WO2009082189A2 - Compressed natural gas composite tank for vehicles - Google Patents

Compressed natural gas composite tank for vehicles Download PDF

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Publication number
WO2009082189A2
WO2009082189A2 PCT/MY2008/000194 MY2008000194W WO2009082189A2 WO 2009082189 A2 WO2009082189 A2 WO 2009082189A2 MY 2008000194 W MY2008000194 W MY 2008000194W WO 2009082189 A2 WO2009082189 A2 WO 2009082189A2
Authority
WO
WIPO (PCT)
Prior art keywords
tank
composite
liner
carbon fiber
reinforced
Prior art date
Application number
PCT/MY2008/000194
Other languages
French (fr)
Other versions
WO2009082189A3 (en
Inventor
Fakhru'l-Razi Ahmadun
Mohamad Amran Mohd Salleh
Elsadiq Mahdi Ahmed Saad
Original Assignee
Universiti Putra Malaysia
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Universiti Putra Malaysia filed Critical Universiti Putra Malaysia
Publication of WO2009082189A2 publication Critical patent/WO2009082189A2/en
Publication of WO2009082189A3 publication Critical patent/WO2009082189A3/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C1/00—Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge
    • F17C1/02—Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge involving reinforcing arrangements
    • F17C1/04—Protecting sheathings
    • F17C1/06—Protecting sheathings built-up from wound-on bands or filamentary material, e.g. wires
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2201/00—Vessel construction, in particular geometry, arrangement or size
    • F17C2201/01—Shape
    • F17C2201/0104—Shape cylindrical
    • F17C2201/0109—Shape cylindrical with exteriorly curved end-piece
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2201/00—Vessel construction, in particular geometry, arrangement or size
    • F17C2201/05—Size
    • F17C2201/056—Small (<1 m3)
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2203/00—Vessel construction, in particular walls or details thereof
    • F17C2203/06—Materials for walls or layers thereof; Properties or structures of walls or their materials
    • F17C2203/0602—Wall structures; Special features thereof
    • F17C2203/0604—Liners
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2203/00—Vessel construction, in particular walls or details thereof
    • F17C2203/06—Materials for walls or layers thereof; Properties or structures of walls or their materials
    • F17C2203/0602—Wall structures; Special features thereof
    • F17C2203/0612—Wall structures
    • F17C2203/0614—Single wall
    • F17C2203/0619—Single wall with two layers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2203/00—Vessel construction, in particular walls or details thereof
    • F17C2203/06—Materials for walls or layers thereof; Properties or structures of walls or their materials
    • F17C2203/0634—Materials for walls or layers thereof
    • F17C2203/0636—Metals
    • F17C2203/0646—Aluminium
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2203/00—Vessel construction, in particular walls or details thereof
    • F17C2203/06—Materials for walls or layers thereof; Properties or structures of walls or their materials
    • F17C2203/0634—Materials for walls or layers thereof
    • F17C2203/0636—Metals
    • F17C2203/0648—Alloys or compositions of metals
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2203/00—Vessel construction, in particular walls or details thereof
    • F17C2203/06—Materials for walls or layers thereof; Properties or structures of walls or their materials
    • F17C2203/0634—Materials for walls or layers thereof
    • F17C2203/0658—Synthetics
    • F17C2203/0663—Synthetics in form of fibers or filaments
    • F17C2203/0665—Synthetics in form of fibers or filaments radially wound
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2203/00—Vessel construction, in particular walls or details thereof
    • F17C2203/06—Materials for walls or layers thereof; Properties or structures of walls or their materials
    • F17C2203/0634—Materials for walls or layers thereof
    • F17C2203/0658—Synthetics
    • F17C2203/0663—Synthetics in form of fibers or filaments
    • F17C2203/0673—Polymers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2205/00—Vessel construction, in particular mounting arrangements, attachments or identifications means
    • F17C2205/03—Fluid connections, filters, valves, closure means or other attachments
    • F17C2205/0302—Fittings, valves, filters, or components in connection with the gas storage device
    • F17C2205/0323—Valves
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2205/00—Vessel construction, in particular mounting arrangements, attachments or identifications means
    • F17C2205/03—Fluid connections, filters, valves, closure means or other attachments
    • F17C2205/0388—Arrangement of valves, regulators, filters
    • F17C2205/0394—Arrangement of valves, regulators, filters in direct contact with the pressure vessel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2221/00—Handled fluid, in particular type of fluid
    • F17C2221/03—Mixtures
    • F17C2221/032—Hydrocarbons
    • F17C2221/033—Methane, e.g. natural gas, CNG, LNG, GNL, GNC, PLNG
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2223/00—Handled fluid before transfer, i.e. state of fluid when stored in the vessel or before transfer from the vessel
    • F17C2223/01—Handled fluid before transfer, i.e. state of fluid when stored in the vessel or before transfer from the vessel characterised by the phase
    • F17C2223/0107—Single phase
    • F17C2223/0123—Single phase gaseous, e.g. CNG, GNC
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2223/00—Handled fluid before transfer, i.e. state of fluid when stored in the vessel or before transfer from the vessel
    • F17C2223/03—Handled fluid before transfer, i.e. state of fluid when stored in the vessel or before transfer from the vessel characterised by the pressure level
    • F17C2223/036—Very high pressure (>80 bar)
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2260/00—Purposes of gas storage and gas handling
    • F17C2260/01—Improving mechanical properties or manufacturing
    • F17C2260/011—Improving strength
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2260/00—Purposes of gas storage and gas handling
    • F17C2260/01—Improving mechanical properties or manufacturing
    • F17C2260/012—Reducing weight
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2260/00—Purposes of gas storage and gas handling
    • F17C2260/01—Improving mechanical properties or manufacturing
    • F17C2260/018—Adapting dimensions
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F17—STORING OR DISTRIBUTING GASES OR LIQUIDS
    • F17C—VESSELS FOR CONTAINING OR STORING COMPRESSED, LIQUEFIED OR SOLIDIFIED GASES; FIXED-CAPACITY GAS-HOLDERS; FILLING VESSELS WITH, OR DISCHARGING FROM VESSELS, COMPRESSED, LIQUEFIED, OR SOLIDIFIED GASES
    • F17C2270/00—Applications
    • F17C2270/01—Applications for fluid transport or storage
    • F17C2270/0165—Applications for fluid transport or storage on the road
    • F17C2270/0168—Applications for fluid transport or storage on the road by vehicles

