Composite function module prefabricated valve cold insulation tank and manufacturing mold and manufacturing method thereof

Abstract

The application relates to a composite function module prefabricated valve cold insulation tank and a manufacturing mold and a manufacturing method thereof. The cold insulation tank comprises a first module, a second module and a third module which are sequentially arranged from inside to outside, and each module is a two-piece structure. The first module is prefabricated by combining a PIR foaming inner layer and a PAP aluminum foil secondary moisture-proof layer, the second module is prefabricated by combining a PIR foaming outer layer and a butyl rubber primary moisture-proof layer, and the third module is prefabricated by combining an aerogel thermal insulation layer and a valve metal outer protective layer. The first module and the second module and the two pieces of each module are connected through concave-convex engagement, the joints are circumferentially staggered, and the end portions are overlapped with the pipeline cold insulation layer through longitudinal steps and filled with flexible cold insulation materials. The application realizes multi-layer collaborative sealing and double-layer composite moisture-proof, has high modular installation efficiency, can be repeatedly disassembled and assembled, and has superior cold insulation performance.

Description

Technical Field

[0001] This invention relates to the field of valve thermal insulation and cold preservation technology, specifically to a prefabricated valve cold preservation box with composite functional modules, its manufacturing mold, and manufacturing method. Background Technology

[0002] Valves are crucial equipment in industries such as petrochemicals, coal chemicals, LNG (liquefied natural gas), air separation, hydrogen energy, refrigeration, and cryogenic energy storage. In these fields, many valves need to operate continuously within a temperature range of -196℃ to +80℃, and the quality of their cold insulation performance directly affects the economic efficiency and operational safety of the system. Currently, traditional valve cold insulation devices require on-site operation and mainly fall into two categories.

[0003] The first method involves on-site cutting and assembly of cold insulation materials.

[0004] The inner layer of the insulation device is composed of insulation materials cut and spliced ​​on-site, such as PIR polyisocyanurate foam insulation boards. During construction, the PIR foam insulation boards are cut and assembled onto the valve body, and the joints are treated with adhesive. Insulation material is then wrapped around the outer layer of the PIR foam insulation boards, followed by the installation of a moisture-proof layer and an outer protective layer.

[0005] This cold insulation process has the following drawbacks: First, the PIR foam insulation board is cut and assembled, resulting in complex components, numerous installation steps, and slow installation speed. Second, manual assembly of the PIR foam insulation board is prone to improper installation, leading to large gaps in the inner insulation material, severe cold leakage, and poor insulation effect. Third, the on-site splicing and processing precision is limited, and the installation quality of the insulation layer is uncontrollable. In addition, on-site cutting of insulation material at irregular parts such as elbows and valves can easily cause shrinkage and cracking at low temperatures, forming cold bridges and resulting in poor sealing. The multi-layer insulation structure relies on natural adhesion between layers without dedicated bonding measures, leading to a high risk of interlayer slippage and poor overall stability of the insulation layer.

[0006] The second method: on-site foaming to manufacture the cold insulation device.

[0007] On-site, PIR material is used directly to foam the valve body. After the PIR foaming is completed, a moisture-proof layer and an outer protective layer are installed.

[0008] This cold insulation process has the following drawbacks: First, on-site foaming is significantly affected by ambient temperature—in winter, low temperatures result in high raw material viscosity, uneven mixing, large cell size, and incomplete curing; in summer, excessively high material temperatures lead to rapid foaming, causing hollow areas, scorching, and high internal stress—often resulting in uneven foaming and voids within the foamed insulation layer, leading to poor insulation performance. Second, it is difficult to accurately control the ratio of white and black materials on-site. Most of the mixing relies on manual pouring by feel, without precise weighing. Too much white material causes the product to soften, resulting in low closed-cell rate, soaring water absorption, and low-temperature shrinkage and cracking; too much black material causes brittleness, high internal stress, cold shrinkage and cracking, and overheating and core scorching. Simple manual stirring easily leads to localized imbalances in the ratio, resulting in localized soft or hard foam layers. Third, the on-site foamed PIR only adheres to the outside of the valve, forming a single unit that cannot be disassembled. During valve maintenance, the insulation device needs to be damaged, requiring repeated on-site foaming after maintenance, resulting in high costs and a long construction period. Fourth, the traditional on-site foaming and external moisture-proofing processes are cumbersome and time-consuming. The insulation process for a single valve is lengthy, leading to high costs and impacting the overall project construction cycle. Fifth, removing the insulation layer generates significant dust and debris, causing environmental pollution.

