Abstract
A reinforcement element, suitable for composite pressure vessel, may be configured to be inserted and to fill in a hollow shaft of a plastic liner of the composite pressure vessel, the hollow shaft connecting opposite walls of the liner. The reinforcement element may include a central part and two external parts constituted by a plurality of continuous fibres impregnated with a first resin. The central part of the reinforcement element may have a dimension substantially equal to the dimension of the hollow shaft and being a full part. The two external parts may be able to be unfolded and fixed on the external surface of opposite walls of the liner. A composite pressure vessel may include such a reinforcement element.
Claims
1. A reinforcement element suitable for composite pressure vessel, the reinforcement element being configured to be inserted and to fill in a hollow shaft of a plastic liner of the composite pressure vessel, the hollow shaft connecting opposite walls of the plastic liner, the reinforcement element comprising: a central part; a first and a second external part each constituted by a plurality of continuous fibers impregnated with a first resin, wherein the central part of the reinforcement element has a dimension substantially equal to a dimension of the central part of the hollow shaft wherein the central part is a full part, and wherein the first and second external parts are unfoldable and fixable on an external surface of opposite walls of the plastic liner.
2. The reinforcement element of claim 1, wherein a ratio between a surface of the first or second external part of the reinforcement element, in unfolded form, provided to be fixed to the external surface of one wall of the plastic liner, and a section of the central part of the reinforcement element is at least 5.
3. The reinforcement element of claim 1, wherein the continuous fibres of the central part of the reinforcement element and of the first and second external parts of the reinforcement element comprise glass fibers, basalt fibers, carbon fibers, or aramid fibers.
4. A composite pressure vessel, comprising: (a) a plastic liner comprising pairs of opposite surfaces, the opposite surfaces of at least one of these pairs being connected by a plurality of hollow shafts whose ends are in one piece with these surfaces, the plastic liner further comprising reinforcement elements traversing the hollow shafts and connected to the external surfaces of the plastic liner adjacent to the central part of the hollow shafts; (b) a fiber-reinforced polymer shell enclosing the plastic liner, the fiber-reinforced polymer shell being made of continuous fiber-reinforced composite matrix, comprising reinforcing fibers and a second resin matrix, wherein the reinforcement element comprises a central part and a first and a second external part, wherein the first and a second external part are constituted by a plurality of continuous fibers impregnated with a first resin, wherein the central part of the reinforcement element has a dimension substantially equal to a dimension of the central part of the hollow shaft and is a full part, wherein the first and second external parts of the reinforcement element are unfolded and fixed on the external surface of opposite walls of the plastic liner, and wherein the continuous fibers of the reinforcement element are parallel with an external surface of opposite walls of the plastic liner and the surface of the hollow shaft.
5. The composite pressure vessel of claim 4, further comprising: an insert, located at a center of the first or second external part, in unfolded form.
6. The composite pressure vessel of claim 5, wherein the insert is a metallic insert or a fiber-reinforced paste insert.
7. The composite pressure vessel of claim 4, further comprising: an intermediate reinforcing element located between the plastic liner and the first or second external part of the reinforcement element, in unfolded form.
8. The composite pressure vessel of claim 7, wherein the intermediate reinforcing element is a resin-impregnated mat.
9. The composite pressure vessel of claim 4, wherein the continuous fibers of the first and second external parts of at least two adjacent reinforcement elements are tangled.
10. The composite pressure vessel of claim 4, wherein outer parts of the hollow shaft are flared and form a depression on the external surface of the plastic liner.
11. The composite pressure vessel of claim 4, wherein a gas input or output is located in a hollow shaft.
12. A method for manufacturing a composite pressure vessel, the method comprising: molding a plastic liner comprising kiss-points; forming hollow shafts by cutting away the kiss-points; inserting in the hollow shafts a reinforcement element comprising a central part and a first and a second external part, the first and second parts constituted by a plurality of continuous fibers impregnated with a first resin; unfolding the first and second external parts of the reinforcement element; applying the first and second external parts of the reinforcement element to an external surface of the plastic liner; winding a fiber-reinforced polymer shell enclosing the plastic liner; and curing to obtain the composite pressure vessel.
13. The method of claim 12, further comprising: inserting an insert in the first or second external part of the reinforcement element, in unfolded form.
14. The method of the claim 12, further comprising: applying an intermediate reinforcing element, located between the plastic liner and the first or second external part of the reinforcement element, in unfolded form, wherein the applying is performed before the unfolding of the first and second external parts of the reinforcement element.
15. The method of claim 12, comprising: curing the central part of the reinforcement element before the inserting in the hollow shafts of the reinforcement element.
