Multi-Layer Catalyst Container Assembly with Rigid and Woven Layers
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Solution Overview
Problem
Developing containers that are both robust and lightweight to prevent premature exposure of catalysts to the environment, while also being able to withstand exothermic reactions without leaking, is challenging due to the need for materials that are both protective and easy to transport.
Innovation Solution
A multi-layer container assembly comprising a sealed inner liner, a rigid middle layer, a woven outer layer with a spout structure, and a flexible outer shell, which provides protection and facilitates transportation, with additional features like access ports and a hinged bottom for easy emptying and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a robust container is used to prevent premature exposure of catalysts to the environment, then the reliability of catalyst protection is improved, but the weight of the container increases
Solution Approach 1:
The patent employs a nested multi-layer container structure where an inner liner containing the catalyst is placed inside a rigid intermediate layer, which is then enclosed by a flexible outer layer. This nested arrangement provides robust catalyst protection through multiple protective barriers while distributing the weight across different materials and layers, avoiding the need for a single heavy container.
Solution Approach 2:
The container utilizes composite material construction with distinct layers serving different functions: an inner liner material for catalyst containment, a rigid intermediate layer for structural support, and a flexible outer layer for impact resistance. This composite approach optimizes the weight-to-protection ratio by selecting materials specifically tailored for each protective function rather than using a single heavy material throughout.
2Ease of operation
If a lightweight container is used for easy transportation, then the ease of operation is improved, but the strength of the container decreases
Solution Approach 1:
The nested multi-layer structure allows each layer to contribute to overall strength while keeping individual layers relatively lightweight. The inner liner provides baseline containment, the rigid intermediate layer adds structural strength, and the flexible outer layer provides impact protection, achieving cumulative strength without proportionally increasing weight.
Solution Approach 2:
Different regions of the container have different material properties optimized for their specific functions: the inner liner uses material suitable for chemical containment, the intermediate layer uses rigid material for structural integrity, and the outer layer uses flexible material for impact absorption. This local optimization allows the container to be lightweight overall while maintaining strength where needed.
3Reliability
If a robust container is used to withstand exothermic reactions, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The nested container structure provides progressive protection against exothermic reactions: the inner liner contains the catalyst and initial reaction, the rigid intermediate layer provides thermal and structural stability during reaction, and the flexible outer layer contains any potential breach while dissipating heat. This nested approach achieves reliable reaction withstand capability through a systematic, modular structure that is relatively simple to manufacture and assemble.
Data Source
AI summary
A container assembly and methods for making and using such an assembly are disclosed herein. In one embodiment, an assembly is configured to hold an amount of catalyst. The assembly includes a first layer forming an inner liner that, when sealed, contains the amount of catalyst. Additionally, the assembly includes a second layer that at least partly surrounds the first layer and that is substantially rigid. Further, the assembly includes a third layer that substantially completely surrounds the second layer and that is at least partly made from a woven material, the third layer including a portion forming a spout structure, and a fourth layer that at least partly surrounds the third layer.