[0009] To overcome these shortcomings, some improvement solutions have emerged in recent years. For example, some technical solutions propose using a factory-prefabricated internal PIR foam layer structure and external protective layer structure to achieve detachable installation of the valve insulation device; other solutions improve the sealing and moisture-proof structure by using a flanged structure and an outer moisture-proof layer to achieve sealing of the detachable insulation device. However, the internal PIR foam layer structure and the external protective layer structure in existing improvement solutions are still single integral layers, with limited prefabrication between functional layers. Multiple layers still need to be installed sequentially on-site, and the modularity and installation efficiency need further improvement. Furthermore, the insulation layer and moisture-proof layer are not integrated prefabricated composites, resulting in a large workload for on-site joint treatment and difficulty in guaranteeing sealing quality. The moisture-proof system is usually a single-layer structure, with insufficient reliability in moisture protection.

[0010] In view of this, the present invention provides a composite functional modular prefabricated valve cold insulation box to solve the problems existing in the prior art. Summary of the Invention

[0011] This invention designs a prefabricated valve cold insulation box with composite functional modules, its manufacturing mold, and its manufacturing method. The technical problems it solves are: in existing valve cold insulation devices, the multi-layer cold insulation structure lacks a reliable connection and fixing method between layers, and cold leakage channels are easily formed at the joints; the moisture-proof system is weak and set separately from the cold insulation layer, resulting in insufficient moisture-proof reliability; each functional layer needs to be constructed on-site in sequence, resulting in low installation efficiency and difficulty in ensuring quality; the cold insulation layer is not removable, and it needs to be destructively removed during valve maintenance, resulting in high construction costs and long cycles.

[0012] To solve the aforementioned technical problems, the present invention adopts the following solution: A modular prefabricated valve cold insulation box with composite functions, comprising: The first module (A) is prefabricated and composited with a PIR foam inner layer and a PAP aluminum foil secondary moisture-proof layer composited on the outer side of the PIR foam inner layer. The second module (B) is prefabricated and composited with a PIR foam outer layer and a butyl rubber primary moisture-proof layer compounded on the outside of the PIR foam outer layer; The third module (C) is a prefabricated composite of an aerogel insulation layer and a valve metal outer protective layer. The first module, the second module, and the third module are all two-lobed structures that correspond to each other. From the inside out, they are the first module, the second module, and the third module. The second module covers the outside of the first module and the seams of the two are staggered in the circumferential direction. The third module covers the outside of the second module and the first module and the second module are pressed tightly onto the valve body by a buckle or bolt. The first module and the second module, the two-lobed structures of the first module and the two-lobed structures of the second module are all connected to each other by interlocking parts prefabricated on the inner layer and / or outer layer of PIR foam. The PAP aluminum foil secondary moisture-proof layer of the first module and the butyl rubber primary moisture-proof layer of the second module together form a double-layer moisture-proof system for the entire cold insulation layer from the inside out; The ends of the first module and the second module are respectively connected to the pipe insulation layer on both sides of the valve through a longitudinal stepped structure, and the overlapping surfaces are filled with flexible insulation material.

[0013] Preferably, the PIR foaming layers of both the first module and the second module are prefabricated after 3D scanning of the valve body model.

[0014] Preferably, the valve's outer metal protective layer is fixed by a latch or bolt, and the first module and the second module are pressed tightly onto the valve body.

[0015] Preferably, the PIR foam inner layer and the PIR foam outer layer are formed by casting and foaming in the factory using a high-pressure foaming machine with a special foaming mold.

