US 11,745,391 B2
Method of manufacturing complex-shaped, flexible, and reusable tanks
David A. Pettey, Westport, MA (US); and Edmund Francis Bard, Cumberland, RI (US)
Assigned to RESPONSE TECHNOLOGIES, LLC, West Warwick, RI (US)
Filed by RESPONSE TECHNOLOGIES, LLC, West Warwick, RI (US)
Filed on Oct. 18, 2017, as Appl. No. 15/787,155.
Application 15/787,155 is a continuation in part of application No. 15/098,783, filed on Apr. 14, 2016, granted, now 10,688,775.
Claims priority of provisional application 62/148,406, filed on Apr. 16, 2015.
Prior Publication US 2018/0036916 A1, Feb. 8, 2018
Int. Cl. B29C 33/38 (2006.01); B29C 33/50 (2006.01); B29C 49/44 (2006.01); B33Y 10/00 (2015.01); B33Y 80/00 (2015.01); B29C 64/10 (2017.01); B29L 31/00 (2006.01)
CPC B29C 33/3842 (2013.01) [B29C 33/505 (2013.01); B29C 49/44 (2013.01); B29C 64/10 (2017.08); B33Y 10/00 (2014.12); B33Y 80/00 (2014.12); B29L 2031/7172 (2013.01)] 12 Claims
OG exemplary drawing
 
1. A method of fabricating a seamless fuel tank, the method comprising:
3D-printing a mold, the mold including a body having a first side wall, a second side wall opposite the first side wall, an inner surface, an outer surface and a nozzle extending outwardly from and supported by the second side wall, the first side wall having a first wall thickness and the second side wall having a second wall thickness that is greater than the first thickness, the outer surface having a concave portion and a convex portion;
connecting a pressure source to the nozzle on the mold;
inflating the mold via the nozzle;
forming a seamless, flexible fuel tank by layering-up a plurality of layers over the outer surface of the inflated mold via additive manufacturing, the flexible fuel tank having a port formed about the nozzle, and the tank surrounding the mold;
deflating the mold; and
withdrawing the mold through the port of the fully formed, flexible fuel tank,
wherein the mold is a male mold, and
wherein the mold is fabricated from a durable and rigid material having a Shore A rating between 20 and 95.