Patent Description:
Conformal aircraft potable water systems supply drinkable water throughout an aircraft for various uses. Aircraft potable water systems typically include many parts, including but not limited to: fluid vessels, hydraulic pumps, fluid heaters, control valves, and hydraulic fluid line tubing. The fluid vessels used for aircraft potable water vessels are generally pressurized and must maintain their shape while under internal pressure. The preferred shape for high-pressure fluid vessels is a cylindrical or spherical shape because there are few corners, reducing the number of stress concentration locations.

High-pressure fluid vessels for aircraft potable water systems should fit into a limited space, shape, and size. In some application, the shape may significantly deviate from the cylindrical or spherical shape preferred by pressurized vessels. Further, as with any other aircraft components, the high-pressure fluid vessel should be lightweight to meet aircraft weight restrictions. <CIT> and <CIT> each disclose a high-pressure fluid vessel for use in aircraft potable water systems. <CIT> discloses a method of constructing a compartmented tanker. <CIT> discloses a method of making a compartmented fuel tank. <CIT> discloses a composite pressure vessel assembly and a method of manufacture thereof. <CIT> discloses a pressure vessel with a coating. <CIT> discloses a unitized composite structure manufacturing system. The document <CIT> discloses a method of manufacturing a cured vessel, the method comprising: wrapping a first bladder with a first composite laminate, the first bladder being in a rigid state; wrapping a second bladder with a second composite laminate , forming a noodle with a third composite laminate, the noodle being complementary in shape to an intersection of a proximal composite laminate and a distal composite laminate, wherein the first composite laminate is the proximal composite laminate and the second composite laminate is the distal composite laminate; joining the first composite laminate to the second composite laminate; wrapping the first composite laminate, the second composite laminate and the third composite laminate in a fourth composite laminate and forming an uncured vessel; curing the un-cured vessel in a vessel mold to form a cured vessel.

A method of manufacturing a cured vessel, in accordance with the invention, is provided according to claim <NUM>.

In various embodiments, the method may further comprise removing the cured vessel from the vessel mold. The method may further comprise, prior to wrapping the first bladder: disposing the first bladder and the second bladder in a bladder mold; heating the first bladder into a first elastic state and the second bladder into a second elastic state; pressurizing the first bladder and the second bladder; and cooling the first bladder into the first rigid state and the second bladder into the second rigid state. The curing the un-cured vessel in the vessel mold may further comprise heating and pressurizing the first bladder and the second bladder. The first bladder and the second bladder may be removed when they are in a first elastic state and a second elastic state. The internal support adjacent surface may abut an internal support of the first composite laminate. The protrusion may abut an adjacent protrusion of the second bladder during the curing of the un-cured vessel.

In various embodiments, the method may comprise: heating a plurality of bladders disposed within a plurality of compartments of an un-cured vessel, the un-cured vessel disposed in a vessel mold, each compartment being adjacent to an adjacent compartment in the plurality of compartments; pressuring the plurality of bladders, each bladder in the plurality of bladders being in an elastic state; removing each bladder in the plurality of bladders from an aperture of a respective compartment in the plurality of compartments; removing a first cured vessel from the vessel mold; cooling each bladder in the plurality of bladders until each bladder is in a rigid state; disposing each bladder in the plurality of bladders in a bladder mold; heating each bladder in the plurality of bladders until each bladder is in the elastic state; and pressuring each bladder in the plurality of bladders.

In various embodiments, the method may further comprise wrapping each bladder in the plurality of bladders in a composite laminate of a plurality of composite laminates. The method may further comprise joining each composite laminate with an adjacent composite laminate. The method may further comprise wrapping the plurality of composite laminates in an outer composite laminate. The method may further comprise disposing the outer composite laminate in the vessel mold. The method may further comprise: heating each bladder in the plurality of bladders until each bladder is in the elastic state; pressurizing each bladder in the plurality of bladders; and curing each composite laminate in the plurality of composite laminates to an adjacent composite laminate in the plurality of composite laminates. The method may further comprise: curing the outer composite laminate to the plurality of composite laminates. Each composite laminate in the plurality of composite laminates may define a compartment of a second un-cured vessel.

The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration and their best mode. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosures, it should be understood that other embodiments may be realized and that logical, chemical, and mechanical changes may be made without departing from the spirit and scope of the disclosures. For example, the steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented. Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option.

<FIG> is a schematic of aircraft <NUM> with potable water system <NUM>, in accordance with various embodiments, which includes air compressor <NUM>, control valve <NUM>, point of use <NUM>, and high-pressure fluid vessel <NUM>. <FIG> is a cross-sectional view of aircraft <NUM>, in accordance with various embodiments, showing high-pressure fluid vessel <NUM>, external fuselage structure <NUM>, and internal aircraft structure <NUM>.

Potable water system <NUM> is situated in an aft portion of aircraft <NUM>. Within potable water system <NUM>, tubes, lines, or hoses connect air compressor <NUM>, control valve <NUM>, point of use <NUM>, and high-pressure fluid vessel <NUM>. Fluid flow within potable water system <NUM> is induced by air compressor <NUM>, which pressurizes the vessel and drives water through the potable water system. Control of the fluid flow within potable water system <NUM> is achieved by utilizing control valve <NUM>. Potable water, for use in potable water system <NUM>, is stored at an elevated pressure (e.g., around <NUM> psig between the inside and outside of the vessel) within high-pressure fluid vessel <NUM>.