[0016] Preferably, the pipe insulation layer includes an inner pipe insulation layer and an outer pipe insulation layer; at the pipe positions on both sides of the valve, from the inside out, the layers are: inner pipe insulation layer, secondary pipe moisture-proof layer, outer pipe insulation layer, primary pipe moisture-proof layer, and pipe protective layer; two pipe air barrier layers are respectively set on the end faces of the inner and outer pipe insulation layers to prevent humid air from entering the interior of the insulation layer from the end faces of the insulation layer; the primary pipe moisture-proof layer is set on the outer surface of the outer pipe insulation layer, and the secondary pipe moisture-proof layer is set on the outer surface of the inner pipe insulation layer, forming a double-layer moisture-proof system.

[0017] A foaming mold for manufacturing a PIR foam inner layer and a PIR foam outer layer, characterized in that it comprises: Top cover of foaming mold; Inner mold of foaming mold; Lower cavity of the foaming mold; The inner wall of the foaming mold inner mold and / or the lower cavity of the foaming mold is provided with grooves and / or protrusions for forming an interlocking structure on the surface of the PIR foamed product; the top cover of the foaming mold and the inner mold of the foaming mold are combined to form an upper mold, and the lower cavity of the foaming mold is a lower mold. After the upper mold and the lower mold are closed, a mold cavity is formed that roughly corresponds to the outer contour of the valve body and leaves room for subsequent cutting and processing in terms of size, for casting the foamed PIR foamed product blank.

[0018] A method for manufacturing a prefabricated valve cold insulation box with composite functional modules includes the following steps: Step 1: Use 3D scanning technology to obtain the shape and size data of the valve body and the pipes on both sides, and reverse model the point cloud file to obtain the solid 3D file of the valve body; Step 2: Based on the solid 3D file of the valve body, design and manufacture the above-mentioned foaming mold; Step 3: In a factory environment, polyisocyanurate raw material is poured into the foaming mold using a high-pressure foaming machine. The inner wall of the mold cavity of the foaming mold is provided with grooves and / or protrusions for forming an interlocking structure. After curing and molding, a PIR foamed product blank with an interlocking structure integrally formed on the surface is obtained. Step 4: Cut and process the PIR foam product blank to form a PIR foam inner layer and a PIR foam outer layer; use automated equipment to cut PAP aluminum foil and butyl rubber, and prefabricate and bond the PIR foam inner layer with the PAP aluminum foil secondary moisture-proof layer to form the first module; prefabricate and bond the PIR foam outer layer with the butyl rubber primary moisture-proof layer to form the second module; Step 5: Prefabricate and composite the aerogel insulation layer with the valve's metal outer protective layer to form the third module.

[0019] Preferably, in step two, the shape and size of the inner mold of the foaming mold are manufactured by metal machining based on the solid three-dimensional file of the valve body; the top cover of the foaming mold and the lower cavity of the foaming mold are manufactured by sheet metal design.

[0020] Preferably, in step five, the valve metal outer protective layer is manufactured by sheet metal design and blanking, laser cutting and welding, and then the aerogel heat insulation layer is pasted on the inner side of the valve metal outer protective layer.

[0021] Compared with existing technologies, the prefabricated valve cold insulation box with composite functional modules, its manufacturing mold, and its manufacturing method have the following advantages: (1) In this invention, the first module and the second module, as well as the two-part structures of each module, are connected by interlocking parts to provide reliable mechanical interlocking and prevent interlayer slippage and joint opening. The joints of the second module and the first module are staggered in the circumferential direction to avoid forming a through-through cold leakage channel. The end of the module overlaps with the pipe insulation layer through a longitudinal stepped structure and is filled with flexible insulation material to achieve seamless connection between valve and pipe insulation. The synergistic effect of the multiple sealing structures significantly improves the cold insulation effect compared to the prior art.

[0022] (2) The PAP aluminum foil secondary moisture-proof layer and the butyl rubber primary moisture-proof layer of the present invention together form a double-layer moisture-proof system. The two layers are made of different materials and have complementary functions. At the same time, they overlap and seal with the secondary moisture-proof layer and the primary moisture-proof layer of the pipeline respectively, so as to achieve the overall continuous sealing of the valve and the pipeline moisture-proof layer, completely eliminate the risk of water vapor infiltration, prevent the cold insulation layer from deteriorating due to moisture, and greatly extend the service life.

[0023] (3) All three modules of the present invention are prefabricated in the factory. On-site installation can be completed simply by fitting them into the modules one by one and fixing them with buckles or bolts. The installation steps are simple and easy to operate. The installation efficiency is 5-8 times higher than that of the traditional method, which greatly shortens the construction cycle and cost.

