Continuous Polymeric Liner Production via Dynamic Mold Reconfiguration
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Solution Overview
Problem
Existing fabrication methods for polymeric pressure vessel liners face limitations such as insufficient production speed, inconsistent mechanical properties, and inflexibility, leading to reduced capacity and potential leak paths due to constraints in equipment design and the need for reconfiguration.
Innovation Solution
The introduction of automated methods for changing mold elements and alternative forming techniques that allow for variable length production of main body sections and return lines without stopping the extrusion process, using apparatuses like corrugators and molding presses with interchangeable mold elements and drums to improve mechanical properties and reduce leak risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the corrugator speed is reduced to fabricate larger main body sections and smaller return lines, then the production capacity is restricted, but the production volumes can be increased by adding numerous pieces of expensive production equipment
Solution Approach 1:
The mold elements are made changeable during operation, allowing the corrugator to dynamically adjust between different patterns (first pattern for main body sections, second pattern for return lines) without stopping production. This dynamic reconfiguration enables a single corrugator to handle variable production requirements that previously required multiple fixed equipment pieces
Solution Approach 2:
The corrugator is designed with interchangeable mold elements that enable it to perform multiple functions: fabricating both main body sections and return lines, and producing different geometries by changing the mold pattern. This multi-functionality eliminates the need for numerous specialized production equipment pieces
2Adaptability or versatility
If additional mold elements are added to achieve certain pressure vessel liner geometries, then the equipment length and cost increase, but the desired geometries can be achieved
Solution Approach 1:
Instead of adding more mold elements to the pattern, the system dynamically changes the mold pattern itself. The mold elements can be reconfigured from a first pattern to a second pattern, allowing diverse geometries to be achieved through pattern variation rather than through adding more physical elements to the equipment
3Productivity
If separate production of extruded main body sections and formed return lines is used, then throughput is improved, but joining segments introduces potential leak paths
Solution Approach 1:
The corrugator operates continuously without stopping to produce both main body sections and return lines in sequence. The mold elements are changed during operation rather than requiring separate production runs, maintaining continuous useful action while producing complete pressure vessel liners without segmentation joints that could leak
4Adaptability or versatility
If production is stopped and equipment reconfigured to produce flexible main body lengths, then production capacity is reduced, but the equipment flexibility is improved
Solution Approach 1:
The mold elements are designed to be dynamically reconfigurable during operation, allowing the equipment to adapt to different main body lengths without stopping production. The pattern can be changed from first to second pattern while the extrusion process continues, maintaining both flexibility and production capacity
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 enhances production speed, reduces equipment size and cost, and minimizes leak paths by enabling continuous production of pressure vessel liners with improved mechanical properties and flexibility in geometry, thereby increasing production capacity and efficiency.
Implementation Method 1
forming an extruded tube by extruding a parison through a die and a mandrel
Implementation Method 2
send the plastic tube through a corrugation process that creates the desired profile comprising rigid main body sections and flexible return lines
Data Source
AI summary
A method and apparatus for forming a pressure vessel liner are disclosed. One method includes forming an extruded tube by extruding a parison through a die and a mandrel and forming main body sections and return line sections in the extruded tube according to a first pattern. A cross-sectional area of the return line sections is smaller than a cross-sectional area of the main body sections. The method further includes changing the pattern according to which the main body sections and the return line sections are formed from the first pattern to a second pattern without stopping the forming of the extruded tube and forming the main body sections and the return line sections in the extruded tube according to the second pattern.