High performance, thin metal lined, composite overwrapped pressure vessel

Abstract

An innovative technology for composite overwrapped pressure vessels (COPVs) has been developed which significantly increases cost effectiveness, increases reliability, and reduces weight over state-of-the-art COPVs. This technology combines an innovative thin liner made of a metal having a high modulus of elasticity and a high ductility, a high-performance composite overwrap and a high-performance film adhesive at the overwrap/liner interface. The metal liner can be fabricated from readily available titanium alloy sheet and plate using a combination of spin forming and machining to fabricate components and electron-beam welding for tank assembly. The composite overwrap is filament-wound onto an adhesive-covered titanium liner and the overwrap and adhesive are co-cured in an oven to yield an integrated tank structure.

What is claimed as invention is:  
     
       1. A method of manufacturing a composite overwrapped pressure vessel, comprising the following steps: 
       (a) using spin forming, making a liner having first and second dome portions and a cylindrical portion made of a metal having a tensile yield strengthened p.s.i./tensile modulus of elasticity in p.s.i.(F TY /E) of at least 0.6% and a ductility of at least 5%;  
       (b) forming first and second bosses made of the metal, the first boss being connected to the first dome portion and the second boss being connected to the second dome portion; and  
       (c) applying a composite overwrap over the liner, applying filaments of the overwrap onto the liner.  
     
     
       2. The method of  claim 1 , wherein the dome portions are heat treated to improve performance. 
     
     
       3. The method of  claim 1 , wherein the dome portions are Ti—6Al—4V and are heat treated by heating them to a temperature of between about 1300° F. and about 1700° F. for about 30-120 minutes, then cooling the dome portions to ambient temperature at a rate of not more than about 200° F. per minute. 
     
     
       4. The method of  claim 1 , wherein the dome portions are made of a titanium alloy and are spun at a temperature of between about 800° F. and about 1600° F. 
     
     
       5. The method of  claim 1 , wherein the metal is a titanium alloy from the group consisting of: Ti—6Al—2Sn—4Zr—2Mo, Ti—5Al—2.5Sn, Ti—5Al—2.5Sn ELI, Ti—6Al—2Cb—1Ta—0.8Mo, Ti—8Al—1Mo—1V, Ti—11Sn—5Zr—2Al—1Mo, Ti—6Al—4V, Ti—6Al—4V ELI, Ti—6V—2Sn, Ti—3Al—2.5V, Ti—6Al—2Sn—4Zr—6Mo, Ti—6Al—2Sn—2Zr—2Mo—2Cr—0.25Si, Ti—5Al—2Sn—2Zr—4Mo—4Cr, Ti—13V—11Cr—3Al, Ti—3Al—8V—6Cr—4Mo—4Zr, Ti—15V—3Al—3Cr—3Sn, and Ti—10V—2Fe—3Al. 
     
     
       6. The method of  claim 1 , wherein the liner is formed in at least two sections and is welded together. 
     
     
       7. The method of  claim 1 , wherein the welding steps are done with an electron beam weld process. 
     
     
       8. The method of  claim 1 , wherein the metal has a F TY /E of at least 0.7%. 
     
     
       9. The method of  claim 1 , wherein the metal has a ductility of at least 10%. 
     
     
       10. The method of  claim 1 , further comprising the step of: 
       applying an adhesive to the liner before applying the overwrap.  
     
     
       11. The method of  claim 10 , wherein the adhesive is a film adhesive. 
     
     
       12. The method of  claim 1 , further comprising the step of: 
       applying a protective coating over the overwrap.  
     
     
       13. The method of  claim 1 , wherein the composite overwrapped pressure vessel has a PV/W of at least 1.05 million inches. 
     
     
       14. The method of  claim 1 , wherein the composite overwrapped pressure vessel has a PV/W of at least 1.25 million inches. 
     
     
       15. The method of  claim 1 , wherein the composite overwrapped pressure vessel has a PV/W of at least 1.45 million inches. 
     
     
       16. The method of  claim 1 , wherein the liner of the composite overwrapped pressure vessel has a ratio of thickness in inches over diameter in inches of about 1.7×10 −3 . 
     
     
       17. The method of  claim 1 , wherein the liner of the composite overwrapped pressure vessel has a thickness of not more than 0.025″. 
     
