Storage Tank Patch Stud Friction Welding in Hazardous Environments

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Solution Overview

Problem

Conventional welding techniques for repairing tank components pose risks due to the potential for igniting combustible materials, and they are not suitable for hazardous environments containing volatile or caustic chemicals.

Innovation Solution

The use of a friction welding apparatus that employs inert gas or a vacuum chamber to prevent combustion, combined with a magnetic apparatus and flexible seals, allows for safe and effective bonding of tank components in hazardous environments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional welding techniques are used to repair tank components, then strong joints can be achieved, but the risk of igniting combustible materials increases

Engineering Contradiction:

Improvejoint strengthVSAvoidcombustion risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent employs friction welding technology that operates without ignition sources, eliminating the risk of igniting combustible materials in hazardous environments. The friction welding process generates heat through mechanical friction rather than external ignition, allowing safe repair operations in tanks containing volatile or caustic chemicals.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The invention replaces conventional thermal welding processes with friction welding, which uses mechanical friction to generate heat and create strong joints. This substitution eliminates the need for external ignition sources, arcs, or flames that characterize conventional welding, thereby removing the combustion hazard while maintaining joint strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If conventional welding techniques are used, then bonding can be achieved, but the process is not suitable for hazardous environments with volatile chemicals

Engineering Contradiction:

Improvebonding capabilityVSAvoidhazardous environment compatibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Friction welding creates an inherently safer process for hazardous environments by eliminating external ignition sources. The mechanical friction-based heating mechanism does not require open flames, arcs, or sparks that could ignite volatile chemicals, making the bonding process suitable for tanks containing hazardous materials.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The invention substitutes thermal welding processes with friction welding, replacing chemical/thermal bonding mechanisms with mechanical friction-based bonding. This fundamental substitution removes the incompatibility with hazardous environments while preserving reliable bonding capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Object-affected harmful factors

If friction welding apparatus with inert gas or vacuum chamber is used, then safety in hazardous environments is improved, but device complexity increases

Engineering Contradiction:

Improvecombustion preventionVSAvoidapparatus complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The friction welding process is inherently self-contained and self-regulating. The mechanical friction generates heat automatically without requiring external ignition sources, and the process can be performed in existing tank environments without necessarily requiring additional inert gas systems or vacuum chambers, reducing overall device complexity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

By replacing complex thermal welding systems with simpler friction welding apparatus, the invention reduces device complexity. The friction welding machine requires only mechanical components to generate friction heat, eliminating the need for complex gas delivery systems, vacuum equipment, or sophisticated thermal control systems required by conventional welding methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 ensures safe repair of tank components by preventing combustion and allowing for bonding in hazardous environments, while also providing strong and reliable joints.

Implementation Method 1

a friction welding apparatus that employs inert gas or a vacuum chamber to prevent combustion

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

combined with a magnetic apparatus and flexible seals

Methodology Applied

Scientific EffectMagnetism: Magnetism

Data Source

PatentUS20250035226A1Plurality of Studs being Friction Welded to an Exterior Surface of a Storage Tank having a Block Patch and a Member between the Exterior Surface and the Studs

Publication Date: 2025.01.30 FORGE TECH

AI summary

In some implementations, an apparatus includes a curved portion of a storage tank having an exterior surface, having an interior surface and having a defect, the apparatus also includes a steel patch positioned over the curved portion of a storage tank, a plurality of studs and nuts positioned near an outer perimeter of the steel patch, in which the plurality of studs being friction welded to the exterior surface of the curved portion of a storage tank.