As shown in <FIG>, high-pressure fluid vessel <NUM> is configured to conform to both external fuselage structure <NUM> and internal aircraft structure <NUM>. The portion of high-pressure fluid vessel <NUM> closest to external fuselage structure <NUM> is curved to conform to the curvature of external fuselage structure <NUM>. Likewise, the portion of high-pressure fluid vessel <NUM> closest to internal aircraft structure <NUM> is more or less flat to conform to internal aircraft structure <NUM>. <FIG> shows one embodiment of conformable high-pressure fluid vessel <NUM> and is not meant to limit the disclosure to a single embodiment. High-pressure fluid vessel <NUM> is conformable for use in a plurality of irregular aircraft spaces.

<FIG> is a front view of high-pressure fluid vessel <NUM>, in accordance with various embodiments. <FIG> is a perspective cross-sectional view of high-pressure fluid vessel <NUM> taken along line 2B-2B of <FIG>, in accordance with various embodiments. With reference to both <FIG> and <FIG>, high-pressure fluid vessel <NUM> includes proximal compartment <NUM>, intermediate compartments <NUM>, <NUM>, and <NUM>, and distal compartment <NUM>. Proximal compartment <NUM> includes capsule 33A with first domed end 34A, second domed end 36A (shown in <FIG>), semicylindrical portion 38A, and cavity 40A (shown in <FIG>). Intermediate compartment <NUM> includes capsule 33B with first domed end 34B, second domed end 36B (shown in <FIG>), semi-cylindrical portion 38B, and cavity 40B (shown in <FIG>). Intermediate compartment <NUM> includes capsule 33C with first domed end 34C, second domed end 36C (shown in <FIG>), semi-cylindrical portion 38C, and cavity 40C (shown in <FIG>). Intermediate compartment <NUM> includes capsule 33D with first domed end 34D, second domed end 36D (shown in <FIG>), semi-cylindrical portion 38D, and cavity 40D (shown in <FIG>). Distal compartment <NUM> includes capsule 33E with first domed end 34E, second domed end 36E (shown in <FIG>), semi-cylindrical portion 38E, and cavity 40E (shown in <FIG>). High-pressure fluid vessel <NUM> further includes internal supports <NUM>, <NUM>, <NUM>, and <NUM> (shown in <FIG>). Internal support <NUM> includes apertures 50A (shown in <FIG>). Internal support <NUM> includes aperture 50B (shown in <FIG>). Internal support <NUM> includes aperture 50C (shown in <FIG>). Internal support <NUM> includes aperture 50D (shown in <FIG>).

Located at a proximal end of high-pressure fluid vessel <NUM> is proximal compartment <NUM>, which is located below and connected to intermediate compartment <NUM>. Intermediate compartment <NUM> is located below and connected to intermediate compartment <NUM>. Intermediate compartment <NUM> is located below and connected to intermediate compartment <NUM>. Intermediate compartment <NUM> is located below and connected to distal compartment <NUM> at a distal end of high pressure fluid vessel <NUM>. In various embodiments, high-pressure fluid vessel <NUM> has three intermediate compartments <NUM>, <NUM>, and <NUM>. In various embodiments, high-pressure fluid vessel <NUM> can include any number of intermediate compartments or no intermediate compartments.

Capsules 33A, 33B, 33C, 33D, and 33E are convex, curved shaped body portions of proximal compartment <NUM>, intermediate compartments <NUM>, <NUM>, and <NUM>, and distal compartment <NUM>, respectively. Capsule 33A of proximal compartment <NUM> includes first domed end 34A, second domed end 36A, and semi-cylindrical portion 38A extending between and connecting first domed end 34A and second domed end 36A. Cavity 40A is positioned in proximal compartment <NUM> and is defined by capsule 33A. Capsule 33B of intermediate compartment <NUM> comprises first domed end 34B, second domed end 36B, and semi-cylindrical portion 38B extending between and connecting first domed end 34B and second domed end 36B. Cavity 40B is positioned in intermediate compartment <NUM> and is defined by capsule 33B. Capsule 33C of intermediate compartment <NUM> includes first domed end 34C, second domed end 36C, and semi-cylindrical portion 38C extending between and connecting first domed end 34C and second domed end 36C. Cavity 40C is positioned in intermediate compartment <NUM> and is defined by capsule 33C. Capsule 33D of intermediate compartment <NUM> includes first domed end 34D, second domed end 36D, and semi-cylindrical portion 38D extending between and connecting first domed end 34D and second domed end 36D. Cavity 40D is positioned in intermediate compartment <NUM> and is defined by capsule 33D. Capsule 33E of distal compartment <NUM> includes first domed end 34E, second domed end 36E, and semi-cylindrical portion 38E extending between and connecting first domed end 34E and second domed end 36E. Cavity 40E is positioned in distal compartment <NUM> and is defined by capsule 33E.

First domed ends 34A, 34B, 34C, 34D, and 34E and second domed ends 36A, 36B, 36C, 36D, and 36E are semispherical shaped. Semicylindrical portions 38A, 38B, 38C, 38D, and 38E are right circular cylindrical shaped where a cross-section of the semicylindrical portions 38A, 38B, 38C, 38D, and 38E are circular shaped.