     
       18. The method of  claim 1 , wherein the overwrap comprises a graphite/epoxy composite. 
     
     
       19. The method of  claim 1 , wherein the ratio of the length of the cylinder to the diameter of the cylinder is at least 1.00. 
     
     
       20. The method of  claim 1 , further comprising the steps of: 
       ( d )  heating the dome portions to a temperature of approximately  1 , 675 ° F. for approximately one hour;    
       ( e )  cooling said dome portions to a second temperature of approximately  1 , 400 ° F. for approximately one hour; and    
       ( f )  cooling the dome portions to ambient temperature at a rate of not more than approximately  200 ° F. per minute.   
     
     
       21. The method of  claim 1 , wherein the step of spin forming further comprises the step of spinning said dome portions at a temperature of approximately  1 , 400 ° F. 
     
     
       22. The method of  claim 6 , wherein the step of welding further comprises the step of pulsed electron beam welding. 
     
     
       23. The method of  claim 20  wherein said dome portions comprise a titanium alloy. 
     
     
       24. The method of  claim 23  wherein said titanium allow is Ti— 6 Al— 4 V. 
     
     
       25. The method of  claim 20 , wherein the metal for the dome portions is a titanium alloy selected from the group consisting of: Ti— 6 Al— 2 Sn— 4 Zr— 2 Mo, Ti— 5 Al— 2 . 5 Sn, Ti— 5 Al— 2 . 5 Sn ELI, Ti— 6 Al— 2 Cb— 1 Ta— 0 . 8 Mo, Ti— 8 Al— 1 Mo— 1 V, Ti— 11 Sn— 5 Zr— 2 Al— 1 Mo, Ti— 6 Al— 4 V, Ti— 6 Al— 4 V ELI, Ti— 6 V— 2 Sn, Ti— 3 Al— 2 . 5 V, Ti— 6 Al— 2 Sn— 4 Zr— 6 Mo, Ti— 6 Al— 2 Sn— 2 Zr— 2 Mo— 2 Cr— 0 . 25 Si, Ti— 5 Al— 2 Sn— 2 Zr— 4 Mo— 4 Cr, Ti— 13 V— 11 Cr— 3 Al, Ti— 3 Al— 8 V— 6 Cr— 4 Mo— 4 Zr, Ti— 15 V— 3 Al— 3 Cr— 3 Sn, and Ti— 10 V— 2 Fe— 3 Al. 
     
     
       26. A method of manufacturing a composite overwrapped pressure vessel, comprising the following steps: 
       ( a )  using spin forming, making a liner having first and second dome portions and a cylindrical portion made of a metal having a tensile yield strengthened p.s.i./tensile modulus of elasticity in p.s.i. ( F   TY   /E )  of at least  0 . 6   %  and a ductility of at least  5   % ;    
       ( b )  forming a boss made of the metal, the boss being connected to the first dome portion; and    
       ( c )  applying a composite overwrap over the liner, applying filaments of the overwrap onto the liner.   
     
     
       27. The method of  claim 26 , wherein the first and second dome portions are heat treated to improve performance. 
     
     
       28. The method of  claim 26 , wherein the first and second dome portions are Ti— 6 Al— 4 V and heat treated by heating them to a temperature of between about  1300 ° F. and about  1700 ° F. for about  30 - 120  minutes, then cooling them to ambient temperature at a rate of not more than about  200 ° F. per minute. 
     
     
       29. The method of  claim 26 , wherein the first and second dome portions are made of a titanium alloy and spun at a temperature of between about  800 ° F. and about  1600 ° F. 
     
     
       30. The method of  claim 26 , wherein the metal is a titanium alloy selected from the group consisting of: Ti— 6 Al— 2 Sn— 4 Zr— 2 Mo, Ti— 5 Al— 2 . 5 Sn, Ti— 5 Al— 2 . 5 Sn ELI, Ti— 6 Al— 2 Cb— 1 Ta— 0 . 8 Mo, Ti— 8 Al— 1 Mo— 1 V, Ti— 11 Sn— 5 Zr— 2 Al— 1 Mo, Ti— 6 Al— 4 V, Ti— 6 Al— 4 V ELI, Ti— 6 V— 2 Sn, Ti— 3 Al— 2 . 5 V, Ti— 6 Al— 2 Sn— 4 Zr— 6 Mo, Ti— 6 Al— 2 Sn— 2 Zr— 2 Mo— 2 Cr— 0 . 25 Si, Ti— 5 Al— 2 Sn— 2 Zr— 4 Mo— 4 Cr, Ti— 13 V— 11 Cr— 3 Al, Ti— 3 Al— 8 V— 6 Cr— 4 Mo— 4 Zr, Ti— 15 V— 3 Al— 3 Cr— 3 Sn, and Ti— 10 V— 2 Fe— 3 Al. 
     