16. A vehicle, comprising: the composite pressure vessel of claim 4.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0056] FIG. 1 is a vertical cross-section of a first embodiment of a reinforcement element according to the invention inserted in a composite pressure vessel.
[0057] FIG. 2 is a vertical cross-section of a second embodiment of a reinforcement element according to the invention inserted in a composite pressure vessel.
[0058] FIG. 3 is a partial vertical cross-section of a first embodiment of a composite pressure vessel according to the invention.
[0059] FIG. 4 is a view from the above showing the fixation step of an intermediate reinforcing means on the first embodiment of a composite pressure vessel according to the invention.
[0060] FIG. 5 illustrates the surface covered by an unfolded external part.
[0061] FIG. 6 is a vertical cross-section of a second embodiment of a composite pressure vessel according to the invention.
[0062] FIG. 7 is a vertical cross section of a composite pressure vessel according to the invention comprising a gas input or output located in a hollow shaft.
[0063] FIG. 8 is a vertical cross section illustrating the step of molding a plastic liner having kiss-points of the method of manufacturing a composite pressure vessel according to the invention.
[0064] FIG. 9 is a vertical cross section illustrating the step of forming hollow shafts by cutting away the kiss-points of the method of manufacturing a composite pressure vessel according to the invention.
[0065] FIG. 10 is a vertical cross section illustration the step of inserting in the hollow shafts a reinforcement element comprising a central part and at least two external parts constituted by a plurality of continuous fibres impregnated with a first resin of the method of manufacturing a composite pressure vessel according to the invention.
[0066] FIG. 11 is a vertical cross section illustrating the step of unfolding the external parts of the reinforcement element and applying the external parts of the reinforcement element to the external surface of the plastic liner of the method of manufacturing a composite pressure vessel according to the invention.
[0067] FIG. 12 is a vertical cross section illustrating the step of inserting an insert between the unfolded external parts of the reinforcement element of the method of manufacturing a composite pressure vessel according to the invention.
[0068] FIG. 13 is a vertical cross section illustrating the step of winding a fibre reinforced polymer shell enclosing the plastic liner of the method of manufacturing a composite pressure vessel according to the invention.
[0069] FIG. 14 a) and b) illustrate possible winding pattern of the fibre reinforced polymer shell enclosing the plastic liner.
[0070] FIG. 15 is an illustration the possible location of the boss used as fixation point for the winding of the fibre reinforced polymer shell.
[0071] FIG. 16 illustrates possible locations of the gas input or output on the composite pressure vessel.
[0072] In the different figures, the same reference signs refer to the same or analogous elements.
DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0073] The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto but only by the claims. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and the relative dimensions do not correspond to actual reductions to practice of the invention.
[0074] It is to be noticed that the term “comprising”, used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It is thus to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression “a device comprising means A and B” should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B.
[0075] FIG. 1 is a vertical cross-section of a first embodiment of a reinforcement element (1) according to the invention inserted in a composite pressure vessel (2). The reinforcement element (1) comprises a central part (10) and two external parts (11, 12) constituted by a plurality of continuous fibres (13) impregnated with a first resin. The fibres (13) are in one piece all along the surface in contact with the liner (20) and are parallel to the profile of the surface of the liner (20), the lengths of the fibres (13) at the extremities of the external parts (11, 12) being such that they permits to fill in the outer parts (2000) of the hollow shaft (200) that are flared and form a depression on the external surface of the plastic liner (20). The extremities of the external parts (11, 12) provided to be unfolded may preferably have a bevelled shape to maximize the contact with the liner (20). The reinforcement element (1) fills in a hollow shaft (200) of a plastic liner (20) of the composite pressure vessel (2), said hollow shaft (200) connecting opposite walls of the plastic liner (20). The central part (10) of the reinforcement element (1) has a dimension substantially equal to the dimension of the central part (2001) of the hollow shaft (200) and being a full part, the two external parts (11, 12) of the reinforcement element being able to be unfolded and fixed on the external surface of opposite walls of the plastic liner (20). The plastic liner (20) of the composite pressure vessel (2) comprises a fibre reinforced polymer shell (21) enclosing the plastic liner (1), said fibre reinforced polymer shell (21) being made of continuous fibre reinforced composite matrix (210), comprising reinforcing fibres (2100) and a second resin matrix. The reinforcement element (1) comprises inserts (14) at the two external parts (11, 12). Said inserts (14) are located at the centre of the unfolded external parts (11, 12). Preferably, the inserts (14) are selected from the group of metallic insert and chopped carbon fibres paste insert. Advantageously, the inserts are made out of a compatible material with the first resin of the reinforcement element and/or the second resin of the fibre reinforced polymer shell external composite.
