Integrated heating and insulation system

Abstract

An exemplary protective insulation system is disclosed that includes a heating element, a layer of insulation material, and optionally a protective layer over the insulation material, and that is lightweight and can be installed with minimal manpower and equipment.

Description

[Technical Field]

[0001] [Background of the invention] Protective insulation systems (insulation materials with integrated protective covers) are used in a variety of locations and environments around the world for pipes, tanks, connectors, valves, etc. In various industries, including manufacturing, petroleum, food, and mining, insulation materials are used not only to protect equipment but also to maintain appropriate temperature conditions. These insulation materials must not only withstand the environment for as long as possible, but also provide excellent protection. [Background technology]

[0002] [Summary of the Invention] This Summary is intended to provide a brief summary of the contents of the Detailed Description of the Invention set forth below, and is not intended to limit or specify the features of the claimed invention, nor is it intended to directly or indirectly define the scope of the claimed invention.

[0003] This invention briefly outlines a protective insulation system that provides heating in addition to environmental durability and protection. Conventional techniques often involve installing insulation separately, wrapping it around pipes, tanks, connectors, valves, etc., over existing heating wire, thermal tape, etc. An integrated unit not only offers quick and easy installation, but also significantly reduces the time and cost of troubleshooting and repairs.

[0004] In some embodiments, the protective insulation system includes a layer of insulating material covered by a protective layer. Other embodiments may include multiple protective layers, various combinations of substrate layers, or other layers. For example, as described below, one or more heater layers may be combined with the insulating material and protective layer.

[0005] In some embodiments, the insulation layer comprises a lightweight foam material (e.g., polyisocyanurate) having a density of 1 to 10 pounds per cubic foot, although some embodiments have densities from less than 1 pound per cubic foot to more than 60 pounds per cubic foot. The protective layer is sprayed in a liquid state and comprises a curable polyurea material. The protective layer adheres to the interior and / or exterior surfaces of the insulation layer. This protective layer can be sprayed or applied to the surface of the insulation layer after it is formed, or it can be applied to the interior surface of a mold and then the insulation layer is deposited into the mold so that it adheres to the exterior surface of the insulation layer. One or more additional protective layers can be applied to the interior surface of the formed insulation layer.

[0006] The substrate layer may be a unitary structure or may be made up of multiple parts or panels. In another embodiment, the thickness of the substrate layer is non-uniform across the length and / or width of the substrate layer. For example, the top or bottom of the substrate layer may be thicker than the sides (or vice versa). The panels (if applicable) may be of the same or different thickness. In other words, the panels may be of uniform or non-uniform thickness.

[0007] In some embodiments, at least the substrate layer is injection molded, which can be made into a variety of shapes and sizes as needed for a multitude of applications.

[0008] The following description refers to the accompanying drawings, in which the leftmost digit(s) of a reference number indicates the figure in which the reference number first appears. The use of the same reference number in different drawings indicates similar or identical items.

