Comparative Study of Layup and Solid Modeling of Composite Reinforced Pressure Vessel for Hydrogen Refueling Station

Abstract To enhance the energy storage density and service life of hydrogen station pressure vessels in China, Composite Reinforced Pressure Vessels (CRPVs) have become a key area of research. However, the mechanical performance of CRPVs is significantly influenced by the unique properties of fiber materials and the complexity of their layup structures, making detailed simulation calculations computationally expensive. To improve the efficiency of simulation-based optimization for CRPV design and facilitate the study of fatigue, strength, and other performance characteristics, this paper develops both layup models and simplified solid models based on the structural and material parameters of a 99MPa steel-liner hydrogen station pressure vessel. These models clearly define critical parameters such as fiber winding layer thickness, number of layers, and winding direction. The mechanical responses of both models under different operating conditions are analyzed and validated through strain testing. The results indicate that the layup model offers distinct advantages in capturing the structural complexity of composite materials, both models require further refinement to enhance accuracy and stability under varying loading conditions. This study provides valuable insights for modeling and simulation-based optimization of composite reinforced pressure vessels for hydrogen storage applications.