Composite Panel Tank With Honeycomb Core And Metal Frame
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Solution Overview
Problem
Existing tank designs fail to effectively manage high forces from contained liquids and provide adequate insulation for large-scale applications, such as hydraulic fracturing, while maintaining structural integrity and preventing freezing in cold climates.
Innovation Solution
A tank constructed from composite panels featuring a honeycomb core with fibrous reinforcing sheets and a thermosetting resin, supported by a metal frame with tension members and corner posts, providing enhanced rigidity and insulation by using a liner and floating panels to manage liquid containment and temperature regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional tank designs are used, then manufacturing simplicity is maintained, but structural rigidity and insulation performance are insufficient to accommodate high forces from contained liquids and prevent freezing in cold climates
Solution Approach 1:
The patent applies composite panel construction consisting of multiple layers including outer and inner skins with insulating core materials (such as foam or air gaps) bonded together. This composite structure provides enhanced structural rigidity, strength-to-weight ratio, and thermal insulation performance simultaneously, resolving the contradiction between strength improvement and construction complexity by integrating multiple functions into a unified composite system.
Solution Approach 2:
The tank is divided into modular panel sections that can be manufactured separately and assembled on-site. Each panel is a self-contained composite unit with integrated insulation and structural elements. This segmentation allows for simplified manufacturing of individual components while achieving high overall structural rigidity when assembled, and facilitates easier transportation and installation of large-volume tanks.
2Temperature
If conventional tank designs are used, then construction simplicity is maintained, but insulation performance is insufficient to prevent freezing in cold climates
Solution Approach 1:
The composite panel structure incorporates dedicated insulating layers (foam cores or air-filled cavities) between the inner and outer skins. This multi-layer composite design provides high thermal resistance while maintaining structural integrity, eliminating the need for separate insulation systems and reducing overall construction complexity despite the enhanced insulation performance.
Solution Approach 2:
The insulation system is nested within the tank wall structure itself, with insulating materials positioned between the inner and outer structural layers. This nested arrangement integrates insulation functionality into the load-bearing structure, providing thermal protection without adding external bulk or complexity to the overall tank design.
3Volume of moving object
If conventional tank designs are used, then manufacturing simplicity is maintained, but ability to accommodate large dimensions for hydraulic fracturing applications is limited
Solution Approach 1:
The large-volume tank is constructed from multiple standardized composite panels assembled in a modular fashion. Each panel is manufactured to consistent dimensions and can be joined using standardized connection details. This segmentation enables the creation of very large tank capacities (suitable for hydraulic fracturing operations) while maintaining manufacturing simplicity through repetition of standard components and assembly procedures.
Solution Approach 2:
The composite panels are designed as universal building blocks that can be used for various tank sizes and configurations by varying the number and arrangement of panels. The same panel design and connection details can accommodate different volume requirements, from smaller storage tanks to large-scale hydraulic fracturing tanks, reducing the need for custom engineering and simplifying manufacturing across different applications.
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
The solution enables the creation of large, rigid, and insulated tanks capable of withstanding high forces and maintaining liquid containment, while reducing heating costs and preventing freezing, suitable for large-scale applications like hydraulic fracturing.
Implementation Method 1
composite panels featuring a honeycomb core with fibrous reinforcing sheets and a thermosetting resin
Implementation Method 2
The advantage of using the composite panels is that they provide a high level of insulation to the tank which avoids or reduces heating costs to prevent freezing of the water in cold climates
Implementation Method 3
a tension member extending along the tank wall applying a longitudinal tension to the panels to hold them end to end
Data Source
AI summary
A tank is formed from panels fastened together edge to edge to form four upstanding side walls and base panels where across the base the panels extend from one side to the other. The panels are composite and formed from a honeycomb core panel with a foam material filling the tubular cells and a fibrous reinforcing cover sheets. The walls are supported by a metal frame including a base member extending along the wall at the bottom of the panels and a plurality of joining members connected to the base member and upstanding therefrom for holding the ends of the panels in end to end relationship. Cables extend along the walls adjacent the base member and connect to end posts of the walls. A series of posts stand along the walls on the outside and are connected across the tank by cables extending over the top edge of the walls.