Hydrocarbon Storage Vessel Wall Structure Using Calendered Composite Layers

Solution Overview

Problem

Current methods for forming fuel cells are complex and costly, limiting their use in lower-cost vehicles due to the multi-step processes involved in manufacturing.

Innovation Solution

A wall structure for hydrocarbon storage vessels is developed, comprising an inner layer of a first rubber compound, a center layer of a polymer film, and an outer layer of a second rubber compound, with a method involving calendering rubber sheets on either side of the polymer film to form a cured structure for storing hydrocarbons.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If current multi-step manufacturing processes are used for fuel cells, then structural integrity and impermeability are achieved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple manufacturing steps into a single calendering operation. The calendering process simultaneously bonds the inner liner, outer liner, and intermediate fabric layer together while applying heat and pressure, eliminating the need for separate bonding operations and reducing overall manufacturing complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fuel cell uses a composite structure with an inner rubber liner, intermediate fabric layer, and outer rubber liner. This composite design maintains structural integrity and impermeability while allowing for simplified manufacturing through the calendering process that bonds all layers simultaneously

Inventive Principle:

Principle #40Composite materials

2Reliability

If current multi-step manufacturing processes are used for fuel cells, then structural integrity and impermeability are achieved, but manufacturing cost increases

Engineering Contradiction:

ImproveimpermeabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines multiple manufacturing steps into a single calendering operation. The calendering process simultaneously bonds the inner liner, outer liner, and intermediate fabric layer together while applying heat and pressure, eliminating the need for separate bonding operations and reducing overall manufacturing complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses calendering with controlled temperature and pressure parameters to bond all layers in one operation. By optimizing the thermal and pressure parameters during calendering, the process achieves reliable bonding and impermeability while reducing manufacturing steps and cost

Inventive Principle:

Principle #35Parameter changes

3Reliability

If vulcanization is used to increase strength and reduce permeability, then fuel resistance and impermeability improve, but processing time and energy consumption increase

Engineering Contradiction:

ImproveimpermeabilityVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent uses calendering with controlled temperature and pressure parameters to bond all layers in one operation. By optimizing the thermal and pressure parameters during calendering, the process achieves reliable bonding and impermeability while reducing manufacturing steps and energy consumption compared to traditional vulcanization

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach simplifies the formation process while maintaining or improving the structural integrity and impermeability of fuel cells, reducing costs and complexity, and enabling their use in various applications including vehicles and portable storage.

Implementation Method 1

calendering rubber sheets on each side of a polymer film to form a wall structure

Methodology Applied

Scientific EffectCalendering:

Implementation Method 2

combining two or more layers of material to create an inner liner bonded to an outer liner... Fuel cells formed from nitrile rubber compounds are vulcanized (autoclave cured) to increase strength and reduce permeability

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS9573460B2Hydrocarbon storage vessels

Publication Date: 2017.02.21 FLOATS & FUEL CELLS

AI summary

Methods and systems described herein provide or use a wall structure for a hydrocarbon storage vessel. The wall structure includes an inner layer that includes a first rubber compound. A center layer includes a polymer film. An outer layer includes a second rubber compound.