Packed Macrosphere Buoyancy Blocks for Stable High-Density Filling

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Solution Overview

Problem

Existing subsea buoyancy solutions face challenges in achieving optimal packing density and stability of macrospheres, leading to reduced buoyancy and increased structural costs due to low packing factors, especially in large structures where vibration is impractical and matrices are prone to creep and degradation.

Innovation Solution

A method involving optimizing the packing of macrospheres in a mould cavity, followed by fixing them with a matrix material that solidifies, and then transferring the packed block into a chamber, allowing for increased packing factor and stability without the need for a permanent matrix, enabling flexible or rigid envelopes to maintain buoyancy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If macrospheres are used in syntactic foams, then buoyancy is provided, but packing factor is reduced leading to lower buoyancy efficiency

Engineering Contradiction:

Improvepacking factorVSAvoidbuoyancy stability

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-freezing the matrix material before inserting macrospheres into the mould. This frozen matrix acts as a supporting structure that maintains optimal packing density during the subsequent insertion and curing processes, preventing sphere displacement and ensuring high packing factors are achieved and maintained.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes parameter changes by controlling the temperature state of the matrix material. The matrix is maintained in a frozen state during macrosphere insertion to provide structural support for optimal packing, then transitions to a cured solid state to permanently fix the spheres in their optimally-packed positions, thereby achieving both high packing factor and buoyancy stability.

Inventive Principle:

Principle #35Parameter changes

2Quantity of substance

If vibration is used to optimize packing, then packing factor increases, but vibration is impractical for large structures

Engineering Contradiction:

Improvepacking factorVSAvoidoperability in large structures

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

The patent replaces the mechanical vibration system with a thermal field system. Instead of using vibration to optimize packing, the invention uses a frozen matrix (thermal state) to provide a rigid supporting structure that enables macrospheres to be inserted and packed optimally without requiring vibration. This substitution makes the process feasible for large structures where vibration would be impractical.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Stability of the object's composition

If matrix material is used to fix macrospheres, then packing stability is improved, but matrix creep and degradation occur over time

Engineering Contradiction:

Improvepacking stabilityVSAvoidservice life

Core Design Contradiction:

Stability of the object's compositionVSDuration of action of stationary object

Solution Approach 1:

The patent applies preliminary action by pre-freezing the matrix material before macrosphere insertion. This frozen state provides temporary structural support during assembly, then the matrix is cured to achieve final stabilization. This two-stage process allows the matrix to perform different functions at different times, reducing long-term degradation while maintaining packing stability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses composite materials by combining the matrix material with macrospheres in a structured arrangement. The frozen matrix provides initial structural support, while the cured matrix provides long-term stabilization. This composite approach leverages the strengths of both materials to achieve both immediate packing stability and long-term durability.

Inventive Principle:

Principle #40Composite materials

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 enhances the packing factor of macrospheres, maintaining optimal buoyancy and stability, even in large structures, while reducing material costs and minimizing matrix-related degradation issues.

Implementation Method 1

optimizing packing of the spheres to form an optimally-packed mass and then fixing the spheres in the optimally-packed mass

Methodology Applied

Scientific EffectFreezing: Freezing

Implementation Method 2

This invention relates to the provision of buoyancy in subsea applications, using packed macrospheres to produce buoyancy modules or other buoyant elements

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Data Source

PatentUS10895333B2Construction of buoyant elements comprising packed macrospheres

Publication Date: 2021.01.19 ACERGY FRANCE

AI summary

A method of filling a chamber with buoyant macrospheres places a mass of the spheres into a mould cavity. In the mould cavity, packing of the spheres is optimized to form an optimally-packed mass, followed by fixing the spheres in the optimally-packed mass to form a block. The block is then transferred from the mould cavity into the chamber while the spheres of the block remain fixed in the optimally-packed mass. This method enables the production of a buoyant element comprising an envelope defining an internal chamber that contains a mass of buoyant macrospheres each with an external diameter of at least 5 mm, packed with a packing factor of at least 50%.