US4974739A — Storage tank and method of making a storage tank

Claim 1

Independent Claim 94 words

A storage tank for a liquid, comprising: an inner wall and an outer wall in closely spaced adjacent relation, a porous, needled non-woven fibrous, material disposed between said inner and outer walls, said porous material being in intimate contact with said inner and outer walls, and a fiber-coating binder coating all fibers of said porous material, said binder also bonding all fibers of said porous material together and to said inner and outer walls, and said binder leaving small passages having a capillary characteristic between said coated and bonded fibers of said porous material.

Claim 2

Dependent Claim 94 words

A storage tank for a liquid, comprising: an inner wall and an outer wall in closely spaced adjacent relation, a porous, needled non-woven fibrous, material disposed between said inner and outer walls, said porous material being in intimate contact with said inner and outer walls, and a fiber-coating binder coating all fibers of said porous material, said binder also bonding all fibers of said porous material together and to said inner and outer walls, and said binder leaving small passages having a capillary characteristic between said coated and bonded fibers of said porous material.

Claim 3

Dependent Claim 44 words

The storage tank as defined by claim 1 wherein said porous material disposed between said inner and outer walls is a batt comprised of a needled non-woven fibrous composite material having inner and outer surfaces in intimate contact with said inner and outer walls.

Claim 4

Dependent Claim 50 words

The storage tank as defined by claim 1 including sensing means associated with said porous material at strategic points, said sensing means being adapted to detect the presence of a leak, said sensing means including at least one type sensor for detecting the presence of a preselected type of liquid.

Claim 5

Dependent Claim 62 words

The storage tank as defined by claim 3 wherein said sensing means includes at least two different types of sensors, one of said sensor types being adapted to detect the presence of said liquid in said storage tank, the other of said sensor types being adapted to detect the presence of another liquid normally intended to be maintained outside said storage tank.

Claim 6

Dependent Claim 139 words

In a storage tank for a liquid having an inner wall and an outer wall spaced from said inner wall, the improvement comprising a batt of porous material comprised of a needled non-woven fibrous composite material disposed between said inner and outer walls, said composite material containing a fiber-coating binder coating and bonding all fibers of said composite material together, said binder leaving small passages having a capillary characteristic between said coated and bonded fibers of said composite material, said batt being in intimate contact with said inner and outer walls and being adapted to wick any liquid coming into contact therewith, sensing means associated with said batt at strategic points relative to said inner and outer walls for detecting the presence of a leak, and means associated with said sensing means for indicating the presence of said leak.

Claim 7

Dependent Claim 139 words

In a storage tank for a liquid having an inner wall and an outer wall spaced from said inner wall, the improvement comprising a batt of porous material comprised of a needled non-woven fibrous composite material disposed between said inner and outer walls, said composite material containing a fiber-coating binder coating and bonding all fibers of said composite material together, said binder leaving small passages having a capillary characteristic between said coated and bonded fibers of said composite material, said batt being in intimate contact with said inner and outer walls and being adapted to wick any liquid coming into contact therewith, sensing means associated with said batt at strategic points relative to said inner and outer walls for detecting the presence of a leak, and means associated with said sensing means for indicating the presence of said leak.

Claim 8

Dependent Claim 43 words

The storage tank as defined by claim 5 wherein said sensing means includes at least two different types of sensors with one type sensor detecting the presence of one type liquid and the other type sensor detecting the presence of another type liquid.

Claim 9

Dependent Claim 70 words

The storage tank as defined by claim 6 wherein said one type sensor detects the presence of said liquid in said storage tank in the event said liquid in said storage tank should leak through said inner wall and the other type sensor detects the presence of another liquid normally intended to be maintained outside said storage tank in the event said other liquid should leak through said outer wall.

