Sprayed Foam Insulation with Junction Elements for Cryogenic Tank Walls
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Solution Overview
Problem
Existing methods for manufacturing thermally insulating membrane tanks, such as those for liquefied natural gas storage and transportation, are costly and inefficient due to the use of prefabricated panels and formwork that do not account for thermal contraction, leading to discontinuities in insulation and mechanical stress.
Innovation Solution
A method involving the in-situ spraying of insulating foam into compartments defined by modular formwork elements, with anchoring elements and insulating junction elements that expand to maintain continuity of thermal insulation and simplify installation, while allowing for mechanical stress relief and adherence to the support structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If prefabricated insulating panels are used, then the insulation can be installed using standardized components, but the installation process becomes lengthy and costly due to transporting and installing panels one by one
Solution Approach 1:
The patent replaces the mechanical assembly of prefabricated panels with a chemical foaming process. Insulating foam is sprayed directly onto the support structure, where it expands and cures in situ, eliminating the need for mechanical handling, transportation, and assembly of multiple panels. This substitution of mechanical installation with a chemical formation process dramatically increases installation productivity.
Solution Approach 2:
The insulating foam serves multiple functions automatically: it adheres to the support structure, forms the insulation layer, and creates its own structural integrity through expansion and curing. The material self-configures to fill the space between the support structure and the membrane, eliminating the need for separate installation steps required by prefabricated panels.
2Ease of manufacture
If formwork is used to contain insulating foam, then the foam can be sprayed in situ, but the formwork does not permit compensation for thermal contraction, leading to discontinuity in insulation
Solution Approach 1:
The patent changes the physical state and mechanical properties of the insulation system by using a flexible foam material that can undergo phase changes and dimensional adjustments. The foam's ability to change volume and density allows it to compensate for thermal contraction at cryogenic temperatures, maintaining insulation continuity without rigid formwork constraints.
Solution Approach 2:
The patent explicitly utilizes thermal expansion and contraction principles by designing the foam insulation system to accommodate dimensional changes. The foam's cellular structure and material properties enable it to expand when warm and contract when cold, maintaining continuous insulation coverage throughout temperature cycles without creating gaps or discontinuities.
3Device complexity
If rigid formwork is used to define compartments, then the structure provides defined sections, but it creates mechanical stresses due to temperature differences between external and internal surfaces
Solution Approach 1:
The patent employs the flexible foam material as a compliant insulation layer that can accommodate thermal stresses. Unlike rigid formwork, the foam can deform elastically in response to temperature differentials, distributing mechanical stresses uniformly and preventing stress concentration that would occur with rigid compartmentalization structures.
Solution Approach 2:
The patent transforms the static, rigid compartmentalization into a dynamic system where the foam insulation can adapt its shape and volume in response to thermal conditions. The foam's viscoelastic properties allow it to continuously adjust to temperature changes, maintaining structural integrity and reducing mechanical stresses through dynamic deformation rather than rigid resistance.
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 method reduces installation costs and ensures continuous thermal insulation by allowing the insulating foam to expand and contract, maintaining insulation integrity at cryogenic temperatures and simplifying the installation process.
Implementation Method 1
spraying insulating foam into said compartments through the open side so as to form a plurality of insulating sectors made from sprayed insulating foam; arranging insulating junction elements in a stressed position in which they are stressed between said insulating sectors and capable of expanding when said insulating sectors contract
Implementation Method 2
manufacturing such tanks from prefabricated insulating panels. These insulating panels have a layer of insulating foam... forming a sealed and thermally insulating barrier for a storage tank
Data Source
AI summary
A method for producing a sealed and thermally insulating wall for a fluid storage tank includes attaching plural anchoring elements to a support structure; installing modular formwork elements on the support structure, the modular formwork elements having a shape that protrudes relative to the support structure and that defines, with the support structure and the plurality of anchoring parts, compartments having an open side opposite the support structure; spraying insulating foam into the compartments through the open side to form plural insulating sectors made from sprayed insulating foam; arranging insulating junction elements in a stressed position in which they are stressed between the insulating sectors and capable of expanding when the insulating sectors contract, to ensure continuity of the thermal insulation; and attaching a sealing membrane to the anchoring elements.