Title: Enabling Superior Storage Efficiency for Composite Tanks with FPP Dome Reinforcements

Authors: Dr. Florian Lenz, Dr. Dimitrios Sikoutris

DOI: 10.33599/nasampe/c.22.0016

Abstract: On the way to emission neutrality and decarbonization of the transportation sector, hydrogen plays a major role. Electrification of powertrains, along with limitations in battery technology, gives rise to hydrogen-powered, fuel cell electric vehicles (FCEV), in particular for long-haul transport like trucks, buses and trains. However, one of the challenges for FCEV is to efficiently and safely store hydrogen in the vehicle. H2 is typically stored in type 4 pressure vessels, which have a very high consumption of carbon fiber material due to their high working pressure (up to 700 bar). This negatively influences the production costs of hydrogen tanks, with carbon fibers representing over 50 % of the total costs.
To decrease the material consumption, Cevotec developed an industrial automation solution to reinforce the domes of pressure vessels, using Fiber Patch Placement (FPP) technology. The reinforcements are placed directly on the liner by a robotic FPP system. They substitute the high-angle helical layers (HAHL), traditionally applied by a filament winding (FW) process. However, unlike the HAHL, the patches don’t span across the cylindrical portion of the vessel, where they would contribute only marginally to the mechanical performance. This translates into a considerable saving of material, depending on the aspect ratio of a vessel.
The patches are applied in an independent process, parallel to the FW, which reduces the overall cycle time by up to 20 %. While achieving equivalent mechanical properties, the dome reinforcement solution reduces net material consumption by 15 % and amortizes already in the first 10-20 months of series production.
To underpin the presented approach, an optimized, full-scale demonstrator was developed and tested in a joint project with industry partners. The goal was to optimize the fiber lay-up, also by simulation, in order to minimize cycle time and cost, ensure required mechanical properties and subsequently evaluate the impact of FPP dome reinforcement in an industrial production setting. The project comprised the laminate design, simulation and optimization, as well as the production and comprehensive testing of the reinforced type 4 pressure vessels. The results will be presented in this paper.

References: [1] Estin & Co. and JEC Group, JEC Observer: Current trends in the global composite industry 2021 – 2026. Paris, 2022. [2] S. McWorther, G. Ordaz, Department of Energy USA, Onboard Type IV Compressed Hydrogen Storage Systems. in DOE Fuel Cell Technologies Office Record, 2013. [3] S. McWorther, G. Ordaz, Department of Energy USA, Onboard Type IV Compressed Hydrogen Storage Systems. in DOE Fuel Cell Technologies Office Record, 2015.

Conference: CAMX 2022

Publication Date: 2022/10/17

SKU: TP22-0000000016

Pages: 11

Price: $22.00