Claim 10

Dependent Claim 165 words

In a storage tank for a liquid having an inner wall and an outer wall spaced from said inner wall, the improvement comprising a batt of porous material comprised of a needled non-woven fibrous composite material disposed between said inner and outer walls, said batt having inner and outer surfaces in intimate contact with confronting spaced apart surfaces of said inner and outer walls, respectively, and having the characteristic of wicking any liquid coming in contact therewith, said composite material containing a fiber-coating binder coating and bonding all fibers of said composite material together, said binder leaving small passages having a capillary characteristic between said coated and bonded fibers of said composite material, sensing means mounted in strategic points about both said inner and outer surfaces of said batt for detecting the presence of any liquid leaking through either of said inner and outer walls of said tank, and means operatively associated with said sensing means for warning of the presence of any leaking liquid.

Claim 11

Dependent Claim 165 words

In a storage tank for a liquid having an inner wall and an outer wall spaced from said inner wall, the improvement comprising a batt of porous material comprised of a needled non-woven fibrous composite material disposed between said inner and outer walls, said batt having inner and outer surfaces in intimate contact with confronting spaced apart surfaces of said inner and outer walls, respectively, and having the characteristic of wicking any liquid coming in contact therewith, said composite material containing a fiber-coating binder coating and bonding all fibers of said composite material together, said binder leaving small passages having a capillary characteristic between said coated and bonded fibers of said composite material, sensing means mounted in strategic points about both said inner and outer surfaces of said batt for detecting the presence of any liquid leaking through either of said inner and outer walls of said tank, and means operatively associated with said sensing means for warning of the presence of any leaking liquid.

Claim 12

Dependent Claim 103 words

The storage tank as defined by claim 8 wherein said sensing means includes at least two different types of sensors with one type sensor detecting the presence of one type liquid and the other type sensor detecting the presence of another type liquid, said one type sensor detecting the presence of said liquid in said storage tank in the event said liquid in said storage tank should leak through said inner wall, the other type sensor detecting the presence of another liquid normally intended to be maintained outside said storage tank in the event the other liquid should leak through said outer wall.

Claim 13

Independent Claim 105 words

A method of making a storage tank for a liquid comprising the steps of laying up a shell forming one wall of said tank, applying a porous, needled non-woven fibrous, material to one surface of said one wall of said tank; forming a structural bond by applying a fiber-coating binder to coat and bond all fibers of said porous material together and to said one wall, said binder leaving small passages having a capillary characteristic between said coated and bonded fibers of said porous material, laying up another shell on said porous material to form another wall of said tank bonded to said porous material.

Claim 14

Independent Claim 105 words

A method of making a storage tank for a liquid comprising the steps of laying up a shell forming one wall of said tank, applying a porous, needled non-woven fibrous, material to one surface of said one wall of said tank; forming a structural bond by applying a fiber-coating binder to coat and bond all fibers of said porous material together and to said one wall, said binder leaving small passages having a capillary characteristic between said coated and bonded fibers of said porous material, laying up another shell on said porous material to form another wall of said tank bonded to said porous material.

Claim 15

Dependent Claim 65 words

The method of making a storage tank as defined by claim 10 wherein said porous material is a batt formed of a needled non-woven fibrous composite material having inner and outer surfaces, said batt being applied to said one wall of said tank by placing one of said surfaces of said batt in contact with said one surface of said one wall of said tank.

Claim 16

Dependent Claim 73 words

The method of making a storage tank as defined by claim 10 wherein said structural bond is formed by first applying said binder to said one surface of said one wall of said tank, next applying one surface of said porous material to said binder coated surface, next applying said binder to the other surface of said porous material, and then forming said other wall on the other surface of said porous material.

Claim 17

Dependent Claim 42 words

The method of making a storage tank as defined by claim 11 including the step of first saturating said batt with a fiber-coating binder to substantially coat fibers of said composite material with said binder so as to bond said fibers together.

Claim 18

Dependent Claim 40 words

The method of making a storage tank as defined by claim 13 including the step of next removing excess fiber-coating binder from said batt by compressing said batt after saturation to ensure that said fibers are coated and bonded together.

