Composite Tank Breakwater Integration via Filament Winding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The integration of breakwaters in composite material tanks is complex and costly, and existing solutions that facilitate cleaning, such as those with integral central openings, compromise the structural rigidity of metal tanks, making them unsuitable for composite materials, which lack the necessary mechanical strength to resist hydrostatic pressures during accelerations.
Innovation Solution
A method for manufacturing composite material tanks that includes integrating breakwaters using a vacuum resin infusion process, filament winding, and stratification to enhance mechanical strength and facilitate cleaning, with breakwaters having a 'sandwich' structure and additional reinforcements at junction zones to improve rigidity and reduce mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If breakwaters are integrated into composite material tanks, then the mechanical strength and rigidity of the tank are improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The breakwater is merged with the tank shell into a single integrated composite structure. The breakwater ribs are formed as integral parts of the tank shell during the same filament winding manufacturing process, eliminating separate manufacturing steps and reducing overall complexity while maintaining mechanical strength.
Solution Approach 2:
The breakwater structure is built into the tank shell during the initial manufacturing process before the tank is put into service. The filament winding process automatically forms the breakwater ribs as the tank shell is being constructed, so the breakwater is already in place and structurally integrated before the tank begins operation.
2Ease of operation
If breakwaters with integral central openings are used, then the ease of cleaning the tank is improved, but the structural rigidity of the tank deteriorates
Solution Approach 1:
The breakwater structure has varying properties in different locations: the rib sections provide structural rigidity where needed, while the central opening provides cleaning access where required. Each part of the breakwater structure is optimized for its specific function - structural support or cleaning access - rather than being uniformly designed.
Solution Approach 2:
The breakwater is segmented into multiple rib sections around the tank circumference, with strategic openings in selected sections. This segmentation allows the tank to maintain rigidity through the continuous rib structure while providing cleaning access through the openings in specific segments where it is most beneficial.
3Reliability
If breakwaters are integrated into composite material tanks using traditional methods, then the anti-sloshing function is achieved, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The breakwater manufacturing process is merged with the tank shell manufacturing process. Both components are formed simultaneously using the filament winding method, using the same equipment, materials, and production line, which eliminates the need for separate breakwater manufacturing and assembly operations.
Solution Approach 2:
The filament winding manufacturing process serves multiple functions: it forms the tank shell, creates the breakwater ribs, provides structural reinforcement, and ensures proper positioning all in one operation. This multi-functionality reduces the number of manufacturing steps and lowers overall production cost.
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 method allows for the easy integration of breakwaters into composite material tanks, enhancing mechanical strength and reducing manufacturing costs while maintaining the ability to facilitate cleaning, resulting in a tank with improved resistance to hydrostatic pressures and reduced mass compared to traditional designs.
Implementation Method 1
the step of manufacturing a breakwater is carried out by means of a vacuum resin infusion manufacturing process
Implementation Method 2
a first sub-step of winding reinforcing fibers on a cylindrical mandrel having an outside diameter corresponding to the inside diameter of the tank to be manufactured, a second sub-step of applying a resin
Data Source
Figure 1~3
Figure 4~6
Figure 7
AI summary
The disclosure relates to a method of manufacturing a tank (10) made of composite materials for the transport of liquid or powdered products, said tank (10) comprising a tank (200) having at least one storage compartment incorporating at least one baffle (250), said manufacturing method comprising: a step (101) of manufacturing a first cylindrical section (211a) and a second cylindrical section (211b) made of composite materials; a step (103) of integrating at least one baffle (250) made of composite materials between said first cylindrical section (211a) and said second cylindrical section (211b) so as to form a ferrule (210); said baffle (250) forming a junction between said first cylindrical section (211a) and said second cylindrical section (211b); a step (105) of integrating funds (220, 230) at the ends of said ferrule (210) so as to form an intermediate structure (300);a step (106) of strengthening the outer surface of the intermediate structure (300), carried out in the previous step, by applying an outer layer of reinforcement made of composite materials.;