Composite Tank Diaphragm Segmentation for Air-Water Separation
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Solution Overview
Problem
Type IV fiberwound tanks face inefficiency when the pre-charge pressure is insufficient to maintain the diaphragm or bladder away from the tank wall, leading to ineffective separation of air and water, which compromises their functional integrity.
Innovation Solution
A composite tank design featuring a polymeric upper and lower dome with a polymeric shell, a flexible diaphragm, and a fiberwinding layer, where the domes and shell form a cavity with connections that ensure a hermetical seal and support high burst pressures, and a support stand for stable installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-charge pressure is increased to maintain diaphragm separation, then air-water separation effectiveness is improved, but tank complexity and manufacturing difficulty increase
Solution Approach 1:
The tank is divided into distinct functional zones: an upper air dome, a lower water dome, and a connecting shell. The diaphragm is segmented to attach to specific anchor points on the shell, creating defined separation zones. This segmentation allows the diaphragm to maintain separation effectiveness without requiring excessive pre-charge pressure, as the structured zones provide geometric support.
Solution Approach 2:
The tank employs composite construction with a polymeric liner and external fiberwinding layers. This composite structure provides high strength-to-weight ratio and burst pressure resistance, allowing the tank to maintain structural integrity and diaphragm separation under varying pressure conditions without over-engineering the pre-charge system.
2Reliability
If diaphragm is kept away from tank wall through adequate pre-charge, then functional integrity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The diaphragm is pre-positioned and secured to anchor points on the shell during manufacturing, establishing its correct position before the tank is put into service. The anchor points are strategically located to ensure the diaphragm maintains proper separation from the tank wall under normal operating conditions, reducing the need for post-installation adjustment and minimizing precision requirements during assembly.
Solution Approach 2:
The shell incorporates specific structural features at localized positions, such as anchor points and connection regions, that provide enhanced support where needed. The fiberwinding pattern is optimized in specific zones to reinforce areas where the diaphragm attaches, ensuring proper diaphragm positioning and separation without requiring uniform high precision throughout the entire tank structure.
3Strength
If fiberwinding layer is added to enhance burst pressure resistance, then strength is improved, but manufacturing complexity increases
Solution Approach 1:
The fiberwinding construction is divided into distinct layers with different orientations and material compositions. The inner layer provides baseline strength, while outer layers add incremental reinforcement. This segmented approach allows manufacturers to build up strength in controlled stages, simplifying the manufacturing process compared to applying a single complex winding pattern.
Solution Approach 2:
The tank uses a composite structure combining polymeric liner material with fiber reinforcement layers. This composite approach provides high burst pressure resistance because the fibers carry the primary mechanical loads while the polymer provides corrosion resistance and seals the structure. The modular composite construction simplifies manufacturing compared to using monolithic high-strength materials.
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 design maintains the diaphragm's separation from the tank wall under varying pressures, ensuring effective air and water separation and enhancing the tank's operational reliability and longevity.
Implementation Method 1
a fiberwinding layer around an outer surface of the polymeric upper dome, polymeric lower dome, and polymeric shell
Implementation Method 2
a flexible diaphragm connected to an inner wall of the polymeric shell in the cavity
Data Source
AI summary
Provided is a tank including a polymeric upper dome having a neck with a through passage, a polymeric lower dome having a neck with a through passage, a polymeric shell having a first end connected to the upper dome and a second end connected to the lower dome, and a connection attached to each of the upper and lower domes in the through passages of the necks, wherein the upper dome, lower dome, and shell form a cavity.