[0024] (4) In this invention, aerogel, as the solid insulation material with the lowest thermal conductivity, provides excellent insulation performance in a limited cold insulation space, effectively blocks heat transfer, and further reduces cold loss. Attached Figure Description

[0025] Figure 1 : A schematic diagram showing the structural breakdown of the composite functional module of this invention; Figure 2 : A schematic diagram of the structure of the special foaming mold of this invention; Figure 3 : A cross-sectional view of the overall structure of the present invention after installation.

[0026] Explanation of reference numerals in the attached figures: A—Module 1; B—Module 2; C—Module 3.

[0027] 101—Top cover of foaming mold; 102—Inner mold of foaming mold; 103—PIR foamed product blank; 104—Lower cavity of foaming mold.

[0028] 1—PIR foam inner layer; 2—PAP aluminum foil secondary moisture-proof layer; 3—PIR foam outer layer; 4—Butyl rubber primary moisture-proof layer; 5—Aerogel insulation layer; 6—Valve metal outer protective layer; 7—Metal sealant; 8—Drip tray; 9—Flexible cold insulation material; 10—Pipe protection layer; 11—Pipe cold insulation inner layer; 12—Pipe secondary moisture-proof layer; 13—Pipe primary moisture-proof layer; 14—Pipe air resistance layer; 15—Pipe cold insulation outer layer. Detailed Implementation

[0029] The following is combined with Figures 1 to 3 The present invention will be further described as follows: like Figure 1 As shown, the present invention provides a composite functional modular prefabricated valve cold insulation box, which consists of three prefabricated composite functional modules, namely the first module A, the second module B and the third module C.

[0030] The first module A is prefabricated and composited from a PIR foam inner layer 1 and a PAP aluminum foil secondary moisture-proof layer 2 adhered to its outer side. The PIR foam inner layer 1 serves as the main inner layer of the cold insulation structure, undertaking the main functions of cold insulation and heat insulation; the PAP aluminum foil secondary moisture-proof layer 2 is adhered to the outer surface of the PIR foam inner layer 1, playing a secondary moisture-proof role and blocking water vapor penetration, preventing the cold insulation layer from reducing its cold insulation performance due to moisture.

[0031] The second module B is prefabricated and composited from a PIR foam outer layer 3 and a butyl rubber primary moisture barrier 4 adhered to its outer side. The PIR foam outer layer 3 serves as the main outer layer of the cold insulation structure, forming a double-layer cold insulation system together with the PIR foam inner layer 1; the butyl rubber primary moisture barrier 4 is adhered to the outer surface of the PIR foam outer layer 3, serving as the first moisture barrier and possessing excellent waterproof and sealing performance.

[0032] The third module C is prefabricated and composited with an aerogel insulation layer 5 and a valve metal outer protective layer 6. The aerogel insulation layer 5 is adhered to the inner side of the valve metal outer protective layer 6. Aerogel, as one of the best-performing solid insulation materials known, has an extremely low thermal conductivity and can effectively block the transfer of cold energy. The valve metal outer protective layer 6, as the outermost protective structure, provides mechanical protection for the entire device and also has a certain degree of moisture protection.

[0033] The spatial relationship of the three modules after installation is as follows: from the inside out, they are module A, module B, and module C. Specifically, module A is located on the innermost side, and the inner surface of its PIR foam inner layer 1 matches the outer surface of the valve body. Module B is located on the outer side of module A, and its butyl rubber primary moisture-proof layer 4 is bonded to the outer surface of the PIR foam outer layer 3. The two moisture-proof layers together form a double-layer moisture-proof system. The two-lobed structure of module B covers the outer side of the two-lobed structure of module A, and the seams between them are staggered in the circumferential direction to prevent cold energy from being transferred in a straight line along the seam. Module C is located on the outermost side, and the inner surface of its aerogel insulation layer 5 matches the outer surface of the butyl rubber primary moisture-proof layer 4 of module B. The valve metal outer protective layer 6 completely wraps around module A and module B, forming a three-layer composite structure from the inside out: a cold-insulating inner layer, a cold-insulating outer layer, and a heat-insulating protective outer layer. All three modules are two-lobed structures that correspond to each other. The two lobes of each module are installed together with the valve as the center. After the outermost third module C is fixed by a buckle or bolt, the first module A and the second module B are pressed tightly onto the valve body to ensure a tight fit between the layers.