[0009] The devices and systems depicted in the figures herein are shown as having multiple equipment components. The devices and / or systems described herein may have fewer equipment components and remain within the scope of this disclosure. Alternatively, additional equipment components, or various combinations, may be included and remain within the scope of this disclosure. The shapes and / or dimensions shown in the figures are examples, and unless otherwise specified, other shapes and / or dimensions may be used and remain within the scope of this disclosure. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a perspective view of an example embodiment heating and insulation system. [Figure 2] FIG. 2 is an end view of an example embodiment heating and insulation system. [Figure 3] FIG. 3 is an example of a heating element according to an example embodiment. [Figure 4] FIG. 4 is a cross-sectional view showing an example of a heating and insulation system member. [Figure 5] FIG. 5 is an example of a heating element in another embodiment. [Figure 6] FIG. 6 is a cross-sectional view of an example of a heating and insulating member including an integrated heating element. [Figure 7] FIG. 7 shows an example of a heating and heat insulating member configured for a straight pipe. [Figure 8] Figure 8 shows an example of the installation of a heating system and insulation system on a pipe section. [Figure 9] Figure 9 shows an example of the installation of a heating system and insulation system on a pipe section. [Figure 10] FIG. 10 illustrates a side view, a detailed view, and an end view of one example of an exemplary heating and insulation system including an integrated electrical connector. [Figure 11] FIG. 11 shows a side view, a detailed view, and an end view of one example of an exemplary heating and insulation system including an integrated electrical connector. [Figure 12]FIG. 12 shows a side view, a detailed view, and an end view of one example of an exemplary heating and insulation system including an integrated electrical connector. [Figure 13] FIG. 13 is a perspective view and a side view of an example of a heating and insulation system including a control box. [Figure 14] FIG. 14 is a perspective view and a side view of an example of a heating and insulation system including a control box. [Figure 15] FIG. 15 is a side view of an example of an electrical connection portion of a heating and insulation system. [Figure 16] FIG. 16 is a perspective view showing an example of a molded part of a heating and insulation system. [Figure 17] FIG. 17 is a cutaway side view of the right and left sides of the molded part of FIG. [Figure 18] FIG. 18 is a cutaway side view of the right and left sides of the molded part of FIG. [Figure 19] FIG. 19 is a perspective view of an example molded part for a heating and insulation system. [Figure 20] FIG. 20 is a side view of the molded part of FIG. 19, cut away from the right side. [Figure 21] FIG. 21 is a side view of the molded part of FIG. 19 with the left side cut away. [Figure 22] FIG. 22 is a flow diagram illustrating an exemplary process for forming a heating and insulation system.

[0011] [Detailed explanation] (overview) Traditionally, exterior insulation applied to pipes, fittings, valves, tanks, etc. has come in separate forms, such as sheets or blankets, that are attached to the surface of the material to create a protective layer or shield. The insulation sheet or blanket is a soft insulating material, while the protective layer can be metal, composite, or plastic. It is sometimes desirable to maintain these pipes, fittings, valves, tanks, etc. at a specific temperature. This can happen for a variety of reasons: for optimal system performance, to maintain a temperature range for materials stored or transported within the system, or to protect the system from damage caused by extreme temperatures. In these cases, it may be advisable to install a heater on the pipe, fitting, valve, tank, etc.

[0012] Typically, pipes, fittings, valves, and tanks are wrapped with electric heat tape or electrical wire to heat them, and then a layer of insulation is applied over the heat tape. Once the insulation is in place, a protective layer is applied over the insulation. This multi-layer construction method has drawbacks. For example, if the heat tape or electrical wire fails, repair or replacement requires removing the protective layer and then the insulation. Troubleshooting the system to identify the fault can also be tedious, often requiring a reverse process to locate the fault. Furthermore, the multi-step installation process requires time and effort, not only for the initial installation, but also for maintenance, troubleshooting, and repair, with associated costs. Long-term costs can be substantial if underlying pipes, fittings, valves, and tanks leak or fail, or if any part of the multi-layer system fails.

[0013] The example embodiments presented herein can be commercialized as individual devices and / or packaged kits. For example, an insulation / heating kit may include pre-installed insulation components (straights, elbows, valve covers, etc.) with heating elements and electrical connectors integrated into the insulation components. It can also be modular. For example, the insulation components can be easily interconnected, and electrical connections can be made between sections. Furthermore, these various components can be quickly and easily installed into existing infrastructure.

[0014] The advantages described herein are merely exemplary and are not intended to be limiting in any way. It is believed that further advantages will be appreciated from the implementations presented herein. The exemplary embodiments herein are described with reference to the drawings, in which like elements are designated by like reference numerals.