Internal supports <NUM>, <NUM>, <NUM>, and <NUM> are positioned in high-pressure fluid vessel <NUM> to provide structural support for high-pressure fluid vessel <NUM>. Internal supports <NUM>, <NUM>, <NUM>, and <NUM> are baffles in the embodiment shown in <FIG>. Internal support <NUM> is positioned between proximal compartment <NUM> and intermediate compartment <NUM>. Internal support <NUM> is positioned between intermediate compartment <NUM> and intermediate compartment <NUM>. Internal support <NUM> is positioned between intermediate compartment <NUM> and intermediate compartment <NUM>. Internal support <NUM> is positioned between intermediate compartment <NUM> and distal compartment <NUM>.

Aperture 50A extends through internal support <NUM> to connect proximal compartment <NUM> to intermediate compartment <NUM>. Aperture 50B extends through internal support <NUM> to connect intermediate compartment <NUM> to intermediate compartment <NUM>. Aperture 50C extends through internal support <NUM> to connect intermediate compartment <NUM> to intermediate compartment <NUM>. Aperture 50D extends through internal support <NUM> to connect intermediate compartment <NUM> to distal compartment <NUM>. In various embodiments, internal supports <NUM>, <NUM>, <NUM>, and <NUM> can include one or more apertures 50A, 50B, 50C, and 50D, each aperture being of equal or varying size.

High-pressure fluid vessel <NUM> is capable of holding potable water on aircraft <NUM>. High-pressure fluid vessel <NUM> includes proximal compartment <NUM>, intermediate compartments <NUM>, <NUM>, and <NUM>, and distal compartment <NUM> that are designed to conform to aircraft <NUM>. High-pressure fluid vessel <NUM> includes internal supports <NUM>, <NUM>, <NUM>, and <NUM> to provide structural support to high-pressure fluid vessel <NUM> to prevent high-pressure fluid vessel <NUM> from deforming under pressure. Apertures 50A, 50B, 50C, and 50D extend through internal supports <NUM>, <NUM>, <NUM>, and <NUM> respectively, to allow potable water to flow through high-pressure fluid vessel <NUM>.

<FIG> is a side cross-sectional view of high-pressure fluid vessel <NUM>. High-pressure fluid vessel <NUM> includes proximal compartment <NUM>, intermediate compartments <NUM>, <NUM>, and <NUM>, and distal compartment <NUM> with capsules 33A, 33B, 33C, 33D, and 33E having first domed ends 34A, 34B, 34C, 34D, and 34E (shown in <FIG>), second domed ends 36A, 36B, 36C, 36D, and 36E (shown in <FIG>), semi-cylindrical portions 38A, 38B, 38C, 38D, and 38E, and cavities 40A, 40B, 40C, 40D, and 40E, respectively. High-pressure fluid vessel <NUM> further includes internal supports <NUM>, <NUM>, <NUM>, and <NUM>, with apertures 50A, 50B, 50C, and 50D, respectively. Semi-cylindrical portions 38A, 38B, 38C, 38D, and 38E include curved external walls 52A, 52B, 52C, 52D, and 52E, concave inner surfaces 54A, 54B, 54C, 54D, and 54E, and convex outer surfaces 56A, 56B, 56C, 56D, and 56E, respectively. Also shown in <FIG> are first intersection locations 58A, 58B, 58C, and 58D and second intersection locations 60A, 60B, 60C, and 60D.

High-pressure fluid vessel <NUM> includes proximal compartment <NUM> at a base, intermediate compartments <NUM>, <NUM>, and <NUM>, and distal compartment <NUM> at a distal end. Capsules 33A, 33B, 33C, 33D, and 33E are arcuate shaped body portions of proximal compartment <NUM>, intermediate compartments <NUM>, <NUM>, and <NUM>, and distal compartment <NUM>, respectively. Proximal compartment <NUM> includes capsule 33A with first domed end 34A opposite of second domed end 36A and semi-cylindrical portion 38A extending there between. Cavity 40A is formed in proximal compartment <NUM>. Intermediate compartment <NUM> includes capsule 33B with first domed end 34B opposite of second domed end 36B and semi-cylindrical portion 38C extending there between. Cavity 40B is formed in intermediate compartment <NUM>. Intermediate compartment <NUM> includes capsule 33C with first domed end 34C opposite of second domed end 36C and semi-cylindrical portion 38C extending there between. Cavity 40C is formed in intermediate compartment <NUM>. Intermediate compartment <NUM> includes capsule 33D with first domed end 34D opposite of second domed end 36D and semi-cylindrical portion 38D extending there between. Cavity 40D is formed in intermediate compartment <NUM>. Distal compartment <NUM> includes capsule 33E with first domed end 34E opposite of second domed end 36E and semi-cylindrical portion 38E extending there between. Cavity 40E is formed in distal compartment <NUM>.