Definitions

  • the present invention relates generally to vehicle fuel tanks. More particularly, the present invention relates to a reinforced compressed natural gas (CNG) composite tank for vehicles.
  • CNG compressed natural gas
  • CNG Compressed natural gas
  • a typical pressure vessel is used for storing the compressed natural gas, particularly a cylindrical bottle with spherical ends or a completely spherical bottle.
  • the cylinder and spherical form are advantageous for tension loading of the walls.
  • Pressure vessels of this nature have been well developed and are regulated by various standards such as ASME, British Standard, and CSA (Canadian Standard Association). Flat surfaces, on the other hand, may bend and increase tension, requiring greater thickness.
  • wall thickness of the pressure vessel is in square proportion to the vessel diameter. This means a heavy storage bottle is needed to hold significant amount of gas. However, heavy storage bottles are not convenient for vehicles and reduced weight tanks are preferred.
  • a number of small pressure vessels are connected in a battery to achieve the desired driving range.
  • the battery is dimensionally larger than the usual vehicle gasoline tank and thus cannot be located in the same place as the usual vehicle gasoline tank.
  • the battery of tanks has to be placed on the bed of a truck or in a trunk, taking up cargo space. Also, locating the battery of tanks in those places will subject them to accidental damage because of the connections between the composite bottles.
  • the present invention is directed to overcoming one or more of the problems set forth above. Briefly summarized, the present invention relates to a reinforced compressed natural gas (CNG) composite tank and a method of making the same for direct injection in vehicle systems at high pressure.
  • CNG compressed natural gas
  • the method of making a reinforced CNG composite tank having a desired tank configuration with a cylindrical protuberance on one end of the tank and bossless dome section on the other end comprises:
  • the primary advantage of the CNG composite tank of the present invention is a weight reduction of the composite tank over thick metal lined tanks.
  • the choice of aluminum is dedicated due to its high strength to density ratio, low modulus, outstanding toughness and environmental compatibility.
  • Another advantage of the invention is the provision of CNG composite tank for maintaining large volumes of natural gas at high pressure levels. Due to the lower weight of the composite, fuel efficiency of a CNG vehicle can be improved. Driving range of the CNG vehicle and load-carrying capacity can also be improved.
  • a further advantage of the invention is the provision of CNG composite tank for a lower cost per unit strength compared to currently available systems such as steel tank.
  • Typical thickness of steel tank with the same strength as the composite tank is 2 cm. This result in the steel tank weighting approximately 10 times the composite tank.
  • Fig. 1 illustrates a longitudinal view of a reinforced compressed natural gas (CNG) composite tank according to the present invention
  • Fig. 2 illustrates a cross section view of a reinforced CNG composite tank according to the present invention.
  • a liner 201 for a reinforced compressed natural gas (CNG) composite tank having a desired configuration with a cylindrical protuberance 205 at one end of the tank which provides access to inside the liner 201 and bossless dome section 206 at the other end of the tank.
  • the liner 201 is preferably made of a single layer of metal aluminum with a thickness of 2.5 mm.
  • the liner 201 is overlayered by composite layer 202 with a thickness of 4 mm that consists of 18 layers of carbon fiber immersed in epoxy resin.
