Apparatus and method for making large diameter wound-fiber reinforced tanks

• US 20070151974A1
• Filed: 12/30/2005
• Published: 07/05/2007
• Est. Priority Date: 12/30/2005
• Status: Active Grant

• Current Assignee: John Boyd
• Original Assignee: John Boyd
• Inventors: Boyd, John
• Granted Patent: US 7,481,899 B2
• Time in Patent Office: Days
• US Class Current: 220/560.30
• CPC Class Codes: B29C 53/66 with axially movable winding feed member , e.g. lathe type winding
• CPC Class Codes: B29C 53/821 Mandrels especially adapted for winding and joining
• CPC Class Codes: B65D 88/08 with a vertical axis
• CPC Class Codes: B65D 90/029 Wound structures
• CPC Class Codes: F17C 1/06 built-up from wound-on bands or filamentary material, e.g. wires
• CPC Class Codes: F17C 1/16 constructed of plastics materials shaping of plastics B29C
• CPC Class Codes: F17C 2201/0104 cylindrical
• CPC Class Codes: F17C 2201/032 with substantially vertical main axis
• CPC Class Codes: F17C 2201/052 large (>1000 m3)
• CPC Class Codes: F17C 2203/0617 with one layer
• CPC Class Codes: F17C 2203/0663 in form of fibers or filaments
• CPC Class Codes: F17C 2203/067 helically wound
• CPC Class Codes: F17C 2209/2163 with a mandrel
• CPC Class Codes: F17C 2209/23 Manufacturing of particular parts or at special locations
• CPC Class Codes: F17C 2260/013 Reducing manufacturing time or effort
• CPC Class Codes: F17C 2270/0136 Terminals

Abstract

A process of constructing a large diameter tank is provided. The process includes the step of providing a tank wall mandrel that has at least one drive wheel and at least one curved panel. Glass fibers are applied from a vertical winder to the curved panel in order to form a segment of a tank wall shell. Additional glass fibers are also applied to the curved panel at a location above the segment of the tank wall shell in order to form a unitary tank shell.

Claims

1. A process of constructing a large diameter tank, comprising:

providing a tank wall mandrel;

supporting a circumference of said mandrel with a plurality of drive and support wheels;

positioning a plurality of curved panels along an exterior of said mandrel;

rotating said mandrel and said curved panels by use of said drive wheels;

positioning a vertical winder adjacent said mandrel;

applying glass fibers from said vertical winder to the surface of said rotating curved panels, thereby constructing a segment of a tank wall shell;

detaching said curved panels from the interior surface of said tank wall shell;

positioning said curved panels above said previously formed tank wall shell;

rotating said mandrel and said previously formed tank wall shell;

applying additional glass fibers to said curved panels and to an upper portion of said tank wall shell, thereby forming a unitary tank shell; and

, repeating the last four of said steps until a desired tank shell height is obtained.

2. The process as set forth in claim 1, wherein said unitary tank shell has a diameter of at least sixteen feet.

3. The process as set forth in claim 1, wherein said unitary tank shell has a diameter of at least sixty feet.

4. The process as set forth in claim 1, wherein said steps are repeated until a desired tank shell height of at least thirty feet is obtained.

5. The process as set forth in claim 1, wherein said steps are repeated until a desired tank shell height of at least fifteen feet is obtained.

6. The process as set forth in claim 1, wherein said mandrel has a plurality of vertical trusses extending above said previously formed tank wall shell and onto which said curved panels are positioned.

7. The process as set forth in claim 1, wherein said step of rotating said mandrel and said previously formed tank wall shell and said step of rotating said mandrel and said curved panels by use of said drive wheels are conducted in a circular direction.

8. The process as set forth in claim 1, wherein said step of applying additional glass fibers includes moving vertically said vertical winder above said previously formed tank wall shell.

16. The process as set forth in claim 1, wherein said unitary tank has a height of at least fifteen feet.

9. A process of constructing a large diameter tank, comprising:

providing a tank wall mandrel having at least one drive wheel and at least one curved panel;

applying glass fibers from a vertical winder to said curved panel so as to form a segment of a tank wall shell; and

applying additional glass fibers to said curved panel at a location above said segment of a tank wall shell so as to form a unitary tank shell.

10. The process as set forth in claim 9, further comprising the steps of:

closing said unitary tank shell with a tank bottom; and

closing said unitary tank shell with an upper tank closure.

11. The process as set forth in claim 9, further comprising the step of positioning a plurality of said curved panels on said mandrel above said segment of the tank wall shell in order for said additional glass fibers to be applied.

12. The process as set forth in claim 9, wherein said application steps of said glass fibers and said additional glass fibers are performed by a vertical winder, and further comprising the step of rotating said mandrel and said curved panel with respect to said vertical winder to perform said application steps of said glass fibers and said additional glass fibers.

13. The process as set forth in claim 9, wherein said mandrel has a plurality of said drive wheels and a plurality of support wheels, and wherein said mandrel has a plurality of vertical trusses onto which said curved panels are positioned.

14. The process as set forth in claim 9, wherein said unitary tank shell has a diameter of at least sixty feet.

15. The process as set forth in claim 9, wherein said unitary tank shell has a height of at least thirty feet.

17. A large diameter tank made by a process comprising the steps of:

providing a tank wall mandrel having at least one drive wheel and a plurality of curved panels;

rotating said mandrel by said drive wheel;

positioning a vertical winder adjacent said mandrel;

applying glass fibers from said vertical winder to said curved panels so as to form a segment of a tank wall shell;

repositioning said curved panels above said segment of the tank wall shell;

rotating said mandrel and said segment of the tank wall shell by said drive wheel

repositioning said vertical winder; and

applying additional glass fibers to said curved panel at a location above said segment of the tank wall shell so as to form a unitary tank shell.

18. The large diameter tank made by the process as set forth in claim 17, further comprising the step of repeating said repositioning steps, said rotating said mandrel and said segment step, and said applying additional glass fibers step until a desired unitary tank shell height is obtained.

19. The large diameter tank made by the process as set forth in claim 17, wherein said unitary tank shell has a diameter of at least sixty feet.

20. The large diameter tank made by the process as set forth in claim 17, wherein said mandrel has a plurality of vertical trusses onto which said curved panels are positioned.