[0015] [Standard heating and insulation system] Exemplary embodiments of devices and techniques are presented herein that provide an efficient, cost-effective heating and insulation solution with a single-step installation. The integrated heating and insulation system 100 includes a protective insulation system 104 with a heating element 102. The protective insulation system 104 includes an insulating insulation material 106, which further includes a protective layer 108 that surrounds all or a portion of the insulation material 106. In various embodiments, the novel system 100 is much easier and more cost-effective to install and maintain, and also provides improved weather resistance and longevity.

[0016] 1-21, the exemplary embodiment of the system 100 comprises a protective insulation system 104, which comprises an insulating substrate layer 106 covered by at least one protective layer 108. The insulating substrate layer 106 is typically formed into a shape that conforms to the desired application (e.g., pipe, tank, related components, etc.). The heating element 102 is integrated into the substrate layer 106 and / or one or more protective layers 108, such that installation of the protective insulation system 104 on the protected object also integrates the heating element 102 into the protected object. Electrical connections for the heating element 102 may also be integrated into the substrate layer 106 or protective layer 108. While the drawings and description illustrate an exemplary application of the protective system 100 to a piping / tank system, this is not intended to be limiting. The system 100, along with some or all of the associated equipment components described herein, may be applied to any other equipment component or system where protection and temperature control are desired. In various embodiments, the equipment components of the system 100 can have a variety of shapes, sizes, textures, etc. and remain within the scope of the present disclosure.

[0017] The substrate layer 106 is a lightweight insulating material, such as foam, that can be molded into any shape. The protective layer 108 is a polymer, such as polyurea. The thickness and density of the substrate layer 106 and protective layer 108 vary depending on the particular components to be protected and / or temperature controlled. For example, the thickness of the substrate layer 106 can range from less than 1 inch to more than 12 inches.

[0018] The insulation 106 can be as thick as a 2-inch layer of foam (e.g., polyisocyanurate) with a density of 2-6 lbs / ft3, depending on the application. Alternatively, any thickness and density can be used, from less than 1 lb / ft3 to over 60 lbs / ft3. Closed-cell foams with densities from 2 lbs / ft3 to over 10 lbs / ft3 are also available. The foam can be molded or formed to fit the shape and size of the component being protected, especially the interior shape and size, optimizing thermal protection and control.

[0019] The substrate layer 106 may be a one-piece structure or a modular structure formed from multiple components. For example, it may be formed into a desired shape (such as a connecting elbow or T-shaped joint) depending on the application. The substrate layer 106 has an inner surface 107 and an outer surface 109, with the outer surface 109 defining the thickness of the substrate layer 106. The thickness of the substrate layer 106 may be constant or may vary across the length and width of the insulation 106. Once formed, a protective layer 108 may be applied, for example, by spray application, to the outer surface 109 of the substrate layer 106. Optionally, one or more protective layers 108 may be applied to the inner surface 107 of the insulation 106.

[0020] The protective layer 108 can be made of pure or hybrid polyurea, providing excellent durability, weather resistance, and long life. Even a thin protective layer 108 provides abrasion resistance, strengthens the insulation layer 106, and protects against environmental factors such as UV rays, oxidation, and moisture. In some cases, various polymers and other synthetic or natural materials are used in one or more of the protective layers. The protective layer 108 can be made of any one or a combination of these materials.

[0021] The protective layer 108 is typically attached to the outer surface 109 of the insulation 106, but can also be adhered to the inner surface 107. For example, the materials described above are available as sprayable (or paintable) liquids and can be applied to the base layer 106 by spraying (or brushing, etc.). Other materials are within the scope of the present invention. The combination of the lightweight insulation 106 and the protective layer 108 provides the benefits described herein, but other benefits will be apparent to those skilled in the art. In installation environments where additional protection is not required, the outer protective layer 108 may be omitted.

