Dimpled Tank Lining with Rounded Pyramids for Flexibility
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Solution Overview
Problem
Existing tank lining materials fail to provide a monitorable cavity with low flow resistance and volume while being easy to handle, and they often form edges when bent, limiting their flexibility and ability to withstand compressive forces.
Innovation Solution
A dimpled film with a textile-reinforced synthetic resin layer, featuring a spatial structure of truncated pyramids and valleys with varying radii, is used to create a flexible and leak-proof lining that can be bent uniformly in any direction, reducing buckling and flow resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high contact pressure is used during embossing to reproduce the roller form fully, then the spatial structure is well-defined, but the foil buckles along the valley bottom and forms sharp edges that increase stress on the coating and fabric
Solution Approach 1:
The patent reduces the contact pressure during embossing from high to reduced levels, fundamentally changing the embossing parameter. This allows the foil to be stretched between the roller surfaces rather than forced into sharp contact, creating rounded valley bottoms with larger radii that eliminate buckling and stress concentration while maintaining adequate spatial structure definition
Solution Approach 2:
The patent transforms the sharp-edged pyramidal structure into a rounded structure by creating valley bottoms with large radii through reduced contact pressure embossing. The rounded geometry eliminates sharp edges that cause stress concentration and buckling, while the curvature maintains the necessary spatial definition for structural integrity
2Shape
If the foil is embossed with sharp-edged pyramids, then the spatial structure is clearly defined, but the foil cannot be bent uniformly in all directions and forms edges when bent
Solution Approach 1:
The patent replaces sharp-edged pyramidal shapes with rounded structures featuring valley bottoms of large radius. This curvature modification allows the foil to bend uniformly in all directions without forming edges, as the rounded geometry distributes stress evenly during flexing while maintaining clear spatial structure definition
Solution Approach 2:
The patent creates different curvature radii in different locations of the embossed structure. The valley bottoms have large radii for flexibility, while the peak regions maintain adequate definition for structural integrity. This local differentiation of geometric properties enables both bending flexibility and structural clarity
3Object-affected harmful factors
If reduced contact pressure is used during embossing, then the foil can be stretched uniformly without buckling, but the spatial structure definition becomes less pronounced
Solution Approach 1:
The patent optimizes the embossing pressure parameter to a reduced but controlled level that balances two competing requirements: low enough to prevent buckling and allow uniform stretching, yet sufficient to maintain adequate spatial structure definition. This parameter optimization resolves the contradiction between preventing harmful buckling and maintaining manufacturing precision
4Manufacturing precision
If the valley bottom radius is small, then the spatial structure is well-defined, but the flow resistance in the cavity increases and the cavity volume increases
Solution Approach 1:
The patent changes the valley bottom radius parameter from small to large values. This parameter change simultaneously achieves multiple benefits: reduces flow resistance in the cavity, minimizes cavity volume, and prevents buckling, while the peak regions maintain adequate spatial structure definition for structural integrity
Data Source
Figure 1~3
Figure 4~7
AI summary
Looking along the length of a valley (21), its base is seen to rise and fall; its height varies in a wavy manner. The valley intersections (23) include a high point (33). Between intersections there are low points (31). At intersections, the valley bases have a greater radius than between them. The embossments are frustrated-pyramidal. The sheet (11) forms the top surface (15), edges (19) and side surfaces (17) of the blunt pyramids, as well as the pattern of intersecting valleys. At the base of the pyramids, the edges have a radius at least 1/5 of the pattern repetition dimension. The sheet forms internal cladding of a tank. An independent claim IS INCLUDED FOR the method of sheet manufacture, by roller-embossing.