Woven Polyethylene Irrigation Tubing for Pressure and Recyclability
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Solution Overview
Problem
Existing crop irrigation systems face inefficiencies due to high water evaporation in aerial spraying methods and limitations in pressure handling and recyclability of irrigation tubing materials, with early systems using recyclable polyethylene but later designs compromising on recyclability for higher pressure capabilities.
Innovation Solution
A woven, extrusion-coated, and laminated irrigation tubing system made from LLDPE, HDPE, and LDPE materials, capable of handling higher pressures, designed for longer life, easy recyclability, and cost-effective manufacturing, with a three-layer structure and UV protection, manufactured through specific processes involving tape formation, weaving, and extrusion coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If later irrigation tubing designs are used to accommodate higher pressures, then pressure handling capability is improved, but recyclability deteriorates
Solution Approach 1:
The patent applies composite materials by combining multiple polyethylene materials (HDPE, LLDPE, LDPE) in a multi-layer woven structure. The outer layer uses HDPE for strength and pressure handling, while inner layers use LLDPE and LDPE for flexibility and recyclability. This composite approach allows the tubing to accommodate higher pressures while maintaining recyclability through the use of polyethylene materials throughout.
2Ease of manufacture
If early irrigation tubing systems are used to maintain recyclability, then recyclability is improved, but pressure handling capability deteriorates
Solution Approach 1:
The patent uses composite materials with a multi-layer construction where the outer layer is HDPE woven fabric providing pressure strength, while inner layers use LLDPE and LDPE extrusions for flexibility and recyclability. This composite structure enables the tubing to handle higher pressures than early single-material systems while remaining fully recyclable.
3Strength
If woven structure is implemented to increase strength, then pressure handling is improved, but manufacturing complexity increases
Solution Approach 1:
The patent implements a woven structure using HDPE tape woven into a tubular fabric, which is then coated with extruded LLDPE and LDPE layers. This composite woven structure provides high strength for pressure handling while the extrusion coating process integrates the different materials in a continuous manufacturing operation, managing complexity through process integration.
Solution Approach 2:
The tubing is segmented into distinct functional layers: an outer woven HDPE layer for strength and pressure handling, and inner extruded LLDPE and LDPE layers for flexibility and recyclability. This segmentation allows each layer to be optimized for its specific function while being manufactured through an integrated process.
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 system effectively addresses the limitations by accommodating higher pressures, extending the tubing's useful life, ensuring recyclability, and reducing manufacturing and shipping costs while maintaining efficiency in water transport.
Implementation Method 1
coating a molten middle layer of Low Density Polyethylene (LDPE) resin on the upper and lower surfaces of the flattened, woven tube
Implementation Method 2
Melting High Density Polyethylene (HDPE) resin... Extruding the melted resin through a flat die to form a sheet
Implementation Method 3
laminating an inside layer of Linear Low Density Polyethylene (LLDPE) film onto said middle layer of LDPE, forming upper and lower LLDPE layers
Implementation Method 4
Stretching the tape along its length using a tentering frame machine to increase longitudinal tape strength
Implementation Method 5
Cooling the extruded sheet in a quenching tank
Data Source
AI summary
Woven irrigation tubing comprising a woven, extrusion coated & laminated tube formed of a high density polyethylene (HDPE) outer layer, a low density polyethylene (LDPE) middle layer and a linear low density polyethylene (LLDPE) inner layer. The finished tubing is treated for ultraviolet resistance. The tubing is tied off at a distal end with a proximal end connected to a pressurized irrigation source. Watering holes are created in the tubing at spaced intervals and the resulting water streams are directed into parallel plowed furrows. The tubing is completely recyclable. The tubing is formed by manufacturing tape for the woven outer tubing cover, stretching the tape along its length to strengthen it, weaving the outer layer from the tape, flattening the woven outer layer, extrusion coating each surface of the outer layer with LDPE, laminating the LLDPE inner layer to the LDPE, reversing and winding the tubing for storage and distribution.