[0022] 1 and 2 illustrate exemplary configurations of a heating and insulation system 100. For example, as shown in FIG. 1, one or more heating elements 102 may be bonded or secured to an inner surface 107 of an insulating material 106, or may be molded or embedded into the insulating material 106 (typically the inner surface 107). This allows the heating elements 102 to be located close to the components to be heated. The heating elements 102 may also be bonded or secured to an outer surface 109 of the insulating material 106. In this case, one or more protective layers 108 may be laminated on the heating elements 102. The heating elements 102 may be attached to the surface of the insulating material 106 (or the protective layer 108) using one or a combination of various adhesives, epoxies, coatings, and the like. For example, the protective layer 108 may be used as an adhesive between the insulating material 106 and the heating elements 102, and also as an adhesive on the heating elements 102 that are disposed on the insulating material 106. Various other fasteners (hardware, mechanical fasteners, adhesives, frictional fasteners, etc.) may be used to secure the heating element 102 to the insulation 106 or protective layer 108. One or more protective layers 108 may be applied over the heating element 102, if desired.

[0023] Referring also to FIG. 2 , the heating element 102 can be positioned between multiple layers of protective layers 108, if desired. For example, a first one or more protective layers 108A can be deposited on some or all of the inner surface 107 of the insulation 106. The heating element 102 can be adhered or secured to the first protective layer 108, and one or more protective layers 108B can be applied over the heating element 102 and over some or all of the first protective layer 108A. This encapsulates the heating element 102 within a protective cover, protecting it from environmental influences. One or more protective layers 108 can be added or omitted as desired. In alternative embodiments, the insulation 106 can be minimized or omitted. For example, the heating element 102 can be sandwiched between two protective layers 108 (or multiple protective layers 108), with the combination including a thin layer of insulation 106 or omitting the insulation 106.

[0024] In another example, the heating element 102 is embedded in a surface (either the inner surface 107 or the outer surface 109) of the insulation material 106. For example, the heating element 102 can be molded into the surface of the insulation material 106 while the insulation material 106 is being molded. Alternatively, the heating element 102 can be molded into the surface of the insulation material 106 while the insulation material 106 is curing or after the insulation material 106 has been molded. For example, the heating element 102 can be embedded in the uncured soft insulation material 106, placed in a recess formed in the cured insulation material 106, or placed on the surface of the insulation material 106. In some examples, the heating element 102 can be positioned on the inner surface 107 and the outer surface 109 of the insulation material 106.

[0025] The heating element 102 may be disposed between the insulation 106 and the component to be heated, rather than being embedded in the material of the insulation 106. In some embodiments, one or more electrical connectors, components, or other fasteners are integrated into or embedded in the material of the insulation 106, and the heating element 102 is permanently or removably attached to the electrical connectors, components, or other fasteners. In this example, the heating element 102 is integrated into the insulation 106 via the connectors, components, fasteners, or the like.

[0026] Referring to Figures 3-6, the heating element 102 can take a variety of shapes depending on the application. As shown in Figure 3, the heating element 102 can be constructed by combining one or more sheets of conductive ink 110 with the desired resistance / impedance and power and ground conductors 112. The conductors 112 can be flat copper foil (or other conductive material) adhered to the conductive ink sheet 110, or they can be embedded / integrated into the insulating material 106 or protective layer 108. This allows the heating element 102 to have a flat shape that fits well within the insulating material 106 and is in contact with or close to the component to be heated. The heating element 102 can be constructed with a resistive portion or medium, such as the conductive ink 110, or with a conductive portion or medium, such as the conductors 112 or other traces or buses.

[0027] In some cases, conductive ink 110 is printed onto a plastic sheet. Copper conductors 112 (or other conductive material) are placed on each edge of the printed ink 110. A second plastic sheet is placed on top of the ink 110, and the conductors 112 are welded to the plastic sheet. Power can be supplied to the conductive strips 112 by having a portion of the conductive strip 112 protrude from the plastic sheet, or by creating openings in the plastic sheets (two on the same sheet, or one on each sheet).

