Cast Structural Component with Internal Lattice Support
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Solution Overview
Problem
Existing structural components, such as containment vessels and tanks, face challenges in withstanding high pressures and increasing load-bearing capacity, particularly when storing pressurized gases like anhydrous ammonia or compressed natural gas, as they require enhanced structural integrity and design to prevent rupture and efficiently distribute stress loads.
Innovation Solution
The method involves casting structural components using a core structure with preforms and a molten material, forming compartments and rectilinear support members that connect between outer wall portions, creating a solidified junction for enhanced structural integrity and stress distribution, using a casting insert with a barrier layer to prevent molten material infiltration and forming interconnected compartments with fluid flow paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick walls are used to increase load bearing capacity, then strength is improved, but weight increases
Solution Approach 1:
The container wall is segmented into a lattice structure composed of multiple struts arranged in geometric patterns (triangles, squares, hexagons). This segmentation distributes the load across numerous individual members rather than relying on a solid thick wall, achieving high strength-to-weight ratio through structural efficiency.
Solution Approach 2:
The patent incorporates curved and angled strut configurations within the lattice structure, including arched members and non-linear geometries that better distribute stress loads compared to straight rigid members. These curved elements enhance load bearing capacity while maintaining lightweight construction.
2Strength
If geometric curves or arcs are incorporated into the design, then load bearing capacity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the lattice structure formation with the container wall formation into a single integrated casting process. The core structure with embedded channels is cast simultaneously with the container wall material, eliminating separate manufacturing steps for creating the geometric lattice patterns and reducing overall manufacturing complexity.
Solution Approach 2:
The patent utilizes phase change of casting material (from molten to solidified state) to form the complex lattice structure with curved elements. By controlling the casting parameters and material flow through embedded channels, intricate geometric patterns are created during the phase transition, achieving complex shapes through process control rather than complex tooling.
3Strength
If internal support structures are added to enhance structural integrity, then strength is improved, but device complexity increases
Solution Approach 1:
The internal support structure (lattice framework) is merged with the container wall structure into a unified lattice wall design. The struts serve dual functions as both internal support elements and wall-forming components, eliminating the need for separate internal bracing structures and reducing overall structural complexity.
Solution Approach 2:
The lattice struts are designed to perform multiple functions simultaneously: providing structural support, forming the container wall, distributing pressure loads, and potentially serving as reinforcement for lining materials. This multi-functionality reduces the number of separate components needed.
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 results in structural components that can effectively withstand higher pressures and store larger volumes of pressurized gases without rupture, while also optimizing material usage and weight distribution, thereby enhancing the load-bearing capacity and structural integrity of the components.
Implementation Method 1
The flow path for the molten material is provided by a core structure used to cast the structural component. Each of the rectilinear support members includes a solidified material formed by a corresponding molten material flow path.
Implementation Method 2
The preform has a barrier layer thereabout that prevents infiltration of the molten material into the preform.
Data Source
AI summary
A structural component having an internal support structure extending between outer wall portions of the component with one or more compartments included within the support structure. The support structure has support members including internal walls positioned between and/or defined by the compartments. At least one support member connects between the outer wall portions of the component to enhance the structural integrity of the component. The structural component, including the internal support, are cast from a molten material, and in some cases the support members of the internal support structure are formed with a rectilinear configuration. In some cases the cast structural component is a container and the one or more compartments are configured to store a fluid, such as a gas or a liquid. One or more preforms can be used to form a container and may be retained or eliminated from the container after casting.