[0034] like Figure 2 As shown, this invention uses a dedicated foaming mold for factory prefabrication of the PIR foam layer. The foaming mold consists of a top cover 101, an inner mold 102, and a lower cavity 104. During foaming, the top cover 101 and the inner mold 102 are combined as the upper mold, and the lower cavity 104 is used as the lower mold. After the mold is closed, a cavity is formed that roughly corresponds to the outer contour of the valve body. The size of this cavity is larger than the final finished product size, leaving room for subsequent cutting and processing. Polyisocyanurate (PIR) raw material is poured into the mold using a high-pressure foaming machine. After curing and molding, a PIR foam product blank 103 is obtained. The PIR foam product blank 103 is a PIR foam product blank formed by the foaming mold. After cutting and processing, this blank forms the PIR foam inner layer 1 of the first module A and the PIR foam outer layer 3 of the second module B. The aerogel insulation layer 5 and the valve metal outer protective layer 6 of the third module C are not formed by foaming molds, but are prefabricated by independent processes and then composited into one.

[0035] Because high-pressure foaming equipment is used in the factory environment, parameters such as raw material temperature, raw material ratio, pouring time, raw material mixing uniformity, and ambient temperature can be precisely controlled. Therefore, the density, thermal conductivity, closed-cell rate, compressive strength, dimensional stability, volumetric water absorption rate, water vapor permeability coefficient, oxygen index, and other performance indicators of the foamed PIR products can be well guaranteed.

[0036] like Figure 3As shown, the overall structural cross-sectional view of the present invention after installation demonstrates the complete installation state of the valve insulation box on the valve and pipeline.

[0037] At the valve body location, from the inside out, are the following layers: a flexible insulation material 9 directly attached to the outer surface of the valve stem, a PIR foam inner layer 1, a PAP aluminum foil secondary moisture-proof layer 2, a PIR foam outer layer 3, a butyl rubber primary moisture-proof layer 4, an aerogel insulation layer 5, and a valve metal outer protective layer 6. The flexible insulation material 9 is positioned between the valve stem and the rigid PIR foam inner layer 1, and its functions include: 1. filling gaps on the uneven surface of the valve stem, squeezing out all air; 2. providing a flexible wrapping around the moving parts of the valve (such as the valve stem), protecting the valve's operating components; 3. acting as a buffer layer between the rigid insulation material and the valve body, preventing direct contact between the rigid materials and potential installation problems. A 10mm thick layer of flexible insulation material 9 is wrapped around the valve stem to ensure the insulation and sealing of the moving parts.

[0038] The first module A (PIR foam inner layer 1 and PAP aluminum foil secondary moisture-proof layer 2) and the second module B (PIR foam outer layer 3 and butyl rubber primary moisture-proof layer 4) are interlocked by the interlocking parts formed during the prefabrication of the PIR foam layer. The joint between the two-part structure is filled and sealed with flexible cold insulation material 9 to ensure that there are no through gaps between the two PIR cold insulation layers and prevent cold leakage.

[0039] From the inside out, the pipes on both sides of the valve consist of: an inner pipe insulation layer 11, a secondary moisture-proof layer 12, an outer pipe insulation layer 15, a primary moisture-proof layer 13, and a protective layer 10. Two air-barrier layers 14 are respectively installed on the end faces of the inner pipe insulation layer 11 and the outer pipe insulation layer 15 to prevent humid air from entering the interior of the insulation layer from the end faces. The primary moisture-proof layer 13 is installed on the outer surface of the outer pipe insulation layer 15, and the secondary moisture-proof layer 12 is installed on the outer surface of the inner pipe insulation layer 11, forming a double-layer moisture-proof system.