[0028] Alternatively, the conductive ink 110 can be printed on or embedded in the surface of the insulation 106 or the protective layer 108. For example, the conductive ink 110 can be disposed (e.g., 3D printed) on either surface of the insulation 106 and / or on either surface of the protective layer 108, or on multiple layers of the insulation 106 and / or protective layer 108. The conductors 112 can be disposed on both ends of the ink 110 in contact with the ink 110, and a poly (or similar) layer can be bonded over the ink 110 and the conductors 112. The poly layer can be the material of the protective layer 108, if desired. Alternatively, the conductors 112 can be bonded or embedded in the surface of the insulation 106 and / or the protective layer 108, thereby contacting the ink 110 during assembly or an initial stage of the system 100.

[0029] The conductive ink 110 can be formulated according to prior art solutions to use variations in the ink composition to achieve a desired resistance value and, therefore, a desired wattage per foot of the heating element 102. For example, the proportions of the components can be adjusted to adjust the heating capacity.

[0030] Indicators such as LEDs can be connected in parallel with the ink sheet 110 to indicate proper installation and operation. Plugs, connectors, or other connecting devices can be bonded to the conductive strips 112 for connection to power, ground, or to another heating element 102. For example, as shown in cross section in FIG. 4, multiple heating elements 102 can be connected in series or parallel to heat a larger surface area. Bus bars 402 run the entire length of the heating and insulation system member and connect power and ground conductors within the section. The bus bars 402 can be connected to a power source external to the insulation 106. Additional conductors 404 for power, ground, signal, etc. can also be routed throughout the entire section of the system 100 or to a portion of the section and connected using conductive connectors (couplers) 406, etc. The conductive connectors 406 are located outside the system 100 member and are used to supply power to the section or sections. Additionally, unit connectors 408 may be provided at each end of the system 100 section to electrically connect multiple sections. The unit connections 408 are embedded in the insulation 106 and are electrically connected (or in electrical communication) with the bus bars 402, the additional conductors 404, and / or the conductive connections 406, thereby providing signals and / or power through multiple sections of the system 100.

[0031] As shown in FIG. 5 , the heating element 102 is coupled to power and ground conductors 504 in the form of a resistive conductor 502 or the like. The resistive conductor 502 is an insulated or non-insulated conductive wire or element (e.g., metal and / or other conductive material) having a predetermined resistance and a predetermined cross-section or profile (e.g., round, stranded, flat, etc.) and can be arranged to dissipate heat as needed. In the example of FIGS. 5 and 6 , the resistive conductor 502 constitutes the resistive portion of the heating element 102 and is coupled in circuit to the power and ground conductors 504 (e.g., the conductive portion of the heating element 102). The resistance of the resistive conductor 502 can be adjusted as needed to achieve a desired heat output (e.g., by connecting additional resistive elements in series or parallel with the resistive conductor 502). The power and ground conductors 504 connect to a power source, such as a wall outlet or power supply. In some cases, the power and ground conductors 504 connect to the power source via an electrical plug 506.

[0032] The resistive conductor 502 is attached to a flexible or semi-flexible support for ease of handling. The support 508 can be placed on the inner surface 107 or outer surface 109 of the insulation 106 (with or without a protective layer 108 between the insulation 106 and the heating element 102). This allows the heating element 102 to fit well within the insulating insulation 106 and to have a flat shape that is in contact with or close to the component to be heated. The resistive conductor 502 can be attached to the support 508 using adhesive, multiple fasteners, or other means. In some cases, the resistive conductor 502 can be bonded to the support 508, such as by sewing it to the support 508. Once the heating element 102 is placed in the insulation 106 (with or without the support 508), the heating element 102 can be coated with one or more protective layers 108, if desired.

