Hydrogen fuel tank. Part 1: Structure of the tank

The structure of a hydrogen fuel tank is critical to ensuring safe and efficient storage of hydrogen gas, particularly in fuel cell vehicles (FCVs) and other hydrogen-powered applications. These tanks are designed to store hydrogen gas at high pressures (usually up to 700 bar or about 10,000 psi) and maintain integrity under extreme conditions. Here's an overview of the layer-by-layer structure of a typical #composite hydrogen fuel tank:

1. Inner Liner (Polymer Layer)

• Material: This is typically made of high-density polyethylene (HDPE), polyamide, or other specialized polymers.
• Purpose: The inner liner forms the primary barrier against hydrogen permeation, preventing the hydrogen gas from escaping. It ensures that the tank retains its gas under high-pressure conditions. The inner liner must have low permeability to hydrogen to avoid gas leakage over time.
• Properties: The polymer layer is flexible and must be capable of withstanding high pressure and thermal cycling without cracking or degrading.

2. Resin Matrix (Thermoset Polymer Layer)

• Material: This layer often consists of thermoset resins, such as epoxy or vinyl ester resins, which are used to bond the composite fibers (typically carbon fiber or glass fiber) in the next layer.
• Purpose: The resin matrix provides additional strength and impact resistance while holding the reinforcement fibers in place. It helps in distributing the load and preventing the fibers from shifting under high-pressure conditions.
• Properties: The resin also contributes to the chemical resistance of the tank, protecting it against external elements like UV rays and weathering.

3. Composite Reinforcement Layer (Carbon Fiber or Glass Fiber)

• Material: This is the main structural layer and is typically made of carbon fibers, but glass fibers can also be used in certain designs.
• Purpose: The composite layer provides the strength and stiffness needed to handle the high-pressure storage of hydrogen. Carbon fiber is particularly beneficial because of its high strength-to-weight ratio, lightweight nature, and durability under stress.
• Properties: This layer is designed to be the load-bearing component, enabling the tank to withstand the pressures and stresses experienced during filling, storage, and transportation. The woven fabric of fibers helps distribute stress across the tank's surface, preventing localized failure.

4. Protective Layer (External Layer)

• Material: The outermost layer is typically made of a protective polymer coating, often polyurethane, or a UV-resistant resin.
• Purpose: This layer provides abrasion resistance, chemical resistance, and UV protection. It acts as a protective barrier against environmental damage, including sunlight, moisture, and chemical exposure.
• Properties: The outer protective layer ensures that the tank does not degrade due to weathering or exposure to harsh chemicals while maintaining the integrity of the tank for long-term use.

5. Additional Layer: Carbon Coating (Optional)

• Material: Carbon coatings may be applied as an additional layer, especially in tanks designed for longer storage times or in systems where hydrogen permeation is a critical concern.
• Purpose: Carbon coatings are used to improve hydrogen barrier properties by reducing the rate at which hydrogen gas permeates through the polymer liner. It enhances the tank’s overall impermeability, further improving the tank’s efficiency and safety.
• Properties: These coatings are typically thin, but they improve the long-term performance and safety of the tank, especially when dealing with high-pressure hydrogen storage.

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