Vacuum-Assisted Rubber Lining Vulcanization System
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Solution Overview
Problem
Current methods for vulcanizing rubber linings, such as chemical curing and steam curing, are inefficient and difficult to apply, especially in complex or hard-to-reach areas like tank flanges or manways, leading to time-consuming and incomplete repairs.
Innovation Solution
A system comprising a rubber body, a heating blanket, a breather fabric, a vacuum cover, and a vacuum pump that creates a partial vacuum to vulcanize the rubber while generating heat, ensuring a complete and efficient bonding process even in challenging environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steam curing is used to vulcanize the rubber patch, then the rubber can be cured, but the process becomes difficult and time-consuming as the entire vessel must be filled with steam or the patch must be isolated
Solution Approach 1:
The invention divides the vulcanization process into localized segments by applying heat directly to the rubber patch area rather than heating the entire vessel. The heating blanket is positioned only over the patch area, creating a localized thermal zone that cures the rubber efficiently without requiring steam filling of the entire vessel.
Solution Approach 2:
The invention introduces a heating blanket as an intermediary device between the heat source and the rubber patch. This blanket acts as a mediator that transfers thermal energy directly to the patch area, enabling controlled and efficient vulcanization without the need for steam or direct flame contact.
2Reliability
If chemical curing is used, then the rubber patch can be cured, but only the exposed surface is cured immediately while the balance cures gradually over time
Solution Approach 1:
The invention replaces the chemical curing mechanism with a thermal/mechanical system. Instead of relying on chemical reactions that cure from the surface inward, the heating blanket applies direct thermal energy that penetrates and cures the entire rubber patch thickness simultaneously, transforming the curing process from chemical to thermal-mechanical.
Solution Approach 2:
The heating blanket is applied in a controlled periodic manner, maintaining consistent temperature over the patch area for a predetermined time period. This sustained thermal application ensures complete and uniform curing throughout the rubber thickness, rather than gradual surface-to-core curing.
3Reliability
If steam curing is used, then the rubber can be vulcanized, but it is difficult to apply to certain elements like flanges or manways due to their nature and position
Solution Approach 1:
The heating blanket is designed to provide localized heat application with varying thermal characteristics across different areas. The blanket can be positioned and adjusted to accommodate complex geometries like flanges and manways, delivering appropriate heat intensity and distribution tailored to each specific surface configuration and position.
Solution Approach 2:
The heating blanket system is made dynamic and adaptable rather than fixed. The blanket can be repositioned, reshaped, or adjusted to conform to different geometries and positions, enabling effective vulcanization of various elements including flanges, manways, and other complex surfaces that would be inaccessible to conventional steam curing.
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 allows for rapid and complete vulcanization of rubber linings on complex surfaces, providing a durable and efficient repair solution that overcomes the limitations of traditional methods by using heat and vacuum to ensure thorough bonding.
Implementation Method 1
a heating blanket for generating heat to vulcanize the rubber portion
Implementation Method 2
a vacuum pump in fluid communication with the interior space, for providing a partial vacuum therein to subject the rubber body to a predetermined pressure, and for removing the gases generated upon vulcanizing the rubber portion from the interior space
Data Source
AI summary
A system including one or more rubber bodies with respective rubber portions. The rubber body is positionable on a preselected portion of a surface of an object. An inner side of the rubber body is engageable with the preselected portion, and an outer side thereof is opposed to the inner side. The system includes a release film positionable on the rubber body, a heating blanket positionable on the release film, and a breather fabric. The system also includes a vacuum cover engageable with the breather fabric, which is sealed along a perimeter surrounding the preselected portion of the surface. A vacuum pump is in fluid communication with an interior space partially defined by the vacuum cover, for subjecting the rubber body to a predetermined pressure. The rubber portion is vulcanizable when subjected to heat generated by the heating blanket and to the predetermined pressure.