Tanks and double-walled tanks and method of manufacturing the same

Abstract

A tank has a base, corrugated side walls structurally mounted directly to the base, the corrugated side walls and the base defining a tank interior, the corrugated side walls having a trough and a crest; the trough being spaced within the inner tank receptacle relative to the crest; and a roof plate above the tank interior, the roof plate being structurally mounted to the corrugated side walls opposite the base. An inner tank may be inserted into the tank, the inner tank having a plurality of rigid or semi-rigid panels that are attached directly to adjacent panels to form a bottom wall and inner side walls of the inner tank.

What is claimed is: 
     
         1 . A method of manufacturing a double-walled tank, comprising the steps of:
 providing an outer shell, the outer shell having a base and corrugated side walls structurally mounted to the base, the corrugated side walls and the base defining an inner tank receptacle accessible through an upper opening that is vertically opposite the base, the corrugations of the corrugated side walls have a trough and a crest, the trough being spaced within the inner tank receptacle relative to the crest;   attaching together a plurality of rigid or semi-rigid panels to form an inner tank having a bottom wall and inner side walls; and   inserting the inner tank into the inner tank receptacle such that the bottom wall rests on the base of the outer shell and the side walls engage the troughs of the corrugations, the inner tank being formed separately and distinctly from the outer shell prior to being inserted into the receptacle.   
     
     
         2 . The method of  claim 1 , further comprising the step of installing a roof plate above the inner tank. 
     
     
         3 . The method of  claim 2 , wherein the roof plate is attached to the inner tank and extends past the outer perimeter of the corrugated side walls. 
     
     
         4 . The method of  claim 3 , wherein the roof plate is attached to the corrugated side walls after the inner tank is inserted into the outer tank. 
     
     
         5 . The method of  claim 2 , wherein the roof plate comprises elongated structural reinforcement members. 
     
     
         6 . The method of  claim 1 , wherein the outer shell comprises an outer wall. 
     
     
         7 . The method of  claim 1 , wherein the base of the outer shell comprises a skid. 
     
     
         8 . The method of  claim 1 , wherein the inner tank is formed without structural reinforcement members. 
     
     
         9 . The method of  claim 1 , wherein the rigid or semi-rigid panels are sufficiently rigid to withstand conforming to the corrugations of the corrugated side walls. 
     
     
         10 . The method of  claim 1 , further comprising the step of supporting the inner tank with a support structure prior to inserting the inner tank into the inner tank receptacle of the outer shell. 
     
     
         11 . A double-walled tank, comprising:
 an inner tank comprising a plurality of rigid or semi-rigid panels that are attached directly to adjacent panels to form a bottom wall and inner side walls of the inner tank; and   an outer shell having a base and corrugated side walls structurally mounted directly to the base, the corrugated side walls and the base defining an inner tank receptacle accessible through an upper opening that is vertically opposite the base, the corrugations of the corrugated side walls have a trough and a crest, the trough being spaced within the inner tank receptacle relative to the crest, the inner tank being positioned within the inner tank receptacle such that the inner tank engages the troughs of the corrugated side walls and such that the bottom wall rests on the base of the outer shell, the inner tank being formed separately and distinctly from the outer shell and the outer shell being formed separately and distinctly from the inner tank.   
     
     
         12 . The double-walled tank of  claim 11 , further comprising a roof plate above the inner tank. 
     
     
         13 . The double-walled tank of  claim 12 , wherein the roof plate is attached to the inner tank and extends past the outer perimeter of the corrugated side walls. 
     
     
         14 . The double-walled tank of  claim 13 , wherein the roof plate is attached to the corrugated side walls. 
     
     
         15 . The double-walled tank of  claim 12 , wherein the roof plate comprises elongated structural reinforcement members. 
     
     
         16 . The double-walled tank of  claim 11 , wherein the outer shell comprises an outer wall. 
     
     
         17 . The double-walled tank of  claim 11 , wherein the base of the outer shell is a skid. 
     
     
         18 . The double-walled tank of  claim 11 , wherein the inner tank is formed without structural reinforcement members. 
     
     
         19 . The double-walled tank of  claim 11 , wherein the rigid or semi-rigid panels are sufficiently rigid to withstand conforming to the corrugations of the corrugated side walls. 
     
     
         20 . A tank, comprising:
 a base;   corrugated side walls structurally mounted directly to the base, the corrugated side walls and the base defining a tank interior, the corrugated side walls having a trough and a crest, the trough being spaced within the inner tank receptacle relative to the crest; and   a roof plate above the tank interior, the roof plate being structurally mounted to the corrugated side walls opposite the base.   
     
     
         21 . The tank of  claim 20 , wherein the roof plate comprises elongated structural reinforcement members. 
     
     
         22 . The tank of  claim 20 , wherein the base comprises a skid.