallic or polymeric liner.

(20) The mandrel 30 is a water-soluble mandrel or tooling (see e.g., R. J. Vaidyanathan et al., A water soluble tooling material for complex polymer composite components and honeycombs. SAMPE Conference Proceedings, (Long Beach, Calif., 2003), hereby incorporated by reference). Because the mandrel 30 is water-soluble, a pressure vessel 20 can be any shape desired for a particular application, including non-spherical shaped or non-cylindrical shaped.

(21) Preferred embodiments, and not all possible embodiments, of the pressure vessel have been described so as to enable of person of ordinary skill in the art to make and use the invention, which is defined by the claims listed below.