DLR Modular Free-Shapeable CNG-Tank- A Hybrid Composite-Intensive Design

Kurzfassung

In the automotive industry, natural gas is currently stored as Compressed Natural Gas (CNG) in cylindrical high-pressure tanks. In order to increase the range of vehicles, a more efficient use of the available design space is needed. For this purpose the Institute of Vehicle Concepts at the German Aerospace Center (DLR) is developing an innovative, lightweight, composite-intensive design for a high-pressure tank: "The DLR Modular-Free-Shapeable CNG Tank". The new manufacturing process, combined with the tank concept, leads to a volume gain of up to 38 % compared to conventional CNG storage systems, based on the available space in the vehicle. However, a new winding process has to be developed for this tank. This paper shows the results of the polar winding of non-rotationally-symmetrical vessels, complexity of the domes and the first tool for the 3D-Winding-System. The German Aerospace Center Institute of Vehicle Concepts is working on the first automated produced prototypes that can be scaled to an industrial level so that a low-cost, shape adaptable CNG tank is possible. With this storage system, CNG vehicles can gain a larger range, further the environment and society will gain an added value because of lower emissions than petrol and diesel, while by using synthetic methane it is possible to reach an emission free mobility.