Minimum weight design of helically and hoop wound toroidal hydrogen storage tanks with variable slippage coefficients

Abstract This article determines the optimal winding parameters for helically and hoop overwound toroidal hydrogen storage tanks, based on the application of variable slippage coefficients. First, an optimality condition between helical winding angle and hoop‐to‐helical thickness ratio is derived from the minimum strain energy density criterion. The winding angle distributions are then obtained with the aid of the optimality condition, taking into account the shell thickness variation along the meridional direction. The general criteria for fiber trajectory stability on a torus are presented, and the relationship for the slippage coefficient and the helical winding angle is formulated according to the windability and manufacturability. The helical winding angle and thickness at the equator are considered as design variables, whereas the minimum weight acts as the objective function. A design example with a toroidal hydrogen storage tank is outlined to demonstrate the favorable performance of the present method. The results show that the present method using variable slippage coefficients leads to a better distribution of the fiber stress in the toroidal shell and an efficient utilization of the laminate strength. The obtained winding parameters can thus be regarded as optimal for filament‐wound toroidal hydrogen storage tanks. POLYM. COMPOS., 2012. © 2012 Society of Plastics Engineers