High-pressure fluid vessel <NUM> further includes internal supports <NUM>, <NUM>, <NUM>, and <NUM>. Internal support <NUM> is positioned between proximal compartment <NUM> and intermediate compartment <NUM>, and aperture 50A extends through internal support <NUM>. Internal support <NUM> is positioned between intermediate compartment <NUM> and intermediate compartment <NUM>, and aperture 50B extends through internal support <NUM>. Internal support <NUM> is positioned between intermediate compartment <NUM> and intermediate compartment <NUM>, and aperture 50C extends through internal support <NUM>. Internal support <NUM> is positioned between intermediate compartment <NUM> and distal compartment <NUM>, and aperture 50D extends through internal support <NUM>.

High-pressure fluid vessel <NUM> will include a port to fill high-pressure fluid vessel <NUM>. The port is preferably positioned in distal compartment <NUM>, but can be positioned in any of proximal compartment <NUM>, intermediate compartments <NUM>, <NUM>, <NUM>, and distal compartment <NUM>. A liquid such as water may be placed into and released from high-pressure fluid vessel <NUM> through the port. The liquid in high-pressure fluid vessel <NUM> may move between proximal compartment <NUM>, intermediate compartments <NUM>, <NUM>, <NUM>, and distal compartment <NUM> by flowing through apertures 50A, 50B, 50C, and 50D. Apertures 50A, 50B, 50C, and 50D can be any size and shape and there can be multiple apertures 50A, 50B, 50C, and 50D in internal supports <NUM>, <NUM>, <NUM>, and <NUM> in various embodiments. High pressure fluid vessel <NUM> will also include a port to remove water from the vessel. The port is positioned at a proximal end of proximal compartment <NUM>.

High-pressure fluid vessel <NUM> is designed to conform to a space on aircraft <NUM> (see <FIG>). Semi-cylindrical portions 38A, 38B, 38C, 38D, and 38E of proximal compartment <NUM>, intermediate compartments <NUM>, <NUM>, and <NUM>, and distal compartment <NUM>, respectively, are curved to help high-pressure fluid vessel <NUM> conform to the space on aircraft <NUM> and to reduce stresses in semi-cylindrical portions 38A, 38B, 38C, 38D, and 38E.

Semi-cylindrical portion 38A of proximal compartment <NUM> includes curved external wall 52A. Curved external wall 52A includes concave inner surface 54A and convex outer surface 56A. Semi-cylindrical portion 38B of intermediate compartment <NUM> includes curved external wall 52B. Curved external wall 52B further includes concave inner surface 54B and convex outer surface 56B. Semi-cylindrical portion 38C of intermediate compartment <NUM> includes curved external wall 52C. Curved external wall 52C includes concave inner surface 54C and convex outer surface 56C. Semi-cylindrical portion 38D of intermediate compartment <NUM> includes curved external wall 52D. Curved external wall 52D further includes concave inner surface 54D and convex outer surface 56D. Semi-cylindrical portion 38E of distal compartment <NUM> includes curved external wall 52E. Curved external wall 52E includes concave inner surface 54E and convex outer surface 56E.

High-pressure fluid vessel <NUM> includes a flat side portion and a curved side portion. The flat side portion is the side in which a tangent line can be drawn from curved external wall 52A to curved external wall 52E and approximately only contact curved extemal walls 52B, 52C, and 52D at a single tangent point of each; the right side of high-pressure fluid vessel <NUM> as oriented in <FIG>. The curved side portion is the side opposite the flat side portion; the left side of high-pressure fluid vessel <NUM> as oriented in <FIG>.

Curved external walls 52A, 52B, 52C, 52D, and 52E abut one another at first intersection locations 58A, 58B, 58C, and 58D and second intersection locations 60A, 60B, 60C, and 60D, respectfully. Proximal compartment <NUM> is connected to intermediate compartment <NUM> at first intersection location 58A and second intersection location 60A. Intermediate compartment <NUM> is connected to intermediate compartment <NUM> at first intersection location 58B and second intersection location 60B. Intermediate compartment <NUM> is connected to intermediate compartment <NUM> at first intersection location 58C and second intersection location 60C. Intermediate compartment <NUM> is connected to distal compartment <NUM> at first intersection location 58D and second intersection location 60D.

Located on the flat side portion of high-pressure fluid vessel <NUM> are first intersection locations 58A, 58B, 58C, and 58D. The intersection of curved external wall 52A and curved external wall 52B defines first intersection location 58A. The intersection of curved external wall 52B and curved external wall 52C defines first intersection location 58B. The intersection of curved external wall 52C and curved external wall 52D defines first intersection location 58C. The intersection of curved external wall 52D and curved external wall 52E defines first intersection location 58D.

Located on the curved side portion of high-pressure fluid vessel <NUM> are second intersection locations 60A, 60B, 60C, and 60D. The intersection of curved external wall 52A and curved external wall 52B defines second intersection location 60A. The intersection of curved external wall 52B and curved external wall 52C defines second intersection location 60B. The intersection of curved external wall 52C and curved external wall 52D defines second intersection location 60C. The intersection of curved external wall 52D and curved external wall 52E defines second intersection location 60D.

According to the present disclosure, high-pressure fluid vessel <NUM> must include at least two compartments connected at a first intersection location and a second intersection location. High-pressure fluid vessel <NUM>, in its smallest form, includes proximal compartment <NUM> and distal compartment <NUM> connected at a first intersection location and a second intersection location. With that said, high-pressure fluid vessel <NUM> is not limited to a maximum number of compartments and intersection locations; high-pressure fluid vessel <NUM> can include as many compartments and intersection locations as desired to conform to an irregular shape or space. The high-pressure fluid vessel described in the preceding paragraphs is a representation of a single embodiment and not meant to limit the disclosure to this particular embodiment.

