Secondary Containment Panel Pre-Coating to Reduce Polyurea Wastage
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Solution Overview
Problem
Conventional secondary containment systems for above-ground fuel and chemical storage tanks face significant challenges due to wastage of polyurea coating material during outdoor application, inefficiencies in transportation, and complexity in equipment management, leading to high costs and environmental concerns.
Innovation Solution
Manufacturing secondary containment panels in an environmentally controlled indoor facility using a computer-controlled robotic sprayer to apply polyurea coating uniformly onto geotextile fabric substrates, reducing wastage and simplifying onsite assembly by pre-fabricating panels with uncoated edges for seamless adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyurea coating is sprayed onto geotextile fabric in outdoor conditions, then the coating provides impermeable protection, but significant coating material is wasted due to wind and rain dissipation
Solution Approach 1:
The patent applies preliminary action by pre-coating the geotextile fabric panels with polyurea coating in a controlled factory environment before transport and installation. This allows the coating to be applied under optimal conditions without weather interference, eliminating wind and rain dissipation issues. The panels are manufactured with the coating already applied and cured, then transported to the site where they are simply assembled and joined, preventing up to 25% coating material wastage that occurs with field application.
2Ease of operation
If polyurea coating is sprayed from a distance to create stippled surface, then slip-resistant texture is achieved, but coating coverage uniformity deteriorates and material loss increases
Solution Approach 1:
The patent applies preliminary action by performing the coating application in a controlled factory setting where distance and angle can be precisely maintained. The robotic or automated spray equipment applies coating at consistent distances from the fabric surface, creating uniform stippled texture across the entire panel. This controlled environment ensures even coating distribution while achieving the required slip-resistant surface, eliminating the coverage variability that occurs with manual field application.
3Quantity of substance
If large amounts of polyurea coating and applicator equipment are transported to site, then complete coating application is possible, but transportation cost and equipment complexity increase
Solution Approach 1:
The patent applies preliminary action by completing the coating application process during panel manufacturing before transport. The panels arrive at the installation site already coated with the required polyurea layer, eliminating the need to transport large quantities of coating material in drums and bulky applicator equipment including pumps and hoses. Only the finished panels need to be transported, significantly reducing transportation costs and equipment complexity while maintaining complete coating coverage.
4Manufacturing precision
If coating is applied in environmentally controlled indoor facility, then coating quality and uniformity improve, but manufacturing process complexity increases
Solution Approach 1:
The patent applies preliminary action by moving the coating application process to a controlled factory environment where quality can be ensured. The manufacturing process uses automated or robotic spray equipment on stationary or conveyor-fed fabric panels, providing consistent coating application with precise control over distance, speed, and material flow. This industrial manufacturing approach, while more complex than field application, produces superior coating quality and uniformity that justifies the controlled environment and automated equipment.
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
Significantly reduces coating material wastage, transportation costs, and equipment complexity, while ensuring uniform coating quality and efficient installation, resulting in a more cost-effective and environmentally friendly secondary containment system.
Implementation Method 1
a computer controlled robotic sprayer to apply a liquid impermeable coating material (e.g., polyurea) to an upper surface of the piece
Data Source
AI summary
A method of manufacturing a plurality of secondary containment panels and assembling and installing the panels in a secondary containment system of an above-ground liquid storage tank or other retention facility includes forming a plurality of flexible substrate pieces. A liquid impermeable coating is applied to the upper surface of each piece such that an edge segment of the piece remains uncoated. The coating is applied to the substrate piece in an indoor enclosure using a computer controlled robotic sprayer that applies a uniform coating. A system for coating secondary containment panels. An apparatus for spraying a coating on a secondary containment panels. The apparatus may be computer controlled and operate automatically to coat the surface of the panel.