[0076] FIG. 2 is a vertical cross-section of a second embodiment of a reinforcement element (1) according to the invention inserted in a composite pressure vessel (2). The reinforcement element (1) comprises a central part (10) and two external parts (11, 12) constituted by a plurality of continuous fibres (13) impregnated with a first resin. The fibres (13) are in one piece all along the surface in contact with the liner (20) and are parallel to the profile of the surface of the liner (20), the lengths of the fibres (13) at the extremities of the external parts (11, 12) being such that they permits to fill in the outer parts (2000) of the hollow shaft (200) that are flared and form a depression on the external surface of the plastic liner (20). The extremities of the external parts (11, 12) provided to be unfolded may preferably have a bevelled shape to maximize the contact with the liner (20). The reinforcement element (1) fills in a hollow shaft (200) of a plastic liner (20) of the composite pressure vessel (2), said hollow shaft (200) connecting opposite walls of the plastic liner (20). The central part (10) of the reinforcement element (1) has a dimension substantially equal to the dimension of the central part (2001) of the hollow shaft (200) and being a full part, the two external parts (11, 12) of the reinforcement element being able to be unfolded and fixed on the external surface of opposite walls of the plastic liner (20). The plastic liner (20) of the composite pressure vessel (2) comprises a fibre reinforced polymer shell (21) enclosing the plastic liner (1), said fibre reinforced polymer shell (21) being made of continuous fibre reinforced composite matrix (210), comprising reinforcing fibres (2100) and a second resin matrix. The reinforcement element (1) comprises inserts (14) at the two external parts (11, 12). Said inserts (14) are located at the centre of the unfolded external parts (11, 12). Preferably, the inserts (14) are selected from the group of metallic insert and chopped carbon fibres paste insert. Advantageously, the inserts are made out of a compatible material with the first resin of the reinforcement element and/or the second resin of the fibre reinforced polymer shell external composite. The reinforcement element (1) comprises a blocking means (15) located above the insert (14). Said blocking means is preferably a fibre disk impregnated with a third resin.
[0077] FIG. 3 is a partial vertical cross-section of a first embodiment of a composite pressure vessel (2) according to invention. The composite pressure vessel (2) comprises two reinforcement element (1) having a central part (10) and two external parts (11, 12) constituted by a plurality of continuous fibres (13) impregnated with a first resin. The fibres (13) are in one piece all along the surface in contact with the liner (20) and are parallel to the profile of the surface of the liner (20), the lengths of the fibres (13) at the extremities of the external parts (11, 12) being such that they permits to fill in the outer parts (2000) of the hollow shaft (200) that are flared and form a depression on the external surface of the plastic liner (20). The extremities of the external parts (11, 12) provided to be unfolded may preferably have a bevelled shape to maximize the contact with the liner (20). The reinforcement element (1) fills in a hollow shaft (200) of a plastic liner (20) of the composite pressure vessel (2), said hollow shaft (200) connecting opposite walls of the plastic liner (20). The central part (10) of the reinforcement element (1) has a dimension substantially equal to the dimension of the central part (2001) of the hollow shaft (200) and being a full part, the two external parts (11, 12) of the reinforcement element being able to be unfolded and fixed on the external surface of opposite walls of the plastic liner (20). The outer parts of the hollow shaft (200) are flared and form a depression on the external surface of the plastic liner (20). The plastic liner (20) of the composite pressure vessel (2) comprises a fibre reinforced polymer shell (21) enclosing the plastic liner (1), said fibre reinforced polymer shell (21) being made of continuous fibre reinforced composite matrix (210), comprising reinforcing fibres (2100) and a second resin matrix. The reinforcement element (1) comprises inserts (14) at the two external parts (11, 12). Said inserts (14) are located at the centre of the unfolded external parts (11, 12). Preferably, the inserts (14) are selected from the group of metallic insert and chopped carbon fibres paste insert. Advantageously, the inserts are made out of a compatible material with the first resin of the reinforcement element and/or the second resin of the fibre reinforced polymer shell external composite. The composite pressure vessel comprises an intermediate reinforcing means (16) located between the plastic liner (20) and the unfolded external parts (11, 12) of the reinforcement element (1). Advantageously, the intermediate reinforcing means is a resin-impregnated mat. The intermediate reinforcing means (16) may cover several hollow shafts in this case, the intermediate reinforcing means (16) is provided with openings allowing the insertion of the reinforcement elements (1) in the hollow shafts (200).
[0078] FIG. 4 is a view from the above showing the fixation step of the intermediate reinforcing means (16) on the first embodiment of a composite pressure vessel (2) according to the invention. The intermediate reinforcing means (16) comprises a plurality of openings (161). Each opening (161) of the intermediate reinforcing means is placed on the top of the opening end of the hollow shafts. A reinforcement element is inserted in each hollow shaft and the external parts (11,12) of the reinforcement element are unfolded. An insert (14) is inserted in the centre of the unfolded external parts (11, 12).
