Seamless Flexible Tank via Additive Manufacturing
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Solution Overview
Problem
Current methods for manufacturing containment bladders are costly, labor-intensive, and result in high waste, with limitations in compatibility and innovation due to complex supply chains and labor-intensive cut-and-sew operations, leading to restrictive product design and frequent seam failures.
Innovation Solution
The method involves additive manufacturing using high tenacity yarns coated with precursor protective coatings, deposited in 3D structures, heat-set, and coated with thermosetting resins, allowing for seamless, lightweight, and universally compatible containment bladders with reduced material waste and increased design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional cut-and-sew fabrication methods are used, then storage units can be manufactured with current materials and processes, but the process is labor-intensive, generates high waste, and results in seam failures
Solution Approach 1:
The patent transitions from traditional cut-and-sew fabrication to additive manufacturing, fundamentally changing the manufacturing parameters and processes. This enables seamless construction without cutting or seaming, eliminating material waste associated with traditional methods while maintaining manufacturing capability
Solution Approach 2:
The patent replaces mechanical cutting and seaming operations with additive manufacturing processes that build the storage unit layer by layer. This substitution eliminates the need for physical cutting tools and sewing mechanisms, reducing both labor intensity and material waste
2Productivity
If traditional fabrication methods with multiple supply chain levels are used, then current storage units can be produced, but the supply chain is complex, capital-intensive, and limits product innovation
Solution Approach 1:
The patent merges multiple supply chain functions into a single additive manufacturing process. By combining material deposition, structural formation, and seamless construction in one integrated system, the complex multi-level supply chain is simplified, reducing capital intensity and enabling faster product innovation
Solution Approach 2:
The additive manufacturing system serves multiple functions simultaneously - it can create various storage unit geometries, incorporate different materials, and produce seamless structures all through one platform. This universality eliminates the need for specialized tools and processes for each product variant, streamlining the supply chain
3Strength
If heavier materials are used in traditional storage units, then structural strength can be achieved, but the storage units become heavier and less efficient
Solution Approach 1:
The additive manufacturing process enables local optimization of material distribution within the storage unit structure. Material is deposited only where structurally necessary, creating varying wall thicknesses and densities in different regions. This maintains overall structural strength while minimizing total material usage and weight
Solution Approach 2:
The patent utilizes composite material structures created through additive manufacturing, combining different materials with complementary properties. This allows the storage unit to achieve high strength-to-weight ratio by strategically placing materials based on their specific mechanical properties rather than using uniform heavy materials throughout
4Ease of manufacture
If adhesive chemistries and overlapped seams are used to assemble storage units, then parts can be joined together, but the seams become the primary mode of failure and require skilled labor
Solution Approach 1:
The additive manufacturing process extracts the seaming operation entirely from the manufacturing process. By building the storage unit as a single seamless structure, the patent eliminates adhesive application, seam overlapping, and associated skilled labor requirements, while completely removing the reliability issue of seam failures
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 reduces manufacturing costs, minimizes waste, and enables the production of lighter, more versatile containment bladders with enhanced performance and compatibility across various contents, while eliminating seam failures and allowing for faster, more scalable production.
Implementation Method 1
coating the yarn materials with a precursor protective coating
Implementation Method 2
heat-set
Data Source
AI summary
A method of fabricating a tank includes connecting a pressure source to a nozzle on a male mold, inflating the male mold via the nozzle, forming a tank by applying at least one layer over the outer surface of the male mold, the tank having a port formed about the nozzle, deflating the male mold, and withdrawing the male mold through the port. A method of fabricating a tank includes 3D-printing a male mold, connecting a pressure source to a nozzle on the male mold, inflating the male mold via the nozzle, forming a tank by applying at least one layer over the outer surface of the male mold, the tank having a port formed about the nozzle, deflating the male mold, and withdrawing the male mold through the port. A method of fabricating a tank includes forming a tank on a mold formed from a foam blocks.