Linerless Sealed Tank Wall Formation With Knitted Thermoplastic Envelope
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Solution Overview
Problem
The production of sealed tanks without an inner liner is hindered by the time-consuming process of winding a thermoplastic material strip around a mandrel, which limits the scalability of the production process.
Innovation Solution
A process that forms a sealed wall in a single step by winding a material containing fibers, using a knitted item made of thermoplastic material as a base, which melts and integrates with the fiber-reinforced thermoplastic strip to create a homogeneous, single-piece sealed wall.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermoplastic material strip is wound around a mandrel to form an inner sealed envelope, then the sealing function is improved, but the production time increases significantly
Solution Approach 1:
The mandrel is prepared in advance with a form corresponding to the inner surface of the sealed wall, and the thermoplastic material is applied to the mandrel before the winding process begins. This preliminary preparation enables the material to be positioned and secured more efficiently during the winding operation, reducing overall production time while maintaining sealing integrity.
Solution Approach 2:
The mandrel serves as an intermediary tool that facilitates the winding process. It provides a temporary support structure that allows the thermoplastic material to be wound and secured in the correct position, then removed after the sealing is complete. This intermediary approach enables faster production compared to direct winding without a mandrel.
2Reliability
If a narrow and thin covering strip is wound in multiple turns to form the sealed inner envelope, then the sealing quality is improved, but the production time increases
Solution Approach 1:
The covering strip is made wider than the minimum required width, allowing it to be wound in fewer turns with adequate overlap. This excessive width provides sufficient material for multiple layers and overlap regions, ensuring sealing quality while reducing the number of winding operations needed, thereby decreasing production time.
3Strength
If the covering strip is wound with constrained speed to ensure proper clamping and consolidation, then the structural integrity is improved, but the production speed decreases
Solution Approach 1:
The winding speed is optimized by adjusting process parameters such as pressure application rate, temperature control during heating, and strip tension. These parameter changes allow for faster winding speeds while maintaining adequate clamping force and consolidation quality, thus improving production speed without compromising structural integrity.
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
This approach significantly reduces production time, enhances the mechanical resistance and impermeability of the sealed tank, and allows for the creation of a more homogeneous and durable sealed wall compared to traditional double-layered designs.
Implementation Method 1
the thermoplastic material which forms the knitted item, makes it possible, under the effect of heat and pressure, to melt with the first strip
Implementation Method 2
by applying a temperature selected to melt the thermoplastic material of each section of the first layer of first strip together with the underlying threads of the envelope, and in order to melt the sections of the successive layers of first strip
Implementation Method 3
by exerting a pressure selected to clamp each section of the first wound strip against the envelope, forming the first layer of first strip, and to clamp the sections covering the first layer of first strip
Data Source
AI summary
An aspect of the invention concerns a process for production of a sealed tank in order to contain a gas and/or a liquid, including a step of formation of a sealed wall of the tank, having the following sub-steps: forming an envelope by application of at least one knitted item covering the outer surface of the mandrel, the knitted item having knitted threads of a thermoplastic material which can be sealed by heat; filament winding, around the envelope, of successive sections of a first strip comprising a thermoplastic material which can be sealed by heat and is reinforced by fibres, such as to melt the successive wound sections of the first strip; and cooling the envelope and the first strip in order to form the sealed wall in a single material.