  • the other end of the reinforced composite tank is a bossless dome surface 206 having the same liner 201 thickness as the main body.
  • the size of the composite tank may vary as desired depending on the particular application and demand.
  • the reinfoced composite tank is made as a pressure tank in particular for storing CNG at a pressure of less than or equal to 200 bar.
  • Fig. 2 shows the composite layer 202 on top of the liner wall 201.
  • the ratio of the composite layer 202 thickness to the liner 201 thickness is between 1 and 2 depending on the area of the liner 201.
  • the composite layer 202 at the dome section at both ends 205, 206 is thicker than in the main body.
  • the weight ratio of the composite to the liner 201 is approximately 2:1.
  • the overlayered liner 201 with a layer of carbon fiber 203 at the dome surface is further wetted with an epoxy resin before overwrapping the liner 201 by winding process. Further, the dome layer 203 is layered by low angle winding 204. The carbon fiber layer 203 at the dome can also be cured first before the liner 201 is ready for winding. Carbon fiber cloth 203 is either made of pre- preg carbon fiber (pre-impregnated composite fibres) or woven carbon fiber. The main purpose of this layer is to give added thickness and strength to the thin section of the liner 201 which will not be overwrapped by the subsequent winding process.
  • the liner 201 is overwrapped with a tow of carbon fibers 203 wetted with an epoxy resin.
  • the epoxy resin is cured to form layers of carbon fibers 203 embedded in cured resin matrix.
  • Three winding methods that are used are low angle winding 204 which ranges from 15 to 20, medium degree winding which ranges from 40 to 45 degree and hoop winding pattern.
  • the overall winding process starts with hoop pattern, medium angle, low angle 204, medium angle and finishes with hoop pass again.
  • the numbers of passes used in the process are 100 to 120 for low angle 204, 90 to 100 for medium angle and 4 hoop passes.
  • One pass is defined as a wrapping movement from one end to the other end of the liner and come to the original position.
  • the curing process is done using a mobile oven which utilizes hot circulating air as the heating technique. After the winding process, the tow of carbon fiber line is cut off from the still rotating liner. A mobile oven is slid to encapsulate the wrapped liner while the liner 201 is rotating. The rotation is to keep the epoxy uniformly distributed on the composite tank surface for good finish.
  • the curing consists of two stage processes where the first process lasting for 2 to 4 hours at 80 ° C and the second lasting for 6 to 8 hours at 140 ° C. After the curing, the mobile oven is shut off and the composite tank slowly is cooled to room temperature.
  • the composite tank can withstand more than 500 bar pressure hydrotest
  • the composite tank is completely filled with water.
  • the inlet of the tank is connected to a high-pressure valve and positioned in a specially build holder.
  • the tank is then connected to a hydrotest machine via a high-pressure flexible tube.
  • the hydrotest machine, tubing and connectors can withstand more than 1000 bar pressure.
  • testing water is pumped slowly into the reinforced tank from the hydrotest machine at slightly above atmospheric pressure.
  • the air from the tube and some remaining air from the tank is allowed to exit the system from a small opening at the valve connecting the tube and tank. Once it is satisfied that air is not present in the tube and the tank, the opening is closed tightly.
  • the tank is then slowly pressurized at the rate of 2 bar/second until the tank bursts. The tank cracksand water leaks out before bursting take place.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Filling Or Discharging Of Gas Storage Vessels (AREA)