Claim 19

Dependent Claim 43 words

The method of making a storage tank as defined by claim 14 wherein the step of applying said batt is performed before said fiber-coating binder cures, and including the step of forming a skin on the other of said surfaces of said batt.

Claim 20

Dependent Claim 49 words

The method of making a storage tank as defined by claim 15 wherein the step of laying up the other shell on said batt is performed before said fiber-coating binder cures, the other shell being laid up on said skin on the other of said surfaces of said batt.

Claim 21

Dependent Claim 45 words

The method of making a storage tank as defined by claim 13 including the step of next removing excess fiber-coating binder from said batt by allowing a solvent in said binder to evaporate after saturation to ensure that said fibers are coated and bonded together.

Claim 22

Dependent Claim 46 words

The method of making a storage tank as defined by claim 10 including the steps of installing at least one type of liquid sensor in said porous material so as to be positioned between said shells at strategic points to detect the presence of a leak.

Claim 23

Dependent Claim 46 words

The method of making a storage tank as defined by claim 18 wherein said one type of sensor detects the presence of said liquid in said storage tank in the event said liquid in said storage tank should leak through an inner one of said walls.

Claim 24

Dependent Claim 51 words

The method of making a storage tank as defined by claim 19 including the step of installing a second type of sensor for detecting the presence of another liquid normally intended to be maintained outside said storage tank in the event of a leak through an outer one of said walls.

Claim 25

Dependent Claim 36 words

The method of making a storage tank as defined by claim 10 including the step of first forming a film on one surface of said porous material capable of subsequently resisting penetration of said fiber-coating binder.

Claim 26

Dependent Claim 149 words

A storage tank for a liquid, comprising: a tank wall and a composite wall formed thereon; said composite wall being applied to said tank wall by first applying a liquid resin to a surface of said tank wall, said composite wall comprising a pours batt comprised of a needled non-woven fibrous composite material having a barrier layer formed on one surface thereof by first coating said one surface of said composite wall with a liquid resin and by then heating said one surface of said composite wall having said liquid resin, said composite wall being placed on said tank wall with the surface opposite said barrier layer in contact with said liquid resin, said liquid resin coating and bonding together all fibers of said composite material inwardly of said barrier layer while leaving small passages having a capillary characteristic between said coated and bonded fibers of said composite material.

Claim 27

Dependent Claim 149 words

A storage tank for a liquid, comprising: a tank wall and a composite wall formed thereon; said composite wall being applied to said tank wall by first applying a liquid resin to a surface of said tank wall, said composite wall comprising a pours batt comprised of a needled non-woven fibrous composite material having a barrier layer formed on one surface thereof by first coating said one surface of said composite wall with a liquid resin and by then heating said one surface of said composite wall having said liquid resin, said composite wall being placed on said tank wall with the surface opposite said barrier layer in contact with said liquid resin, said liquid resin coating and bonding together all fibers of said composite material inwardly of said barrier layer while leaving small passages having a capillary characteristic between said coated and bonded fibers of said composite material.

Claim 28

Dependent Claim 26 words

The storage tank as defined by claim 22 wherein said liquid resin used to coat said one surface of said composite wall is a latex resin.

Claim 29

Dependent Claim 54 words

The storage tank as defined by claim 22 wherein a first coat of said liquid resin is applied to said surface of said tank wall, said first coat being allowed to set until it becomes tacky, and then a second coat of said liquid resin is applied to said surface of said tank wall.

Claim 30

Dependent Claim 24 words

The storage tank as defined by claim 24 wherein said liquid resin applied to said surface of said tank wall is a polyester resin.

Claim 31

Dependent Claim 52 words

The storage tank as defined by claim 24 wherein said composite wall is placed on said tank wall so as to be held in place by said tacky first coat of said liquid resin while said second coat of said liquid resin on said tank wall is penetrating into said composite wall.