[0033] Alternatively, the resistive conductor 502 may be disposed directly on the inner surface 107 or outer surface 109 of the insulation 106. For example, one or more protective layers 108 may be applied to the insulation 106. The resistive conductor 502 may be disposed within the protective layer 108. The one or more protective layers 108 may be applied to the resistive conductor 502, the backing material 508, if present, and some or all of the surface of the insulation 106 to seal the resistive conductor 502 to the insulation 106. The power and ground conductors 504 may be routed through openings in the insulation 106 or through joints between sections of the insulation 106.

[0034] An indicator, such as an LED, can be connected in parallel with the resistive conductor 502 to indicate proper installation or operation. Cables, connectors, or other connecting devices can be attached to the backing 508 to connect one heating element 102 to another. For example, as shown in the cross-section of FIG. 6, multiple heating elements 102 can be connected in series or parallel to heat a larger surface area. Bus bars 402 can be routed throughout a section of the heating and insulation system 100, connecting power conductors 504 and ground conductors 504 within the section. Additional conductors 404, such as those for power, ground, and signal transmission, can be routed throughout the entire section of the system 100 or can be routed to only a portion of the section and connected using conductive connections 406 or similar. In some cases, the conductive connections 406 can be exposed outside the section of the system 100 to allow power to be supplied to that section or multiple sections. For example, each section may have section connections 408 at the end to connect multiple sections together. FIG. 7 is a perspective view of an example straight section of the heating and insulation system 100. An integral heating element 102 is incorporated within a protective insulation system 104 and is configured to contact an object (such as a straight pipe) that requires heating and insulation.

[0035] Figures 8 and 9 show perspective views of two examples of the heating and insulation system 100. The system 100 is available in multiple segments, allowing it to be customized to fit the components being insulated or heated. The connectors 802 protrude from the outer protective layer 108 or insulation 106 and connect to the heating element 102 to energize it. The connectors 802 may include power cables and / or plugs, data cables and / or plugs, etc. The connectors 802 are easy-to-assemble plugs (e.g., plug 506 or other user-friendly plugs) and can be installed without the assistance of an electrician. The power requirements for the heating and insulation system 100 are nominally 110-220 volts, although other voltages can be used if desired. At this voltage, 8-10 AWG conductors can be used to power the system 100. Other conductor sizes can also be used depending on current draw.

[0036] Various connectors can be used to connect power cables, data cables, and the like between sections 1010 of the system 100 and from the system 100 (i.e., equipment components of the system 100, such as the heating element 102) to power sources, data-receiving equipment components, and the like. Referring to FIGS. 10-15 , some connectors 1000 can be positioned in grooves 1002 or pockets 1004 along the outer surface 109 of the insulation 106 or protective layer 108 (not shown). For example, the connectors 1000 can be embedded in the insulating insulation 106 or protective layer 108 to provide some degree of insulation or protection. Connectors 1000 positioned at the ends of insulation sections 1010 can be mated to each other, connecting the sections 1010 from end to end. For example, a male connector 1000 at the end of one section 1010 can be mated to a female connector 1000 at the end of the next section 1010. The connectors 1000 are waterproof in construction and design, allowing them to withstand outdoor use in harsh environments. The wires 1008 connecting the connector 1000 and the heating element 102 can be routed in grooves 1002 or pockets 1004 or can be embedded in the insulation 106 or protective layer 108 (see FIGS. 17-18 and 20-21 ). In various examples, the protective insulation system 104, the heating element 102, and the combination of wires, connectors, equipment components, etc. (e.g., system 100) can all be coated with one or more protective layers 108.

[0037] As shown in FIGS. 13-15 , the connector 1000 often also includes bus bars 1502 and other connecting components. For example, the bus bars 1502 can be positioned within grooves 1002 or pockets 1004, or embedded in the protective layer 108 or insulation 106. The bus bars 1502 have holes for connecting the conductors 1008 from two end-to-end sections 1010. The bus bars 1502 can be connected using screws, bolts, rivets, or other fasteners. The control box 1302 can be integrated into or embedded in the exterior surface 109 of the section 1010 (the insulation 106 or the protective layer 108). The control box 1302 can be used to house a temperature control device or indicator and can incorporate sensors, probes, or other measurement devices. The control box 1302 can be connected to the connector 1000 and / or conductors 1008 (e.g., including power and / or data conductors), which allows for the distribution / transmission of power and / or data to the contained equipment components and instrumentation.

