RF-Welded PVC Liners for Corrosive Tank Containment
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Solution Overview
Problem
Process tanks made of steel often corrode due to stored corrosive fluids and external elements, leading to reduced lifespan, high replacement costs, and safety risks from leaks or ruptures, especially when storing hazardous materials.
Innovation Solution
The development of liners made from polyvinyl chloride (PVC) or polyvinylidene fluoride (PVDF) materials, using radio frequency (RF) compression welding and overlap welding techniques to create a single-piece or multi-piece construction that forms a watertight, durable liner with reduced weld points, enhancing strength and preventing peeling issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel process tanks are used to store corrosive fluids, then the tanks provide structural strength and durability, but the tanks become corroded over time leading to reduced lifespan and safety risks
Solution Approach 1:
The patent applies a flexible plastic liner made from corrosion-resistant materials (PVC, PVDF, or HDPE) that lines the interior surface of the steel tank. This thin film barrier protects the steel structure from direct contact with corrosive fluids while maintaining the tank's structural integrity. The liner can be thermally welded to form a continuous protective layer that prevents corrosion and leakage.
Solution Approach 2:
The patent creates a composite structure combining steel (for structural strength) with plastic materials like PVC, PVDF, or HDPE (for corrosion resistance). This composite approach allows the tank to simultaneously achieve mechanical strength from the steel framework and chemical resistance from the plastic liner, resolving the contradiction between strength and reliability.
2Ease of manufacture
If multiple weld points are used to construct liners from sheets, then the liners can be assembled from available materials, but the weld points create potential failure points for peeling and leaks
Solution Approach 1:
The patent merges multiple liner sheets into a single continuous protective layer using thermal welding. The welding process fuses the sheets together at their overlapping edges, creating a unified membrane with no separate joints or seams. This eliminates potential failure points while maintaining the feasibility of constructing large liners from multiple material sheets.
Solution Approach 2:
The patent replaces mechanical fastening methods (screws, clips, adhesives) with thermal welding to join liner sheets. The welding process uses heat to melt and fuse the thermoplastic materials directly, creating a strong, seamless bond that is more reliable than mechanical connections and eliminates peeling issues associated with adhesives or fasteners.
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 RF-welded liners provide enhanced durability and leak resistance, capable of withstanding corrosive environments and extreme temperatures, extending the lifespan of storage tanks while ensuring safety by preventing leaks and maintaining containment.
Implementation Method 1
a radio frequency welding device is used to weld the plastic sheets together
Data Source
AI summary
The present disclosure relates to liners and methods of making liners. The liners may be suitable for use with tanks and other storage/containment vessels, such as process tanks, immersion tanks, indoor or outdoor containment pits, gravity feed conduits (e.g., concrete trench, canal, or drain, etc.) for transferring or conveying liquid, grain storage tanks or containers (e.g., dielectric or electrically non-conductive liners for grain storage, etc.), etc.