As shown in <FIG> and discussed above, high-pressure fluid vessel <NUM> curves to conform to external fuselage structure <NUM>. The curvature described is achieved by proximal compartment <NUM>, intermediate compartments <NUM>, <NUM>, and <NUM>, and distal compartment <NUM> having different volumes and radii of curvature. Proximal compartment <NUM> has the largest volume and radius of curvature, intermediate compartment <NUM> has a volume and radius of curvature that is smaller than proximal compartment <NUM>, intermediate compartment <NUM> has a volume and radius of curvature that is smaller than intermediate compartment <NUM>, intermediate compartment <NUM> has a volume and radius of curvature that is smaller than intermediate compartment <NUM>, and distal compartment <NUM> has the smallest volume and radius of curvature. The radii of curvature of first domed ends 34A, 34B, 34C, 34D, and 34E, second domed ends 36A, 36B, 36C, 36D, and 36E, and semi-cylindrical portions 38A, 38B, 38C, 38D, and 38E, respectively, are preferably the same for each of capsule 33A, 33B, 33C, 33D, and 33E. The curvature of high-pressure fluid vessel <NUM> is achieved by curved external walls 52A, 52B, 52C, 52D, and 52E having different volumes and radii while maintaining the flat side portion of high-pressure fluid vessel <NUM>. With the flat side portion being held constant and the compartments volume and radii being different, the curved side portion is formed. The curvature of the curved side portion can be varied by modifying the volume and radii of each compartment. In the embodiment shown, high-pressure fluid vessel <NUM> includes five compartments, each of different volumes and radii. In all embodiments of high-pressure fluid vessel <NUM>, at least two of the compartments must be of different volumes and radii.

High-pressure fluid vessel <NUM> further includes internal supports <NUM>, <NUM>, <NUM>, and <NUM> to prevent proximal compartment <NUM>, intermediate compartments <NUM>, <NUM>, <NUM>, and distal compartment <NUM> from deforming under internal pressure. Internal supports <NUM>, <NUM>, <NUM>, and <NUM> include apertures 50A, 50B, 50C, and 50D, respectively.

Internal support <NUM> extends from first intersection location 58A to second intersection location 60A. Internal support <NUM> extends from first intersection location 58B to second intersection location 60B. Internal support <NUM> extends from first intersection location 58C to second intersection location 60C. Internal support <NUM> extends from first intersection location 58D to second intersection location 60D.

High-pressure fluid vessel <NUM> would deform under internal pressure without internal supports <NUM>, <NUM>, <NUM>, and <NUM>. Internal supports <NUM>, <NUM>, <NUM>, and <NUM> provide structural support to curved external walls 52A, 52B, 52C, 52D, and 52E. Further, internal supports <NUM>, <NUM>, <NUM>, and <NUM>, are strategically placed to evenly distribute the stresses in curved external walls 52A, 52B, 52C, 52D, and 52E. This results in a high-pressure vessel that is high strength and structurally efficient.

With reference to <FIG>, a perspective view of a high-pressure vessel assembly <NUM> manufactured utilizing smart tooling manufacturing, is illustrated, in accordance with various embodiments. The high-pressure vessel assembly <NUM> further comprises patches 62A, 62B, 62C, and 62E. Each patch seals an aperture disposed at the first domed end of the respective compartment. Each compartment comprises an aperture disposed at a domed end to allow removal of a smart tool, in accordance with various embodiments. Each patch may be disposed at a first domed end or a second domed end of a respective compartment. For example, a patch 62A may be disposed at the first domed end 36A of the proximal compartment <NUM>, a patch 62B may be disposed at the first domed end 36B of intermediate compartment <NUM>, a patch 62C may be disposed at the first domed end 36C of intermediate compartment <NUM>, a patch 62D may be disposed at the first domed end 36D of intermediate compartment <NUM> , and a patch 62E may be disposed at the first domed end 36E of distal compartment <NUM>.

Referring now to <FIG>, a method <NUM> for manufacturing a vessel, in accordance with various embodiments, is depicted. For the sake of brevity, the method <NUM> of manufacturing a vessel is represented as a two compartment vessel; although any number of compartments are within the scope of this disclosure. The method <NUM> comprises forming bladder(s) in a bladder mold (step <NUM>). A bladder mold <NUM> may have a complimentary shape to a respective compartment of a vessel. A vessel may comprise any number of compartments. The bladder mold <NUM> may be aluminum, epoxy carbon composite, stainless steel, or any other material known in the art. In various embodiments, the bladder mold <NUM> is additively manufactured. A bladder mold <NUM> may comprise any number of receptacles for various bladder shapes to be formed simultaneously. In various embodiments, bladder mold <NUM> may comprise a receptacle for each bladder corresponding to a respective compartment in the of a high-pressure vessel assembly <NUM>.

