Extrusion Press Chamber Expansion to Prevent Gravity Storage Block Cracks
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Solution Overview
Problem
Existing gravity energy storage systems fail to produce reliable blocks due to cracking when formed and pushed out of the press.
Innovation Solution
An extrusion press machine with a receiving chamber, compaction chamber, and movable walls that allow the formed block to expand in three dimensions before exiting, using pistons to move the pressing walls and sidewalls away from the center of the compaction chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the block is formed in a press and immediately pushed out, then the manufacturing process is simple and fast, but the block cracks and fails immediately
Solution Approach 1:
The patent applies preliminary action by allowing the block to expand elastically within the compaction chamber immediately after forming, before removal. The movable walls create expansion space that accommodates the block's natural rebound, preventing crack formation that would occur with immediate removal. This preliminary expansion action resolves the contradiction by maintaining both fast production and block reliability.
Solution Approach 2:
The patent implements dynamics through movable walls that can change position during the block formation and expansion process. The walls transition from a confined compaction state to an expanded state, allowing the block to dynamically adjust its volume and relieve internal stresses. This dynamic approach enables rapid production while ensuring block integrity through controlled expansion.
2Reliability
If the block is allowed to expand in three dimensions within the compaction chamber, then the block reliability improves, but the device complexity increases due to movable walls
Solution Approach 1:
The movable walls serve multiple functions: they confine the material during compaction, then expand to allow block relaxation, and potentially serve as part of the ejection mechanism. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while achieving improved block reliability through three-dimensional expansion.
Solution Approach 2:
The patent changes the physical parameters of the compaction chamber by varying the wall positions from a compacted state to an expanded state. This parameter change allows the block to transition from a high-stress formed state to a lower-stress expanded state, improving reliability. The parameter changes are achieved through relatively simple mechanical means, limiting the increase in device complexity.
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 method enhances the reliability and lifespan of the blocks by allowing them to expand and release elasticity, preventing cracks and improving their structural integrity.
Implementation Method 1
a piston actuatable to slidably move a pressing wall across the receiving chamber and into the compaction chamber with the gate in a closed position to press the material into contact with the gate, the pair of opposite sidewalls, the top wall, the pressing wall and a plate positioned on a base wall of the compaction chamber in order to compact the material within the compaction chamber to form a block
Implementation Method 2
one or more of the pair of opposite sidewalls, the top wall and the pressing wall are operable to move away from a center of the compaction chamber to allow the block to elastically expand to an expanded position while positioned on the plate and prior to exiting from the compaction chamber
Data Source
AI summary
A system for making blocks for gravity energy storage includes an extrusion press machine with a receiving chamber for receiving raw material, a compaction chamber and a pressing wall driven by a piston to push the raw material into the compaction chamber to compact the material to form a block. One or more of a top wall, opposite side walls and the pressing wall are moved away from the a center of the compaction chamber to allow the block to elastically expand prior to exiting the compaction chamber.