Hybrid tanks
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Solution Overview
Problem
Conventional well and expansion tanks face inefficiencies due to inadequate air pre-charge pressure, leading to diaphragm or bladder failure, which compromises their ability to maintain separation between air and water, especially under varying water system pressures.
Innovation Solution
A commercial hybrid tank design featuring a metal liner with a fiber winding layer, a flexible diaphragm, and a weld joint configuration that allows for a pressure rating of up to 300 psi at 240° F, with a fiber winding layer applied helically and circumferentially to enhance structural integrity and resistance to internal pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional metal liner is used to resist internal pressure and corrosion, then corrosion resistance is improved, but the tank weight increases and manufacturing complexity increases due to thick wall requirements
Solution Approach 1:
The patent applies composite materials by combining a metal liner with a fiber winding layer (epoxy resin impregnated glass fiber, carbon fiber, or aramid fiber). This composite structure allows the metal liner to provide corrosion resistance while the fiber layer provides structural strength, enabling thinner metal walls and reduced tank weight while maintaining or improving overall performance.
2Strength
If the metal liner wall thickness is increased to withstand high pressure, then strength is improved, but the tank weight increases and corrosion resistance decreases due to more material exposure
Solution Approach 1:
The fiber winding layer carries a significant portion of the internal pressure load, allowing the metal liner to be thinner while maintaining overall tank strength. The composite action between the metal liner and fiber layer distributes stress effectively, achieving high pressure withstanding capability with reduced weight.
3Strength
If a thick metal liner is used to ensure structural integrity, then strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The fiber winding layer can be applied using automated winding processes that impregnate fibers with epoxy resin and wrap them around the metal liner. This manufacturing approach achieves high structural integrity with controlled material application, potentially reducing manufacturing complexity compared to producing and handling very thick metal liners.
4Weight of moving object
If the metal liner wall thickness is reduced to decrease weight, then tank weight is reduced, but strength and pressure resistance deteriorate
Solution Approach 1:
The fiber winding layer compensates for the reduced metal liner thickness by providing additional structural strength. The epoxy resin matrix binds the fibers to the metal liner surface, creating a composite structure where the fiber layer carries a significant portion of the pressure load, maintaining pressure resistance with reduced weight.
5Object-affected harmful factors
If a thick metal liner is used to resist corrosion, then corrosion resistance is improved, but the tank weight increases
Solution Approach 1:
The fiber winding layer with epoxy resin coating provides an additional corrosion barrier over the metal liner surface. This allows the metal liner to be thinner while maintaining or improving corrosion resistance, as the composite structure protects the metal from environmental exposure.
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 hybrid tank design provides improved durability, reduced weight, increased corrosion resistance, and enhanced performance under high pressures, with the fiber winding layer allowing for a thinner metal liner while maintaining structural integrity and resisting corrosion.
Implementation Method 1
A weld joint joins the upper and lower walls together
Implementation Method 2
A fiber winding layer is wrapped around the outer surface of the metal liner
Implementation Method 3
The diaphragm can separate the cavity into an upper portion and a lower portion. The upper portion of the cavity can be sealed to contain a pressurized gas and the lower portion is sealed to contain a pressurized liquid
Data Source
AI summary
A commercial hybrid tank includes a metal liner with an upper wall and a lower wall. The upper wall and the lower wall define a cavity therebetween. A weld joint joins the upper and lower walls together. A fiber winding layer is wrapped around an outer surface of the metal liner. A method for manufacturing a commercial hybrid tank includes overlapping surfaces of an upper wall and a lower wall to form a metal liner defining a cavity. The method includes joining the surface of the upper wall and the surface of the lower wall together by welding to form a weld joint between the upper wall and the lower wall. The method includes wrapping the metal liner with a fiber winding layer around an outer surface of the metal liner to form a hybrid tank.