In various embodiments, bladder mold <NUM> may comprise a receptacle for bladders of adjacent compartments of a high-pressure vessel assembly <NUM>. For example, bladder mold <NUM> is a bladder mold for a two compartment vessel (e.g., a proximal compartment and a distal compartment). A proximal bladder <NUM> and a distal bladder <NUM> may be disposed in a bladder mold <NUM>. In various embodiments, bladders <NUM>, <NUM> are in a rigid state when they are cold (e.g., between <NUM>°F (<NUM>) and <NUM>°F (<NUM>)) and are in an elastic state when bladders <NUM>, <NUM> are hot (e.g., between <NUM> °F (<NUM>) and <NUM> °F (<NUM>)). A bladder may comprise any shape memory polymer known in the art. Bladders <NUM>, <NUM> may be place in bladder mold <NUM> around room temperature, heated between <NUM> °F (<NUM>) and <NUM> °F (<NUM>), then pressurized to the desired compartment shape, and then cooled to create solid bladders in a complementary shape to a respective compartment of a vessel.

The method <NUM> further comprises wrapping the bladders <NUM>, <NUM>, now in a rigid state, with respective composite laminates <NUM>, <NUM> (step <NUM>). In various embodiments, the composite laminates <NUM>, <NUM> are uncured carbon fiber, or any other material known in the art. The composite laminates may be wrapped in a compartment shape as described with respect to <FIG> above. During step <NUM>, the bladders <NUM>, <NUM> may have an end extending external to the respective wrapped composite laminates <NUM>, <NUM>. Additionally, the bladders <NUM>, <NUM> may each comprise a protrusion corresponding to a respective fluid port of a compartment. For example, a wrapped proximal composite laminate <NUM> comprises an aperture <NUM> disposed at a first end of wrapped proximal composite laminate <NUM> and proximal bladder <NUM> has a port <NUM> extending out the aperture <NUM> of the wrapped proximal composite laminate <NUM>. Additionally, the wrapped proximal composite laminate <NUM> may comprise at least one fluid port <NUM> at respective protrusion <NUM> of proximal bladder <NUM>.

The method <NUM> further comprises forming a noodle <NUM> (step <NUM>). In various embodiments, a noodle <NUM> is an uncured carbon fiber similar to composite laminates <NUM>, <NUM>. Noodle <NUM> is complementary in shape to an intersection of the proximal composite laminate <NUM> and the distal composite laminate <NUM>. For example, noodle <NUM> may comprise a proximal concave surface <NUM> configured to mate with a portion of wrapped proximal composite laminate <NUM>. Similarly, noodle <NUM> may comprise a distal concave surface <NUM> configured to mate with a portion of wrapped distal composite laminate <NUM>. Noodle <NUM> may further comprise a side concave surface <NUM> disposed between proximal concave surface <NUM> and distal concave surface <NUM> and forming a perimeter of noodle <NUM>.

The method <NUM> further comprises joining the wrapped proximal composite laminate <NUM> to the wrapped distal composite laminate <NUM> and noodle <NUM> (step <NUM>). During step <NUM>, a proximal internal support <NUM> of wrapped proximal composite laminate <NUM> abuts a distal internal support <NUM> of wrapped distal composite laminate <NUM>. Additionally, a portion of proximal domed end <NUM> abuts proximal concave surface <NUM> of noodle <NUM> and a portion of distal domed end <NUM> abuts distal concave surface <NUM> of noodle <NUM>. A protrusion <NUM> of proximal domed end <NUM> may abut a protrusion <NUM> of distal bladder <NUM>.

The method <NUM> further comprises wrapping the joined composite laminates and noodle with a second layer of composite laminate <NUM> (step <NUM>). The composite laminate <NUM> may cover the entire outer surface of the joined composite laminates and noodle from step <NUM>. Similar to composite laminates <NUM>, <NUM> and the noodle <NUM>, the composite laminate <NUM> may be made of un-cured carbon fibers, or any other laminate known in the art. The result of step <NUM> is an un-cured vessel <NUM>, in accordance with various embodiments.

The method <NUM> further comprises curing the un-cured vessel in a vessel mold <NUM> (step <NUM>). In various embodiments, the vessel mold <NUM> comprises two pieces that are mirror images of each other. Similar to the bladder mold <NUM>, the vessel mold <NUM> may be aluminum, epoxy carbon composite, stainless steel, or any other material known in the art. The vessel mold <NUM> comprises a complimentary shape to the cured vessel. During step <NUM>, the un-cured vessel <NUM> and the bladders <NUM>, <NUM> are heated to a cure temperature of up to <NUM> °F (<NUM>) and the inside of bladders <NUM>, <NUM> are pressurized compressing the un-cured vessel <NUM> into a unitary, or monolithic, component.

The method <NUM> further comprises removing the bladders <NUM>, <NUM> after the un-cured vessel <NUM> is cured (step <NUM>). The bladders <NUM>, <NUM> are in a hot state after cure, and may be elastic, which may allow removal of bladders <NUM>, <NUM> by pulling on a respective port of bladders <NUM>, <NUM>. For example, a removal tool may be coupled to port <NUM> of bladder <NUM> and pull the bladder <NUM> out of the compartment of the cured vessel <NUM>.

The method <NUM> further comprises removing the cured vessel <NUM> from the vessel mold <NUM> (step <NUM>). After step <NUM>, the bladder may be placed back in the bladder mold while still in a hot state, reformed to the bladder mold, and the method may be repeated to create another vessel.

