To develop sustainable mobility based on hydrogen and fuel cell technology, the availability of suitable vessel systems with pressure storage vessels up to 700 bar is essential. Type-4 pressure vessels made of continuous fibre-reinforced plastic, which are currently used for compressed gas storage, make it difficult to establish hydrogen and fuel cell technology in road transport due to the associated high costs for material and manufacturing as well as heavy component weights. Therefore, the aim of this project is to achieve a reduction in manufacturing costs and current component weight while maintaining safety-relevant aspects. It follows a comprehensive approach from fibre, laminate and liner to the winding process. Innovative, promising manufacturing processes and novel materials are characterised, evaluated and utilised in production. The practical viability of the developed pressure vessel is proven through safety tests.
In the ISATEC sub-project, the development of the liner is based on a comprehensive approach that takes into account the interaction between the main components of the vessel (wrapping, boss, liner, valve). The production process is defined in close cooperation with the liner manufacturer. Subsequently, suitable materials are selected for liner and boss. The liner-boss connection is designed and secured with FEM analyses of the entire vessel to detect important influences. Special attention is given to interaction with the valve interface. Technical manufacturing implementation from sub-scale vessel to full-scale vessel to optimised vessel is monitored closely. The results of adjacent work packages are factored into iterative optimisation. Drop test and temperature distribution in the context of cyclic filling with gas were identified as particularly critical based on the requirements. These effects are analysed in greater depth by means of our own CFD simulations.