Claim 32

Dependent Claim 53 words

The storage tank as defined by claim 26 wherein said barrier layer is formed prior to applying said composite wall to said tank wall by first coating said one surface of said composite wall with a liquid resin and by then heating said one surface of said composite wall having said liquid resin.

Claim 33

Dependent Claim 60 words

The storage tank as defined by claim 26 including a second tank wall on said composite wall, said second tank wall being formed by first applying a first coat of a liquid resin to said barrier layer, said second tank wall being completed by thereafter applying a second coat of a liquid resin and chopped fiberglass to said barrier layer.

Claim 34

Dependent Claim 29 words

The storage tank as defined by claim 28 wherein one of said tank walls is an inner wall and the other of said tank walls is an outer wall.

Claim 35

Dependent Claim 25 words

The storage tank as defined by claim 29 wherein said inner wall comprises a liquid-retaining wall defining a sealed chamber for retaining a liquid therewithin.

Claim 36

Independent Claim 166 words

A method of making a storage tank for a liquid, comprising the steps of: providing a tank wall and a fibrous porous material; forming a barrier layer on said porous material substantially reducing porosity of one surface thereof; applying a first coat of liquid resin to a surface of said tank wall, allowing said first coat to set until it becomes tacky, and applying a second coat of said liquid resin onto said surface of said tank wall; and placing the surface of said porous material opposite said barrier layer in contact with said liquid resin so as to be held in place by said tacky first coat of said liquid resin while said second coat of said liquid resin is penetrating into said porous material to coat and structurally bond together all fibers thereof while leaving small passages having a capillary characteristic between said bonded fibers of said porous material; whereby said porous material and liquid resin form a composite wall on said tank wall.

Claim 37

Independent Claim 166 words

A method of making a storage tank for a liquid, comprising the steps of: providing a tank wall and a fibrous porous material; forming a barrier layer on said porous material substantially reducing porosity of one surface thereof; applying a first coat of liquid resin to a surface of said tank wall, allowing said first coat to set until it becomes tacky, and applying a second coat of said liquid resin onto said surface of said tank wall; and placing the surface of said porous material opposite said barrier layer in contact with said liquid resin so as to be held in place by said tacky first coat of said liquid resin while said second coat of said liquid resin is penetrating into said porous material to coat and structurally bond together all fibers thereof while leaving small passages having a capillary characteristic between said bonded fibers of said porous material; whereby said porous material and liquid resin form a composite wall on said tank wall.

Claim 38

Dependent Claim 27 words

The method of making a storage tank as defined by claim 31 wherein said porous material is a batt formed of a needled non-woven fibrous composite material.

Claim 39

Dependent Claim 56 words

The method of making a storage tank as defined by claim 31 wherein said barrier layer is formed by first coating said one surface of said porous material with a liquid resin and by then heating said one surface of said porous material to substantially reduced porosity of said porous material at said one surface thereof.

Claim 40

Dependent Claim 67 words

The method of making a storage tank as defined by claim 31 including the step of forming a second tank wall on said composite wall, said second tank wall being formed by first applying a first coat of liquid resin to said barrier layer, said second tank wall being formed by thereafter applying a second coat of a liquid resin and chopped fiberglass to said barrier layer.

Claim 41

Dependent Claim 33 words

The method of making a storage tank as defined by claim 34 wherein one of said tank walls is an inner wall and the other of said tank walls is an outer wall.

Claim 42

Dependent Claim 29 words

The method of making a storage tank as defined by claim 35 wherein said inner wall comprises a liquid-retaining wall defining a sealed chamber for retaining a liquid therewithin.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1993-12-03	1994-06-04	1994-12-04	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1997-12-03	1998-06-04	1998-12-04	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2001-12-03	2002-06-04	2002-12-04	$7700.00	Window Closed / Lapsed

Storage tank and method of making a storage tank

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