SBIR-STTR Award

Dynovas High Efficiency Linerless Pressurized Gas Storage (HELP-GAS) system is specifically designed to deliver a gaseous hydrogen storage system for UASs that stores compressed hydrogen at greater than 7% weight efficiency for maximum expected operating pressures (MEOPs) between 350 bar and 700 bar. Additionally, the HELP-GAS system reduces the cost of hydrogen storage systems by eliminating the liner and allowing the use of standard or even low-cost carbon fibers not traditionally seen in Type I-IV pressure vessels due to the weight and performance constraints. Overall, Dynovas HELP-GAS technology achieves an 8+ wt% of GH2 storage masses greater than 200g at a 25%+ reduction in overall cost for low quantity productions seen for UAS applications. The WELP-GAS system leverages four (4) technologies to achieve weight and packaging efficiencies that current commercially available systems cannot: (1) Type V pressure vessel configuration, (2) utilizing matrix additives to reduce microcracking and increase pressurization cycles capability (3) utilization of the pressure vessel as part of the structure of the UA, and (4) utilization of non-traditional geometries to increase the spatial utilization of the integrated pressure vessel system. These four innovations, when combined, will allow spatial utilization and weight efficiencies greater than the Type IV pressure vessels currently being utilized in hydrogen fuel cell systems. When realized, Dynovas HELP-GAS system will provide the Navy with the capability to utilize hydrogen fuel cell powered propulsion in applications that were previously not possible. The Dynovas team has over 20 years of filament wound pressure vessel heritage developing novel pressurized storage and rocket motor case solutions. Based on Dynovas heritage in developing pressure vessels, the output of the Phase I base program will be a design that has attained technology readiness level (TRL) 3 for the desired performance. The proposed Phase I option program will identify key characteristics of the HELP-GAS system and perform validation testing on an as built subscale manufacturing risk mitigation article bringing the HELP-GAS system to TRL 4. Results of the validation testing along with increased material testing will ensure success when transitioning to the Phase II prototype system build. The Phase I base combined with the Phase I option will serve to ready the HELP-GAS system for ultimate attainment of TRL 6 in Phase II.

Benefit:
Dynovas HELP-GAS technology developed under this program has far-reaching relevancy across Warfighter, automotive, and transportation industrial initiatives. Furthermore, as the world turns toward more sustainable energy sources, the Department of Energy, alternative DoD relevant end-uses, NASA, scientific end-users, and local law enforcement / emergency users show several potential avenues for marketing and commercialization of the HELP-GAS technology. Specific cost and lead time savings to all potential end users include the elimination of costly, hard-to-manufacture, and long lead time polymer liners seen in Type IV pressure vessels, shorter production cycles and lower minimum order quantities for custom solutions, and ease of prototyping and configuration changes to optime performance of the application without long change cycles. According to the Department of Energy, the potential for more cost effective and weight and space efficient gaseous hydrogen storage is a keystone technology in enabling the widespread adoption of hydrogen fuel cells as an alternative to fossil fuel-based energy. The HELP-GAS technology innovates and optimizes the current state of the art and fosters in more advanced solutions into the hydrogen storage realm without disrupting the key environmental, safety, or manufacturing characteristics of the state of the art. The technology Dynovas is proposing can utilize the industrial base to swiftly innovate in the energy storage market. Due to the low-cost, simplicity, configurability, and adaptability of the root technology, Dynovas will continue to explore potential cross-industry platforms to access additional funding that will benefit this development effort for the Warfighter.

Keywords:
hydrogen storage, hydrogen storage, Composite pressure vessel, GH2, Nanomaterials, carbon fiber, Type V Pressure Vessel

Dynovas High Efficiency Linerless Pressurized Gas Storage (HELP-GAS) system is specifically designed to deliver a gaseous hydrogen storage system for UASs that stores compressed hydrogen at greater than 7% weight efficiency for maximum expected operating pressures (MEOPs) between 350 bar and 700 bar. Additionally, the HELP-GAS system reduces the cost of hydrogen storage systems by reducing or eliminating the liner and allowing the use of standard or even low-cost carbon fibers not traditionally seen in Type I-IV pressure vessels due to the weight and performance constraints. Overall, Dynovas HELP-GAS technology achieves greater than 12 wt% of GH2 storage masses greater than 200g at a 25%+ reduction in overall cost for low quantity productions seen for UAS applications. The HELP-GAS system leverages four (4) technologies to achieve weight and packaging efficiencies: (1) Type IV pressure vessel configuration, (2) utilizing matrix additives to reduce microcracking and increase pressurization cycles capability, (3) utilization of the pressure vessel as part of the structure of the UA, and (4) utilization of non-traditional geometries to increase the spatial utilization of the integrated pressure vessel system. These four innovations, when combined, will allow spatial utilization and weight efficiencies greater than the Type IV pressure vessels currently being utilized in hydrogen fuel cell systems. When realized, Dynovas HELP-GAS system will provide the Navy with the capability to utilize hydrogen fuel cell powered propulsion in applications that were previously not possible. The Dynovas team has over 20 years of filament wound pressure vessel heritage developing novel pressurized storage and rocket motor case solutions. Based on Dynovas heritage in developing pressure vessels, the output of the Phase II base program will be a prototype design that has attained technology readiness level (TRL) 5 for the desired performance. The proposed Phase II option program will identify further weight savings opportunities for the HELP-GAS system and conclude validation testing on a prototype article bringing the HELP-GAS system to TRL 6. Results of the prototype testing along with further weight reduction efforts will ensure success when transitioning to Phase III. The Phase II base combined with the Phase II option will serve to ready the HELP-GAS system for ultimate attainment of TRL 7+ in Phase III and beyond.

Benefit:
Dynovas HELP-GAS technology developed under this program has far-reaching relevancy across Warfighter, automotive, and transportation industrial initiatives. Furthermore, as the world turns toward more sustainable energy sources, the Department of Energy, alternative DoD relevant end-uses, NASA, scientific end-users, and local law enforcement / emergency users show several potential avenues for marketing and commercialization of the HELP-GAS technology. Specific cost and lead time savings to all potential end users include the optimization of typically costly, hard-to-manufacture, and long lead time polymer liners seen in Type IV pressure vessels, shorter production cycles and lower minimum order quantities for custom solutions, and ease of prototyping and configuration changes to optime performance of the application without long change cycles. According to the Department of Energy, the potential for more cost effective and weight and space efficient gaseous hydrogen storage is a keystone technology in enabling the widespread adoption of hydrogen fuel cells as an alternative to fossil fuel-based energy. The HELP-GAS technology innovates and optimizes the current state of the art and fosters in more advanced solutions into the hydrogen storage realm without disrupting the key environmental, safety, or manufacturing characteristics of the state of the art. The technology Dynovas is proposing can utilize the industrial base to swiftly innovate in the energy storage market. Due to the low-cost, simplicity, configurability, and adaptability of the root technology, Dynovas will continue to explore potential cross-industry platforms to access additional funding that will benefit this development effort for the Warfighter.

Keywords:
Composite pressure vessel, GH2, Nanomaterials, Type IV Pressure Vessel, UAS, COPV, carbon fiber, hydrogen storage