Abstract

The present invention relates to a reinforced compressed natural gas (CNG) composite tank and a method of making the same for direct injection in vehicle systems at high pressure wherein the method of making a reinforced CNG composite tank having a desired tank configuration with a cylindrical protuberance on one end of the tank and bossless dome section on the other end, comprises: (a) layering the middle of the dome section of the back end of the liner with layers of carbon fibers; (b) overlayering the liner with a tow of carbon fibers in epoxy resin by winding process; and (c) heating the composite layer of the composite tank by curing process in a mobile oven. The composite tank provided is constructed from aluminum alloy material based liner reinforced with carbon fiber/epoxy composite.

Description

COMPRESSED NATURAL GAS COMPOSITE TANK FOR VEHICLES
The present invention relates generally to vehicle fuel tanks. More particularly, the present invention relates to a reinforced compressed natural gas (CNG) composite tank for vehicles.
BACKGROUND TO THE INVENTION
Compressed natural gas (CNG) composite tank is used in operating motor vehicles industry as well as other industries as it has many advantages. However, it has drawbacks as well. One of the drawbacks is finding an effective method to store adequate amount of CNG on the vehicle which is normally 3600 psi or higher.
A typical pressure vessel is used for storing the compressed natural gas, particularly a cylindrical bottle with spherical ends or a completely spherical bottle. The cylinder and spherical form are advantageous for tension loading of the walls. Pressure vessels of this nature have been well developed and are regulated by various standards such as ASME, British Standard, and CSA (Canadian Standard Association). Flat surfaces, on the other hand, may bend and increase tension, requiring greater thickness.
Normally, wall thickness of the pressure vessel is in square proportion to the vessel diameter. This means a heavy storage bottle is needed to hold significant amount of gas. However, heavy storage bottles are not convenient for vehicles and reduced weight tanks are preferred.
One approach to reduce the weight of tanks for vehicles is to connect a battery of small diameter vessels. The vessels can be made from light weight metals, composite metals, or combination of both. However, composite vessels are expensive and the exterior connections between the vessels are prone to leaks and damages. Another drawback for use in vehicles is the space requirement. A number of small pressure vessels are connected in a battery to achieve the desired driving range. The battery is dimensionally larger than the usual vehicle gasoline tank and thus cannot be located in the same place as the usual vehicle gasoline tank. Typically the battery of tanks has to be placed on the bed of a truck or in a trunk, taking up cargo space. Also, locating the battery of tanks in those places will subject them to accidental damage because of the connections between the composite bottles.
SUMMARY OF THE INVENTION
The present invention is directed to overcoming one or more of the problems set forth above. Briefly summarized, the present invention relates to a reinforced compressed natural gas (CNG) composite tank and a method of making the same for direct injection in vehicle systems at high pressure.
Accordingly, the method of making a reinforced CNG composite tank having a desired tank configuration with a cylindrical protuberance on one end of the tank and bossless dome section on the other end, comprises:
overlayering the middle of the dome section of the back end of the liner with layers of composite fibers;
overlayering the liner with a tow of carbon fibers in epoxy resin by winding process; and
heating the composite layer of the composite tank by curing process in a mobile oven.
The primary advantage of the CNG composite tank of the present invention is a weight reduction of the composite tank over thick metal lined tanks. The choice of aluminum is dedicated due to its high strength to density ratio, low modulus, outstanding toughness and environmental compatibility. Another advantage of the invention is the provision of CNG composite tank for maintaining large volumes of natural gas at high pressure levels. Due to the lower weight of the composite, fuel efficiency of a CNG vehicle can be improved. Driving range of the CNG vehicle and load-carrying capacity can also be improved.
A further advantage of the invention is the provision of CNG composite tank for a lower cost per unit strength compared to currently available systems such as steel tank. Typical thickness of steel tank with the same strength as the composite tank is 2 cm. This result in the steel tank weighting approximately 10 times the composite tank.
These and other aspects, objects, features and advantages of the present invention will be more clearly understood and appreciated from a review of the following detailed description of the preferred embodiment and appended claims, and by reference to the accompanying drawings.
