Rotational Molded Liquid Tank With Integrated Baffles
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Solution Overview
Problem
Rotationally molded liquid transport tanks face structural integrity issues due to internal pressure and sloshing forces, which can lead to instability and potential tank failure, and existing baffle systems are costly and do not enhance structural strength.
Innovation Solution
A hollow walled structure with integrated thermoplastic supports and baffles formed concurrently through rotational molding, which includes vertically oriented baffles and posts to distribute force and limit liquid movement, enhancing structural integrity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If rotationally molded tanks are used for liquid transport, then light weight and corrosion resistance are achieved, but structural integrity deteriorates under internal pressure and sloshing forces
Solution Approach 1:
The patent combines the tank shell and internal support structures into a single integrated rotomolded component. The support ribs and baffles are formed as integral parts of the tank wall during the rotational molding process, eliminating the need for separate reinforcement elements while maintaining structural integrity under pressure and sloshing forces.
Solution Approach 2:
The patent employs a composite structure where the tank wall incorporates integrated support ribs and baffles formed from the same thermoplastic material. This creates a composite-like structure within a single material system, providing enhanced strength-to-weight ratio while maintaining the advantages of rotomolded construction.
2Stability of the object's composition
If fixed baffles are installed in the tank to limit liquid sloshing, then liquid movement is reduced, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the baffle function directly into the tank wall structure through integrally formed support ribs and baffles. These structures are created as part of the rotational molding process itself, eliminating the need for separate baffle components and their associated installation steps, thereby reducing overall device complexity while maintaining liquid stability.
Solution Approach 2:
The tank structure provides its own baffling function through the integrally formed support ribs and internal structures. The tank wall itself serves the dual purpose of containing the liquid and limiting its movement, eliminating the need for additional dedicated baffling components.
3Stability of the object's composition
If numerous separate baffle components are used to limit liquid movement, then liquid sloshing is reduced, but manufacturing cost and installation complexity increase
Solution Approach 1:
The patent combines multiple functions (tank wall, support structure, and baffle) into a single rotomolded component. This integration eliminates the need for multiple separate parts, reducing manufacturing steps, assembly operations, and associated costs while effectively controlling liquid movement within the tank.
Solution Approach 2:
The rotational molding process itself creates the baffling structures as integral features of the tank wall. The manufacturing process provides the structural reinforcement and liquid control features without requiring separate manufacturing steps for additional components, thereby simplifying production and reducing costs.
4Ease of manufacture
If integrally molded support structures are formed through rotational molding, then manufacturing simplicity and cost-effectiveness are improved, but the ability to withstand high forces may be limited
Solution Approach 1:
The patent combines the tank shell and internal support structures into a single integrated rotomolded component. The support ribs and baffles are formed as integral parts of the tank wall during the rotational molding process, eliminating the need for separate reinforcement elements while maintaining structural integrity under pressure and sloshing forces.
Solution Approach 2:
The patent utilizes curved, ribbed structures integrated into the tank wall that distribute mechanical forces more effectively throughout the structure. The rotational molding process naturally creates smooth, curved surfaces and integrated rib structures that enhance force distribution and resistance while maintaining manufacturing simplicity.
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 solution effectively withstands internal forces, reduces the risk of tank failure, and simplifies manufacturing by integrating supports and baffles within the rotational molding process, providing a cost-effective and durable liquid transport solution.
Implementation Method 1
the mold is heated as it is slowly rotated bi-axially. The simultaneous heating and rotation causes the melting resin to generally coat the entire inner surface of the mold and fuse.
Implementation Method 2
the mold is heated as it is slowly rotated bi-axially. The simultaneous heating and rotation causes the melting resin to generally coat the entire inner surface of the mold and fuse.
Data Source
AI summary
A hollow walled structure (22) includes a shell (36) having a wall defining an interior compartment (46). A first support, in the form of a baffle (48), is disposed within the interior compartment (46) and engages the shell (36) at two locations (52, 54). A second support, in the form of a post (83), engages the shell (36) and extends through the interior compartment (46) to intersect the baffle (48). The shell (36), baffle (48), and post (83) are formed concurrently from a thermoplastic material by a rotational molding process. The rotational molding process can entail operations of pre-heating interior portions of the mold, delivering heat to the interior portions of the mold, and/or filling the mold with excess thermoplastic material prior to preheating the mold. The rotationally molded structure (22) has sufficient strength to function as a tank for carrying a liquid (34) in a liquid transport apparatus (20).