Method of manufacturing a pressure vessel with an improved sidewall structure

A method of constructing a thin-walled pressure vessel having a localized area of increased wall thickness comprising the steps of:

• forming a thermoplastic insert having an aperture;
• forming a thermoplastic inner liner having a substantially cylindrical middle portion, first and second end portions connected to said middle portion and a recess in said middle portion disposed inwardly;
• securing said insert into said recess to substantially fill the recess and form a substantially smooth and curved surface with the outer surface of said inner liner and form a localized area of increased wall thickness;
• forming an outer layer substantially covering said insert and said inner liner;
• making an aperture through said outer layer and said inner liner to complete a port through said insert to the interior of the vessel.

A method of constructing a thin-walled pressure vessel having a localized area of increased wall thickness comprising the steps of:

• forming a thermoplastic insert having an aperture;
• forming a thin thermoplastic inner layer having a substantially cylindrical middle portion, first and second end portions connected to said middle portion and an aperture through said middle portion;
• securing said insert to said inner liner to substantially fill the aperture in said liner and form a substantially smooth and curved surface with the outer surface of said inner liner and form a localized area of increased wall thickness;
• positioning a location marker proximate said insert;
• forming an outer layer substantially covering said insert and said inner liner;
• securing a reinforcing patch to said outer layer proximate said location marker;
• making an aperture through said outer layer to complete a port through the localized area of increased wall thickness to the interior of the vessel.

A method of constructing a thin-walled pressure vessel having a localized area of increased wall thickness comprising the steps of:

• forming a thermoplastic insert;
• forming a thin thermoplastic inner liner having a substantially cylindrical middle portion, first and second end portions connected to said middle portion, and a recess in said middle portion, said recess disposed inwardly;
• securing said insert into said recess to substantially fill the recess and form a substantially smooth and curved surface with the outer surface of said inner liner and form a localized area of increased wall thickness;
• placing a location marker proximate said insert;
• forming an outer layer substantially covering said insert and said inner liner;
• securing a reinforcing patch to said outer layer over said insert;
• forming an aperture through a portion of said reinforcing patch, said outer layer, said insert and said inner liner to complete a port through the localized area of increased wall thickness to the interior of the vessel.

A method of constructing a thin-walled pressure vessel having a localized area of increased wall thickness comprising the steps of:

• forming a thermoplastic insert with an integral location marker;
• forming a thin thermoplastic inner liner having a substantially cylindrical middle portion, first and second end portions connected to said middle portion, and a recess in said middle portion, said recess disposed inwardly;
• securing said insert into said recess to substantially fill the recess and form a substantially smooth and curved surface with the outer surface of said inner liner and form a localized area of increased wall thickness;
• forming an outer layer substantially covering said insert and said inner liner;
• securing a reinforcing patch to said outer layer over said insert;
• forming an aperture through a portion of the reinforcing patch, said outer layer, said insert, and said inner liner to complete a port through the localized area of increased wall thickness to the interior of the vessel.