[0040] At the junction of the valve insulation box and the inner insulation layer 11 and outer insulation layer 15 of the pipeline, the ends of the first module A and the second module B overlap with the inner insulation layer 11 and the outer insulation layer 15 of the pipeline respectively through a longitudinal stepped structure, and flexible insulation material 9 is wrapped and filled between the overlapping surfaces to solve the problem of the joint between the two rigid materials being difficult to seal and prone to cold leakage. The end of the third module C overlaps with the pipeline protective layer 10 to ensure the continuity of the outer protective layer. The PAP aluminum foil secondary moisture-proof layer 2 overlaps and seals with the pipeline secondary moisture-proof layer 12, and the butyl rubber primary moisture-proof layer 4 overlaps and seals with the pipeline primary moisture-proof layer 13, forming a complete double-layer moisture-proof system to ensure the continuity of moisture protection at the junction of the valve and the pipeline.

[0041] At the overlap between the two halves of the valve's metal outer protective layer 6, metal sealant 7 is used to seal the joint, preventing external moisture from seeping in. A drip tray 8 is positioned above the valve's metal outer protective layer 6 to guide condensate from the valve stem out promptly, preventing water accumulation from corroding the insulation layer. The entire assembly is secured to the two halves of the valve's metal outer protective layer 6 using latches or bolts, allowing for detachable installation.

[0042] During on-site installation, first clean the impurities from the valve surface, and then wrap a 10mm thick layer of flexible insulation material 9 around the valve stem. Next, install the first module A and the second module B sequentially. Each module is installed in two halves, which are then fitted onto the valve body. The two halves interlock using pre-fabricated interlocking parts. Each layer is sealed with mesh fiberglass tape, and the joints are filled with flexible insulation material 9 and secured with fiberglass tape. During the installation of each insulation module, flexible insulation material 9 must be wrapped and filled between it and the inner insulation layer 11 and the outer insulation layer 15 of the pipe. After all insulation layers are installed, install the third module C. The third module C is also divided into two halves, which are fitted over the installed insulation layers. The two halves of the valve's metal outer protective layer 6 are secured and locked using buckles or bolts, and the joints are sealed with metal sealant 7.

[0043] Since all modules are prefabricated in the factory, only modular assembly is required on site, resulting in high installation efficiency and a short construction period. When the valve needs maintenance, simply loosen the latches or bolts and cut the metal sealant 7 to completely disassemble each module. After maintenance, it can be reinstalled, enabling the reuse of the cold insulation device and significantly reducing maintenance costs.

[0044] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the implementation of the present invention is not limited to the above-described manner. Any improvements made using the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution of the present invention to other occasions without modification, are all within the protection scope of the present invention.

Claims

1. A modular prefabricated valve cold insulation box with composite functions, characterized in that, include: The first module (A) is prefabricated and composited from a PIR foam inner layer (1) and a PAP aluminum foil secondary moisture-proof layer (2) composited on the outside of the PIR foam inner layer (1); The second module (B) is prefabricated and composited from a PIR foam outer layer (3) and a butyl rubber primary moisture-proof layer (4) composited on the outside of the PIR foam outer layer (3); The third module (C) is prefabricated and composited from an aerogel insulation layer (5) and a valve metal outer protective layer (6); The first module (A), the second module (B), and the third module (C) are all two-part structures that correspond to each other. From the inside out, they are the first module (A), the second module (B), and the third module (C). The second module (B) covers the outside of the first module (A), and the seams of the two are staggered in the circumferential direction. The third module (C) covers the outside of the second module (B), and the first module (A) and the second module (B) are pressed tightly onto the valve body by a latch or bolt. The first module (A) and the second module (B), the two-lobed structures of the first module (A) and the two-lobed structures of the second module (B) are all connected to each other by interlocking parts prefabricated on the PIR foam inner layer (1) and / or PIR foam outer layer (3). The PAP aluminum foil secondary moisture-proof layer (2) of the first module (A) and the butyl rubber primary moisture-proof layer (4) of the second module (B) together form a double-layer moisture-proof system for the entire cold insulation layer from the inside out; The ends of the first module (A) and the second module (B) are respectively connected to the pipe insulation layer on both sides of the valve through a longitudinal step structure, and the overlapping surfaces are filled with flexible insulation material (9).

2. The composite functional modular prefabricated valve cold insulation box according to claim 1, characterized in that: The PIR foam layers of both the first module (A) and the second module (B) are prefabricated after 3D scanning of the valve body model.

