Weak interfacial bonding properties between thermoplastic liners and carbon fiber‐reinforced composites (CFRP) can easily lead to debonding failure, which is a major challenge in development of type IV composite hydrogen storage vessels. We optimized Box–Behnken design atmospheric‐pressure plasma process parameters for maximizing interfacial bonding properties between thermoplastic liner (PA11 liner) and CFRP using Design‐Expert software. From various designs, plasma process parameters, including time (t), nozzle‐to‐specimen distance (d) and gas flow rate (r) of treatment were selected for optimization to assess the effects of their interactions on climbing drum peel (CDP), flatwise tensile (FWT) and asymmetric double cantilever beams (ADCB). The CDP strength, FWT strength and strain energy release rate (GADCB) of untreated samples were 4.2 N·mm/mm, 0.26 MPa and 87.2 J/m2, respectively. After the plasma treatment, optimum process parameters of t = 200 s, d = 12.5 mm, and r = 700 L/h were used to achieve 33.8 N·mm/mm, 2.97 MPa and 1008.4 J/m2, respectively, which were 8.0, 11.4 and 11.6 times that of untreated PA11 surface, respectively. This method has the potential for guiding thermoplastic liner surface treatment of type IV hydrogen storage vessels before winding.

This study optimized the laminate structure of a composite cylinder under the constraint of minimum layup thickness. Based on the progressive damage theory, a finite element model of the cylinder was established, and the NOL ring tensile test was used to verify the accuracy of the damage theory. The winding angle, the number of layers, and the helical/hoop ratio (the stacking sequence) were selected as the optimization factors, and the burst pressure value was used to evaluate the quality of the laminate structure. Then the orthogonal experiments were designed by RSM. Combined with FEA, the function model of the burst pressure of the gas cylinder and each optimization factor was established to obtain the optimal layering scheme, satisfying the minimum burst pressure. In addition, finite element analysis was used to verify the optimal scheme, demonstrating that the error of the burst pressure predicted by the quadratic model established by the response surface design was not more than 5%. This study provides a faster and more efficient optimization method for the optimization design of composite gas cylinder layers.

The rapid development of hydrogen fuel cells has been paralleled by increased demand for lightweight type IV hydrogen storage vessels with high hydrogen storage density, which raises the performance requirements of internal plastic liners. An appropriate manufacturing process is important to improve the quality of polymer liners. In this paper, DSC, WAXD, a universal testing machine and a differential pressure gas permeameter were used to investigate the effect of the cooling rate of the rotational molding polyamide 11 on the thermal, crystallization, mechanical and barrier properties. The cooling rate is formulated according to the cooling rate that can be achieved in actual production. The results suggest that two PA11 liner materials initially exhibited two-dimensional (circular) growth under non-isothermal crystallization conditions and shifted to one-dimensional space growth due to spherulite collision and crowding during the secondary crystallization stage. The slower the cooling process, the greater the crystallinity of the specimen. The increase in crystallinity significantly improved the barrier properties of the two PA11 liner materials, and the gas permeability coefficient was 2-3-fold higher than at low crystallinity. Moreover, the tensile strength, the tensile modulus, the flexural strength, and the flexural modulus increased, and the elongation at break decreased as the crystallinity increased.

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