BRiEF DESCRIPTION OF THE DRAWING
The specific features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings, in which:
Fig. 1 illustrates a longitudinal view of a reinforced compressed natural gas (CNG) composite tank according to the present invention; and
Fig. 2 illustrates a cross section view of a reinforced CNG composite tank according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following description of the preferred embodiments of the present invention, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
Referring to Fig. 1 , there is shown a liner 201 for a reinforced compressed natural gas (CNG) composite tank having a desired configuration with a cylindrical protuberance 205 at one end of the tank which provides access to inside the liner 201 and bossless dome section 206 at the other end of the tank. The liner 201 is preferably made of a single layer of metal aluminum with a thickness of 2.5 mm.
The liner 201 is overlayered by composite layer 202 with a thickness of 4 mm that consists of 18 layers of carbon fiber immersed in epoxy resin. The other end of the reinforced composite tank is a bossless dome surface 206 having the same liner 201 thickness as the main body.
The size of the composite tank may vary as desired depending on the particular application and demand. The reinfoced composite tank is made as a pressure tank in particular for storing CNG at a pressure of less than or equal to 200 bar.
Fig. 2 shows the composite layer 202 on top of the liner wall 201. The ratio of the composite layer 202 thickness to the liner 201 thickness is between 1 and 2 depending on the area of the liner 201. The composite layer 202 at the dome section at both ends 205, 206 is thicker than in the main body. The weight ratio of the composite to the liner 201 is approximately 2:1.
The overlayered liner 201 with a layer of carbon fiber 203 at the dome surface is further wetted with an epoxy resin before overwrapping the liner 201 by winding process. Further, the dome layer 203 is layered by low angle winding 204. The carbon fiber layer 203 at the dome can also be cured first before the liner 201 is ready for winding. Carbon fiber cloth 203 is either made of pre- preg carbon fiber (pre-impregnated composite fibres) or woven carbon fiber. The main purpose of this layer is to give added thickness and strength to the thin section of the liner 201 which will not be overwrapped by the subsequent winding process.
After the layers of carbon cloth 203 is applied to the dome section, the liner 201 is overwrapped with a tow of carbon fibers 203 wetted with an epoxy resin. The epoxy resin is cured to form layers of carbon fibers 203 embedded in cured resin matrix. Three winding methods that are used are low angle winding 204 which ranges from 15 to 20, medium degree winding which ranges from 40 to 45 degree and hoop winding pattern.
The overall winding process starts with hoop pattern, medium angle, low angle 204, medium angle and finishes with hoop pass again. The numbers of passes used in the process are 100 to 120 for low angle 204, 90 to 100 for medium angle and 4 hoop passes. One pass is defined as a wrapping movement from one end to the other end of the liner and come to the original position.
The curing process is done using a mobile oven which utilizes hot circulating air as the heating technique. After the winding process, the tow of carbon fiber line is cut off from the still rotating liner. A mobile oven is slid to encapsulate the wrapped liner while the liner 201 is rotating. The rotation is to keep the epoxy uniformly distributed on the composite tank surface for good finish. The curing consists of two stage processes where the first process lasting for 2 to 4 hours at 80°C and the second lasting for 6 to 8 hours at 140° C. After the curing, the mobile oven is shut off and the composite tank slowly is cooled to room temperature.
EXAMPLE
The present invention will now be described in further details by way of an example, which should not be construed as limiting the invention. To demonstrate that the composite tank can withstand more than 500 bar pressure hydrotest, the composite tank is completely filled with water. The inlet of the tank is connected to a high-pressure valve and positioned in a specially build holder. Then the tank is then connected to a hydrotest machine via a high-pressure flexible tube. Normally the hydrotest machine, tubing and connectors can withstand more than 1000 bar pressure.
Further, the testing water is pumped slowly into the reinforced tank from the hydrotest machine at slightly above atmospheric pressure. The air from the tube and some remaining air from the tank is allowed to exit the system from a small opening at the valve connecting the tube and tank. Once it is satisfied that air is not present in the tube and the tank, the opening is closed tightly. The tank is then slowly pressurized at the rate of 2 bar/second until the tank bursts. The tank cracksand water leaks out before bursting take place.

