Thermoplastic Vessel Manufacturing with Cooling Liquid Rigidity
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Solution Overview
Problem
Existing methods for manufacturing pressure-resistant and leak-tight vessels using thermoplastic materials face challenges such as incompatibility between thermoplastic and thermoset materials, difficulty in recycling, and the need for additional layers that compromise mechanical strength and gas/liquid tightness, especially in smaller vessels like fire extinguishers.
Innovation Solution
A method involving a removable external mandrel for forming a thermoplastic internal wall, followed by reinforcement with additional thermoplastic material through winding and heat consolidation, using a cooling liquid to maintain the internal wall's rigidity and integrity during the process, resulting in a single-layer thermoplastic vessel with enhanced mechanical strength and gas/liquid tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal vessels are used for high pressure storage, then strength and pressure resistance are improved, but weight increases and corrosion resistance deteriorates
Solution Approach 1:
The patent applies composite materials by combining thermoplastic synthetic material (for corrosion resistance and lightweight properties) with thermoset material or reinforcement layers (for strength and pressure resistance). This creates a multi-layer composite structure that achieves both lightweight and high strength requirements, resolving the contradiction between weight and pressure resistance.
2Strength
If metal vessels are used, then strength is improved, but corrosion resistance deteriorates due to rust formation
Solution Approach 1:
The patent uses composite materials where the thermoplastic synthetic material layer provides corrosion resistance by isolating the vessel interior from aggressive substances, while the thermoset material or reinforcement layers provide structural strength. This composite approach simultaneously achieves both corrosion resistance and structural integrity.
Solution Approach 2:
The patent applies local quality by using different materials for different functional requirements: the inner layer uses thermoplastic synthetic material specifically for corrosion resistance where it contacts the stored substance, while outer layers use thermoset material for strength where structural support is needed.
3Object-affected harmful factors
If multi-layer construction is used with thermoplastic and thermoset materials, then corrosion resistance is improved, but compatibility and manufacturing complexity worsen
Solution Approach 1:
The patent applies preliminary action by first forming the thermoplastic synthetic material layer as an inner liner before adding the thermoset material or reinforcement layers. This sequential approach simplifies manufacturing by establishing the corrosion-resistant base layer first, then building strength layers upon it, avoiding the complexity of simultaneously coordinating multiple material applications.
4Ease of manufacture
If air escape holes are provided in metal outer layer, then blow-molding is enabled, but mechanical strength deteriorates
Solution Approach 1:
The patent applies inversion by reversing the traditional approach: instead of providing air escape holes in the outer metal layer during blow-molding, the invention forms the thermoplastic inner layer first using blow-molding techniques, then adds the thermoset material or reinforcement layers subsequently. This eliminates the need for air escape holes in the final structure, preserving mechanical strength while still enabling the blow-molding process for the inner layer.
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 method produces vessels that are lightweight, cost-effective, and resistant to corrosion and high temperatures, maintaining mechanical strength and gas/liquid tightness, while avoiding the limitations of multi-layered constructions and the risks associated with metal vessels.
Implementation Method 1
filling of the thermoplastic internal wall with a cooling liquid; consolidation of the reinforced thermoplastic material by heat; removal of the cooling liquid
Implementation Method 2
consolidation of the reinforced thermoplastic material by heat
Data Source
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AI summary
The present invention relates to a method for the manufacture of pressure-resistant gas and/or liquid tight containers made from thermoplastic materials. To this end the method comprises the following steps : providing a removable external mandrel around a neckpiece, followed by providing at the inside of such mandrel a thermoplastic material for the manufacture of a thermoplastic internal wall. Hereupon the external mandrel is removed and the thermoplastic internal wall is filled with a cooling liquid. Hereupon additional thermoplastic material is provided to the external side of the thermoplastic wall and is consolidated either during the provision hereof, or thereafter or both. Hereupon the cooling liquid is removed and the container is ready for being used.