With reference to <FIG>, proximal domed end <NUM> and distal bladder <NUM> being removed from a bladder mold <NUM> from step <NUM> after step <NUM> of method <NUM>, in accordance with various embodiments, is illustrated. In various embodiments, bladder mold <NUM> comprises a distal shell <NUM> and a proximal shell <NUM>. Each shell may comprise a recess being complimentary in shape to a portion of an exterior surface of a respective bladder. For example, proximal shell <NUM> may comprise a proximal bladder recess <NUM> and/or a distal bladder recess <NUM>. The proximal bladder recess <NUM> may correspond to a first portion of the exterior surface of the proximal domed end <NUM>. The distal shell <NUM> may comprise a complimentary proximal recess for proximal domed end <NUM>, which may correspond to a second portion of the exterior surface of the proximal domed end <NUM>. The proximal bladder recess <NUM> of the proximal shell <NUM> and the complimentary proximal recess of distal shell <NUM> may correspond to the entire exterior surface of the proximal domed end <NUM>.

In various embodiments, each bladder comprises a port, an internal support adjacent surface, and a protrusion. For example, distal bladder <NUM> comprises a port <NUM> disposed at a first end of distal bladder <NUM>. The port <NUM> is in fluid communication with the inside of distal bladder <NUM>. The port <NUM> may be configured to allow an internal pressure to be applied on the internal surfaces of the distal bladder <NUM>.

The distal bladder <NUM> further comprises an internal support adjacent surface <NUM>. Internal support adjacent surface <NUM> may be flat, or any other shape known in the art. Internal support adjacent surface <NUM> may be configured to apply pressure an internal support surface of a respective composite laminate in step <NUM> of method <NUM>. For example, with brief reference to <FIG>, internal support adjacent surface <NUM> abuts distal internal support <NUM> and/or applies a force against distal internal support <NUM> during the curing step <NUM>. A similar force is applied against proximal internal support <NUM> by an internal support adjacent surface of the proximal domed end <NUM> resulting in a compressive force between proximal internal support <NUM> and distal internal support <NUM>. The compressive force may cure the proximal internal support <NUM> and the distal internal support <NUM> into a unitary, or monolithic, internal support surface.

The distal bladder <NUM> further comprises at least one protrusion <NUM> extending away from internal support adjacent surface <NUM>. During step <NUM>, where the bladders are in a rigid state, the composite laminate may be wrapped on the internal support adjacent surface <NUM> up to, or below, a height of the protrusion <NUM> from the internal support adjacent surface <NUM>. During the curing step (step <NUM>), the protrusion <NUM> of distal bladder abuts a respective protrusion of proximal domed end <NUM>. Upon removal of the bladders <NUM>, <NUM>, the cured vessel has a fluid connection where the protrusion <NUM> of distal bladder and the respective protrusion of proximal domed end <NUM> abutted in the curing step (step <NUM>) (see step <NUM> from <FIG>).

Referring now to <FIG>, a cured vessel <NUM> being removed from a vessel mold <NUM> after bladders <NUM>, <NUM> have been removed, in accordance with various embodiments, is depicted. In various embodiments, vessel mold <NUM> comprises a first shell <NUM> and a second shell <NUM>. Similar to the bladder mold <NUM>, the vessel mold <NUM> may have a complimentary shape to a respective cured vessel <NUM>. A cured vessel may comprise any number of compartments. The vessel mold <NUM> may be aluminum, epoxy carbon composite, stainless steel, or any other material known in the art. In various embodiments, the vessel mold <NUM> is additively manufactured. The vessel mold <NUM> may comprise a receptacle for a cured vessel with any number of compartments. In various embodiments, vessel mold <NUM> may comprise a receptacle for a five compartment vessel, as shown in <FIG>.

In various embodiments, vessel mold <NUM> comprises a first shell <NUM> and a second shell <NUM>. Each shell may comprise a recess being complimentary in shape to a portion of an exterior surface of a cured vessel <NUM>. For example, second shell <NUM> may comprise a second recess <NUM>. The second recess <NUM> may correspond to a second portion of the exterior surface of the cured vessel <NUM>. The first shell <NUM> may comprise a complimentary recess, e.g., a first recess, which may correspond to a first portion of the exterior surface of the cured vessel <NUM>. The second recess <NUM> of the second shell <NUM> and the complimentary recess, first recess, of first shell <NUM> may correspond to the entire exterior surface of the cured vessel <NUM>.

In various embodiments, cured vessel <NUM> comprises a proximal compartment <NUM> and a distal compartment <NUM>. Proximal compartment <NUM> may comprise a domed end 436A and distal compartment <NUM> may comprise a domed end 436E. A proximal end aperture <NUM> is disposed at domed end 436E. Similarly, a distal end aperture is disposed at domed end 436E. Each aperture is provided to allow removal of bladders <NUM>, <NUM>. Each aperture may be sealed by a patch as described above with respect to <FIG>. Cured vessel <NUM> may comprise a unitary, or monolithic, component.