Claims

1. A method of making a reinforced compressed natural gas (CNG) composite tank for direct injection vehicle systems at high pressure having a cylindrical protuberance at one end (205) of the tank and a bossless dome section (206) at the other end of the tank, comprising:
overlayering liner (201) with composite layer (202) consisting of layers of carbon fibers (203);
overlayering a middle portion of the dome section (206) of the back end of the liner (201 ) with layers of carbon fiber (203);
overwrapping the liner (201) with a tow of carbon fibers (203) immersed in epoxy resin by winding process; and
heating the composite layer (202) by curing process.
2. A method according to claim 1 , wherein the winding process consists of low angle winding (204), medium angle winding and hoop angle winding.
3. A method according to claim 1 , wherein the layer of carbon fiber (203) can be cured before or after the winding process.
4. A reinforced composite tank for direct injection vehicle systems at high pressure having a cylindrical protuberance on one end (205) of the tank and bossless dome section (206) on the other end, comprising:
liner (201); and
composite layer (202) consisting of carbon fiber layers immersed in epoxy resin.
5. A reinforced composite tank according to claim 4, wherein the liner (201) is made from a single layer of metal aluminum.
6. A reinforced composite tank according to claim 4, wherein the carbon fiber cloth (203) is made of a woven carbon fiber or pre-preg carbon fiber.
PCT/MY2008/000194 2007-12-21 2008-12-22 Compressed natural gas composite tank for vehicles WO2009082189A2 (en)

Applications Claiming Priority (2)

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MYPI20072293 2007-12-21
MYPI20072293 2007-12-21

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101900246A (en) * 2010-07-28 2010-12-01 国营江北机械厂 Solidification method of fiber-wound gas cylinder
CN102529695A (en) * 2012-03-05 2012-07-04 苏州奥杰汽车工业有限公司 Aluminum alloy fuel tank

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2005291415A (en) * 2004-04-01 2005-10-20 Honda Motor Co Ltd Pressure vessel and its manufacturing method
US20060163261A1 (en) * 2003-08-28 2006-07-27 Mitsubishi Rayon Co., Ltd. High-performance pressure vessel and carbon fiber for pressure vessel

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060163261A1 (en) * 2003-08-28 2006-07-27 Mitsubishi Rayon Co., Ltd. High-performance pressure vessel and carbon fiber for pressure vessel
JP2005291415A (en) * 2004-04-01 2005-10-20 Honda Motor Co Ltd Pressure vessel and its manufacturing method

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101900246A (en) * 2010-07-28 2010-12-01 国营江北机械厂 Solidification method of fiber-wound gas cylinder
CN102529695A (en) * 2012-03-05 2012-07-04 苏州奥杰汽车工业有限公司 Aluminum alloy fuel tank

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