[0079] FIG. 5 illustrates the surface covered by an unfolded external part (11, 12).
[0080] FIG. 6 is a vertical cross-section of a second embodiment of a composite pressure vessel (2) according to invention. The composite pressure vessel (2) comprises two reinforcement element (1) having a central part (10) and two external parts (11, 12) constituted by a plurality of continuous fibres (13) impregnated with a first resin. The fibres (13) are in one piece all along the surface in contact with the liner (20) and are parallel to the profile of the surface of the liner (20), the lengths of the fibres (13) at the extremities of the external parts (11, 12) being such that they permits to fill in the outer parts (2000) of the hollow shaft (200) that are flared and form a depression on the external surface of the plastic liner (20). The extremities of the external parts (11, 12) provided to be unfolded may preferably have a bevelled shape to maximize the contact with the liner (20). The reinforcement element (1) fills in a hollow shaft (200) of a plastic liner (20) of the composite pressure vessel (2), said hollow shaft (200) connecting opposite walls of the plastic liner (20). The central part (10) of the reinforcement element (1) has a dimension substantially equal to the dimension of the central part (2001) of the hollow shaft (200) and being a full part, the two external parts (11, 12) of the reinforcement element being able to be unfolded and fixed on the external surface of opposite walls of the plastic liner (20). The outer parts of the hollow shaft (200) are flared and form a depression on the external surface of the plastic liner (20). The plastic liner (20) of the composite pressure vessel (2) comprises a fibre reinforced polymer shell (21) enclosing the plastic liner (1), said fibre reinforced polymer shell (21) being made of continuous fibre reinforced composite matrix (210), comprising reinforcing fibres and a second resin matrix. The reinforcement element (1) comprises inserts (14) at the two external parts (11, 12). Said inserts (14) are located at the centre of the unfolded external parts (11, 12). Preferably, the inserts (14) are selected from the group of metallic insert and chopped carbon fibres paste insert. Advantageously, the inserts are made out of a compatible material with the first resin of the reinforcement element and/or the second resin of the fibre reinforced polymer shell external composite. The continuous fibres (13) of the unfolded external parts (11, 12) of at least two adjacent reinforcement elements (1) are tangled.
[0081] FIG. 7 illustrate a composite pressure vessel (2) according to the invention comprising a gas input or output (17 located in a hollow shaft (200).
[0082] FIG. 8 is a vertical cross section illustrating the step of molding a plastic liner (20) having kiss-points (22) of the method of manufacturing a composite pressure vessel (2) according to the invention. The hollow shafts (200) comprise a central part (2001) and outer parts (2000) that are flared and form a depression on the external surface of the plastic liner (20). The kiss point (22) are still present.
[0083] FIG. 9 is a vertical cross section illustrating the step of forming hollow shafts (200) by cutting away the kiss-points (22) of the method of manufacturing a composite pressure vessel (2) according to the invention. The hollow shafts (200) obtained comprise a central part (2001) and outer parts (2000) that are flared and form a depression on the external surface of the plastic liner (20). The central part of the hollow shafts are preferably tubular.
[0084] FIG. 10 is a vertical cross section illustrating the step of inserting in the hollow shafts (200) a reinforcement element (1) comprising a central part (10) and at least two external parts (11, 12) constituted by a plurality of continuous fibres impregnated with a first resin of the method of manufacturing a composite pressure vessel (2) according to the invention.
[0085] FIG. 11 is a vertical cross section illustrating the steps of unfolding the external parts (11, 12) of the reinforcement element (1) and applying the external parts (11, 12) of the reinforcement element (1) to the external surface of the plastic liner (2) of the method of manufacturing a composite pressure vessel (2) according to the invention.
[0086] FIG. 12 is a vertical cross section illustrating the step of inserting an insert (14) between the unfolded external parts (11, 12) of the reinforcement element (1) of the method of manufacturing a composite pressure vessel (2) according to the invention.
[0087] FIG. 13 is a vertical cross section illustrating the step of winding a fibre reinforced polymer shell (21) enclosing the plastic liner (20) of the method of manufacturing a composite pressure vessel (2) according to the invention.
[0088] FIG. 14 a) and b) illustrate possible winding pattern of the fibre reinforced polymer shell (21) enclosing the plastic liner.
[0089] FIG. 15 is an illustration the possible location of the boss used as fixation point for the winding of the fibre reinforced polymer shell (21). Said fixation point being a one side boss (18) and a “blind” boss, i. e. a boss without opening, located on the opposite side of the composite pressure vessel.
[0090] FIG. 16 illustrates possible locations of the gas input or output (30, 31,32).