Referring now to <FIG>, a method of manufacturing a cured vessel, in accordance with various embodiments, is depicted. The method comprises disposing a first bladder and/or a second bladder in a bladder mold (step <NUM>). The bladder mold may be in accordance with <FIG> and <FIG> as described above. The first bladder and the second bladder may be in a rigid state or elastic state prior to being placed in the mold. A bladder may be in a rigid state when it is under <NUM>°F (<NUM>) and a bladder may be in an elastic state when it is between <NUM>°F (<NUM>) and <NUM>°F (<NUM>) depending on a smart resin utilized.

The method further comprises heating the first bladder and the second bladder into an elastic state, if the first bladder and second bladder are not already in an elastic state (step <NUM>). Then, the first bladder and the second bladder are pressurized internally to take the shape of the bladder mold (step <NUM>). In various embodiments, the first bladder and the second bladder may be pressurized between <NUM> psi and <NUM> psi (<NUM>-<NUM> bar).

The method further comprises cooling the first bladder and the second bladder into a rigid state (step <NUM>). The first bladder and second bladder may take a rigid state upon dropping in temperature below <NUM>°F (<NUM>). In various embodiments, the first bladder and the second bladder may cool to room temperature or the like. Once in a cooled state, the first bladder is wrapped with a first composite laminate (step <NUM>). The first composite laminate may be uncured carbon fiber, or any other material known in the art. Next, the second bladder is wrapped with a second composite laminate (step <NUM>). The second composite laminate may be the same material as the first composite laminate or a different material. In various embodiments, the second composite laminate is the same material as the first composite laminate.

The method further comprises joining the first composite laminate and the second composite laminate (step <NUM>). In various embodiments, this may be done by forming a noodle to dispose between the first composite laminate and the second composite laminate. In various embodiments, the noodle may couple an outer surface of the first composite laminate to an outer surface of the second composite laminate. A first internal support of the first composite laminate may contact a second internal support of the second composite laminate.

The method further comprises wrapping the first composite laminate and the second composite laminate in a third composite laminate and forming an uncured vessel (step (<NUM>). The third composite laminate may be wrapped around the majority of the exterior of the first composite laminate and the second composite laminate. In various embodiments, the third composite laminate is wrapped around the entire exterior of the first composite laminate, the second composite laminate, and/or the noodle. The third composite laminate may be the same material as the first composite laminate and/or the second composite laminate or a different material. In various embodiments, the second composite laminate is the same material as the first composite laminate and the second composite laminate.

The method further comprises curing the un-cured vessel (step <NUM>). In various embodiments, the un-cured vessel may be cured at a temperature between <NUM> °F (<NUM>) and <NUM>°F (<NUM>). In various embodiments, the un-cured vessel may be cured at a pressure between <NUM> psi (<NUM> bar) and <NUM> psi (<NUM> bar). In various embodiments, curing the un-cured vessel may fuse the first composite laminate and the second composite laminate to the third composite laminate. In various embodiments, curing the un-cured vessel may fuse the first internal support to the second internal support. In various embodiments, curing the un-cured vessel may fuse the noodle to the first composite laminate, the second composite laminate, and the third composite laminate.

The method further comprises removing the first bladder and the second bladder (step <NUM>). After curing, the first bladder and the second bladder may still be in a hot state (between <NUM> °F (<NUM>) and <NUM> °F (<NUM>)). As such, the first bladder and second bladder may be disposed back in the bladder mold from step <NUM> and the process repeated for a new vessel. The method may further comprise removing, or de-molding, the cured vessel (step <NUM>).

In various embodiments, method <NUM> allows for removal of the bladders with relative ease and/or allows for manufacturing of conformal vessels with complex geometries that may maintain tight tolerances.

However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosures.

The scope of the disclosures is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean "one and only one" unless explicitly so stated, but rather "one or more.

In the detailed description herein, references to "one embodiment", "an embodiment", "an example embodiment", etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiment.

Claim 1:
A method of manufacturing a cured vessel, the method comprising:
wrapping (<NUM>) a first bladder (<NUM>) with a first composite laminate, the first bladder being in a first rigid state, wherein the first bladder comprises an internal support adjacent surface (<NUM>), a proximal domed end (<NUM>) and a protrusion (<NUM>) extending away from the internal support adjacent surface and from the proximal domed end (<NUM>) when the first bladder is in the first rigid state;
wrapping (<NUM>) a second bladder (<NUM>) with a second composite laminate, the second bladder being in a second rigid state; wherein the second bladder comprises a protrusion (<NUM>) extending away from an internal support adjacent surface (<NUM>) thereof;
forming a noodle (<NUM>) with a third composite laminate, the noodle being complementary in shape to an intersection of a proximal composite laminate and a distal composite laminate, wherein the first composite laminate is the proximal composite laminate and the second composite laminate is the distal composite laminate;
joining the first composite laminate to the second composite laminate;
wrapping (<NUM>) the first composite laminate, the second composite laminate and the third composite laminate in a fourth composite laminate and forming an un-cured vessel;
curing the un-cured vessel in a vessel mold (<NUM>) to form a cured vessel; and
removing the first bladder (<NUM>) and the second bladder (<NUM>), wherein upon removal of the first bladder and the second bladder, the cured vessel has a fluid connection where the protrusion (<NUM>) of the second bladder and a respective protrusion (<NUM>) of the proximal domed end abutted in the curing step.