Composite Roto-Moulded Vessel With Integrated Nozzles
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Solution Overview
Problem
Existing tanks for transporting hazardous materials, typically made of metal with a resilient liner, face issues such as excessive weight, liner degradation, and the need for separate nozzle attachment, which increases costs and complexity.
Innovation Solution
A hollow roto-moulded article composed of a thermoplastic inner layer and a fibrous outer layer, with integrally formed nozzles seamlessly integrated into the structure, eliminating weld lines and allowing for a multilayer structure that is impervious and provides fluid communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal tanks with resilient liners are used for transporting hazardous materials, then structural strength is improved, but weight increases excessively and liner degradation occurs over time
Solution Approach 1:
The patent employs a composite structure consisting of a thermoplastic polymer liner layer and a fibrous reinforcement layer. The thermoplastic layer provides chemical resistance and containment, while the fibrous layer (such as glass fiber or carbon fiber) provides structural strength. This composite approach eliminates the need for heavy metal tanks while maintaining required mechanical properties and reducing overall weight.
2Strength
If metal tanks with resilient liners are used, then structural strength is improved, but liner degradation and detachment occur necessitating repair or replacement
Solution Approach 1:
The composite structure integrates the thermoplastic liner with the fibrous reinforcement layer through chemical bonding and mechanical interlocking. The fibrous layer distributes stresses uniformly across the liner, preventing stress concentration that leads to liner degradation and detachment. This integrated composite structure enhances the overall reliability and service life of the tank.
3Ease of operation
If nozzles are integrated by cutting holes and welding or clamping prefabricated nozzles, then nozzle functionality is achieved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent integrates the nozzle structure directly into the tank body during the foam injection molding process. The nozzle, tank wall, and reinforcement layers are formed as a single monolithic structure, eliminating the need for separate nozzle components and their attachment. This merging of functions simplifies the overall device structure and reduces manufacturing steps.
4Ease of operation
If nozzles are integrated by cutting holes and welding or clamping prefabricated nozzles, then nozzle functionality is achieved, but manufacturing time and costs increase
Solution Approach 1:
The nozzle structures are pre-formed as integral parts of the mold cavity before the actual tank production. During the foam injection molding process, the thermoplastic material flows around and bonds to the pre-positioned nozzle structures, creating a seamless integration in a single manufacturing step. This preliminary preparation eliminates subsequent assembly operations and accelerates production.
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 reduces weight, minimizes liner degradation, and simplifies nozzle integration, resulting in a cost-effective and durable vessel for hazardous material transport.
Implementation Method 1
heating and rotating the hollow mould in the presence of one or more thermoplastic polymers within the hollow mould so that the polymer melts and at least partially infiltrates the fibrous material
Data Source
AI summary
A hollow roto-moulded article, having an inner wall defining an interior of the article and integrally formed structure with the inner wall, the integrally formed structure protruding away from the interior of the article, the article formed of a first layer including one or more thermoplastic polymers, and a second layer including one or more fibrous materials.