3. The composite functional modular prefabricated valve cold insulation box according to claim 1, characterized in that: The valve's outer metal protective layer (6) is fixed by a buckle or bolt, and the first module (A) and the second module (B) are pressed tightly onto the valve body.

4. The composite functional modular prefabricated valve cold insulation box according to any one of claims 1 to 3, characterized in that: The PIR foam inner layer (1) and the PIR foam outer layer (3) are formed by casting and foaming in the factory using a high-pressure foaming machine with a special foaming mold.

5. The composite functional modular prefabricated valve cold insulation box according to claim 1, characterized in that: The pipeline insulation layer includes an inner pipeline insulation layer (11) and an outer pipeline insulation layer (15). On both sides of the valve, the pipeline positions are arranged from the inside to the outside as follows: inner pipeline insulation layer (11), secondary pipeline moisture barrier layer (12), outer pipeline insulation layer (15), primary pipeline moisture barrier layer (13), and pipeline protective layer (10). Two pipeline air barrier layers (14) are respectively set on the end faces of the inner pipeline insulation layer (11) and the outer pipeline insulation layer (15) to prevent humid air from entering the interior of the insulation layer from the end face of the insulation layer. The primary pipeline moisture barrier layer (13) is set on the outer surface of the outer pipeline insulation layer (15), and the secondary pipeline moisture barrier layer (12) is set on the outer surface of the inner pipeline insulation layer (11), forming a double-layer moisture barrier system.

6. A foaming mold for manufacturing the PIR foamed inner layer (1) and PIR foamed outer layer (3) as described in any one of claims 1 to 5, characterized in that, include: Foaming mold top cover (101); Inner mold of foaming mold (102); Lower cavity of foaming mold (104); The inner wall of the foaming mold inner mold (102) and / or the lower cavity (104) of the foaming mold is provided with grooves and / or protrusions for forming an interlocking structure on the surface of the PIR foamed product; the top cover (101) of the foaming mold and the inner mold (102) of the foaming mold are combined to form an upper mold, and the lower cavity (104) of the foaming mold is a lower mold. After the upper mold and the lower mold are closed, a mold cavity is formed that roughly corresponds to the outer contour of the valve body and leaves room for subsequent cutting and processing in terms of size, for casting the foamed PIR foamed product blank (103).

7. A method for manufacturing a prefabricated valve cold insulation box with composite functional modules, characterized in that, Includes the following steps: Step 1: Use 3D scanning technology to obtain the shape and size data of the valve body and the pipes on both sides, and reverse model the point cloud file to obtain the solid 3D file of the valve body; Step 2: Based on the solid 3D file of the valve body, design and manufacture the foaming mold as described in claim 6; Step 3: In a factory environment, polyisocyanurate raw material is poured into the foaming mold using a high-pressure foaming machine. The inner wall of the mold cavity of the foaming mold is provided with grooves and / or protrusions for forming an interlocking structure. After curing and molding, a PIR foam product blank (103) with an interlocking structure integrally formed on the surface is obtained. Step 4: Cut the PIR foam product blank (103) to form a PIR foam inner layer (1) and a PIR foam outer layer (3); use automated equipment to cut PAP aluminum foil and butyl rubber, and prefabricate and bond the PIR foam inner layer (1) with the PAP aluminum foil secondary moisture-proof layer (2) to form the first module (A); prefabricate and bond the PIR foam outer layer (3) with the butyl rubber primary moisture-proof layer (4) to form the second module (B). Step 5: Prefabricate and composite the aerogel insulation layer (5) with the valve metal outer protective layer (6) to form the third module (C).

8. The manufacturing method according to claim 7, characterized in that: In step two, the shape and size of the inner mold (102) of the foaming mold are made by metal machining based on the solid three-dimensional file of the valve body; the top cover (101) of the foaming mold and the lower cavity (104) of the foaming mold are made by sheet metal design.

9. The manufacturing method according to claim 7, characterized in that: In step five, the valve metal outer protective layer (6) is made by sheet metal design and cutting and welding with laser equipment, and then the aerogel heat insulation layer (5) is pasted on the inner side of the valve metal outer protective layer (6).

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