Nested Plastic Water Tank With Secure Joint Seal
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Solution Overview
Problem
Existing water storage tanks face high manufacturing and shipping costs due to bulky designs, and there is a need for a cost-effective, compact, and easily assembled tank with a secure joint for storing potable water that is not sensitive to lid-to-base imperfections.
Innovation Solution
A two-piece plastic water storage tank design with a base and cover that can be nested for compact shipping and storage, featuring various joint configurations such as elastically engageable rims, clips, serrations, and rotating tabs for secure assembly, and a composite wall structure with a thin interior liner made of higher-grade material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a one piece tank is made by blow molding or rotational molding, then the tank structure is simple and manufacturing is straightforward, but the shipping cost becomes unacceptably high due to bulky design
Solution Approach 1:
The tank is divided into two separate half-tanks that can be manufactured independently and then assembled together. This segmentation allows each half to be more compact and nestable, reducing shipping volume while maintaining manufacturing simplicity through standardized half-tank production
Solution Approach 2:
The two half-tanks are designed to nest within each other when not in use, creating a compact shipping configuration. This nesting capability dramatically reduces the shipping volume compared to shipping complete tanks, while the assembly process remains simple and straightforward
2Length of stationary object
If manufacturing sites are dispersed around the country, then shipping distance is reduced, but the price of the product increases due to duplication of manufacturing facilities
Solution Approach 1:
By segmenting the tank into standardized half-tanks, the manufacturing process can be consolidated at fewer locations while still enabling efficient distribution. The standardized design allows for reduced manufacturing facility duplication while maintaining reasonable shipping distances, balancing logistics costs with manufacturing efficiency
Solution Approach 2:
The standardized half-tank design serves multiple functions: it can be manufactured at centralized facilities, shipped efficiently, and assembled at various locations including near the point of use. This universality allows a single manufacturing design to serve multiple distribution scenarios, reducing the need for dispersed manufacturing sites
3Ease of operation
If a joint is used to connect base and cover, then the tank can be assembled from separate parts, but the joint must be secure and not overly sensitive to small imperfections
Solution Approach 1:
The joint design incorporates flexible, elastically engageable rims that can dynamically adapt to minor imperfections in the base and cover surfaces. The elastic engagement provides a compliant seal that maintains reliability even when small deviations exist, while still allowing for easy assembly through simple insertion and rotation movements
Solution Approach 2:
The joint design includes built-in compensation features that anticipate and accommodate minor imperfections before they can cause sealing failures. The elastic rims and flexible joint elements act as a cushioning mechanism that absorbs the effects of small misalignments and surface imperfections, ensuring reliable sealing without requiring precision manufacturing
4Reliability
If a composite wall with liner and substrate is used, then the interior water-contacting surface is protected with higher grade material, but the manufacturing process becomes more complex
Solution Approach 1:
The liner is pre-formed as a separate component and then integrated with the substrate during the manufacturing process. This preliminary formation of the liner allows for quality control of the water-contacting surface while the integration step combines both layers in a single manufacturing sequence, avoiding the need for separate post-processing operations and reducing overall process complexity
Solution Approach 2:
The tank uses a composite structure combining a substrate layer with a liner layer, where each material is selected for its specific properties. The substrate provides structural strength while the liner provides water resistance and food safety. This composite approach allows optimization of each layer's material properties without significantly increasing manufacturing complexity through integrated formation processes
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 reduces manufacturing and shipping costs while providing a secure, easily assembled tank with improved joint seals and a cost-effective solution for potable water storage, allowing for efficient use of recycled and virgin plastic materials.
Implementation Method 1
the liner is integrally adhered to the substrate layer during the manufacturing process
Implementation Method 2
a joint comprised of elastically engageable circumscribing rims
Data Source
AI summary
The cover of a plastic tank suitable for containing water is attached to the tank base by means of alternative joints, including elastically engageable features and lock features to prevent unwanted release. The base of a plastic water tank is comprised of a substrate and a liner and is formed by means which include injection molding into a mold where the core part of the mold is surrounded in part or full by the film which forms the liner.