     
       31. The method of  claim 26 , wherein the liner is formed in at least two sections and is welded together. 
     
     
       32. The method of  claim 31 , wherein the welding steps are done with an electron beam weld process. 
     
     
       33. The method of  claim 26 , wherein the metal has a F TY   /E of at least  0 . 7   % .   
     
     
       34. The method of  claim 26 , wherein the metal has a ductility of at least  10 % .   
     
     
       35. The method of  claim 26 , further comprising the step of applying an adhesive to the liner before applying the overwrap. 
     
     
       36. The method of  claim 35 , wherein the adhesive is a film adhesive. 
     
     
       37. The method of  claim 26 , further comprising the step of applying a protective coating over the overwrap. 
     
     
       38. The method of  claim 26 , wherein the composite overwrapped pressure vessel has a PV/W of at least  1 . 05  million inches. 
     
     
       39. The method of  claim 26 , wherein the composite overwrapped pressure vessel has a PV/W of at least  1 . 25  million inches. 
     
     
       40. The method of  claim 26 , wherein the composite overwrapped pressure vessel has a PV/W of at least  1 . 45  million inches. 
     
     
       41. The method of  claim 26 , wherein the liner of the composite overwrapped pressure vessel has a ratio of thickness in inches over diameter in inches of about  1 . 7 × 10   −3   .   
     
     
       42. The method of  claim 26 , wherein the liner of the composite overwrapped pressure vessel has a thickness of not more than  0 . 025 ″. 
     
     
       43. The method of  claim 26 , wherein the overwrap comprises a graphite/epoxy composite. 
     
     
       44. The method of  claim 26 , wherein the ratio of the length of the cylinder to the diameter of the cylinder is at least  1 . 00 . 
     
     
       45. The method of  claim 26 , further comprising the steps of: 
       ( d )  heating the first and second dome portions to a temperature of about  1 , 675 ° F. for about one hour;    
       ( e )  cooling the first and second dome portions to a second temperature of about  1 , 400 ° F. for about one hour; and    
       ( f )  cooling the first and second dome portions to ambient temperature at a rate of less than about  200 ° F. per minute.   
     
     
       46. The method of  claim 26 , wherein the step of spin forming further comprises the step of spinning the first and second domes portions at a temperature of about  1 , 400 ° F. 
     
     
       47. The method of  claim 31 , wherein the welding steps are done with a pulsed electron beam welding. 
     
     
       48. The method of  claim 45 , wherein the metal for the first and second dome portions is a titanium alloy selected from the group consisting of: Ti— 6 Al— 2 Sn— 4 Zr— 2 Mo, Ti— 5 Al— 2 . 5 Sn, Ti— 5 Al— 2 . 5 Sn ELI, Ti— 6 Al— 2 Cb— 1 Ta— 0 . 8 Mo, Ti— 8 Al— 1 Mo— 1 V, Ti— 11 Sn— 5 Zr— 2 Al— 1 Mo, Ti— 6 Al— 4 V, Ti— 6 Al— 4 V ELI, Ti— 6 V— 2 Sn, Ti— 3 Al— 2 . 5 V, Ti— 6 Al— 2 Sn— 4 Zr— 6 Mo, Ti— 6 Al— 2 Sn— 2 Zr— 2 Mo— 2 Cr— 0 . 25 Si, Ti— 5 Al— 2 Sn— 2 Zr— 4 Mo— 4 Cr, Ti— 13 V— 11 Cr— 3 Al, Ti— 3 Al— 8 V— 6 Cr— 4 Mo— 4 Zr, Ti— 15 V— 3 Al— 3 Cr— 3 Sn, and Ti— 10 V— 2 Fe— 3 Al.