[0038] The sections 1010 can be molded to have shapes, sizes, and configurations appropriate for a variety of predetermined applications. In other words, the sections 1010 (e.g., the substrate layer 106) can be molded to have shapes, sizes, and configurations that closely match the shapes, sizes, and configurations of the components to be enclosed or housed within the protective insulation system 104. In particular, the inner surfaces 107 of the sections 1010 can closely match the outer surfaces of the components to be housed and protected. For example, the example molded part 1010A in FIG. 16 is intended to cover a valve, and the example molded part 1010B in FIG. 19 is intended to cover a 90-degree elbow. The two examples shown in FIGS. 16 and 19 are merely two examples of many molded parts 1010, each with a potentially unique shape, size, and configuration, molded to fit two predetermined applications. In other words, the molded part 1010 can be fully customized to meet unique specifications. Unique customizations also include embedded support infrastructure within each section 1010 to support the heating elements 102 and provide control, data, power, and the like. As shown in FIGS. 16-21 , the molded part 1010 includes wires 1602 (or other conductors, data lines, control lines, optical fibers, shielding, ground planes, etc.) and cable management components 1604 (e.g., bands, clamps, couplers, looms, etc.) embedded within or between layers of insulation 106 and / or protective layers 108, as well as couplers 1606 and connectors. In some cases, communication components (e.g., transmitters and / or receivers, modems, repeaters, amplifiers, global positioning satellite (GPS) components, etc.), sensors, measurement equipment, and the like are also included within the section 1010. Embedding these equipment components provides protection from external factors and allows easy access (e.g., through connectors 1608) to and from the exterior surface 109. As previously mentioned, couplers 408 at the ends of sections 1010 allow for modular connection of sections 1010 end-to-end.

[0039] [Standard Procedure] (1) Figure 22 illustrates an exemplary process 2200 for implementing techniques and / or devices related to a protective heating and insulation system (such as system 100). The system includes a protective insulation system (such as protective insulation system 104) formed from at least one or two layers, and at least one heating element (such as heating element 102). An example of process 2200 is described with reference to Figures 1-21.

[0040] (2) The order of the processes is not necessarily limited to the steps shown, and any number of process blocks may be combined in any order. Individual blocks may also be deleted from the processes without departing from the spirit and scope of the subject matter described herein. Furthermore, the processes may be implemented in any suitable hardware, software, firmware, or combination thereof without departing from the scope of the subject matter described herein.

[0041] (3) Block 2202 includes providing a protective insulation system including an insulating substrate layer (e.g., substrate layer 106) having a predetermined thickness and a predetermined density, the substrate layer having an outer surface and an inner surface that defines the thickness of the substrate layer.

[0042] (4) Block 2204 includes adhering or securing a first heating element (e.g., heating element 102) to an outer or inner surface of the substrate layer, or embedding the first heating element within the substrate layer. The first heating element can be adhered, secured, or embedded in the substrate layer before installing insulation around the component to be protected / heated. In some embodiments, this includes applying a first protective polymer layer (e.g., protective layer 108) over the insulation and the first heating element. In other embodiments, this includes applying a second protective polymer layer between the insulation and the first heating element. For example, the second protective layer may be applied to all or a portion of the insulation before adhering or securing the first heating element to the inner or outer surface of the insulation.

[0043] (5) In some embodiments, the substrate layer may be molded so that its inner surface conforms to the shape and size of the component housed within the substrate layer. For example, the substrate layer may be molded so that its inner surface closely conforms to the shape and size of a straight pipe, elbow, valve, tank, etc. The heating element may also be integrated into the substrate layer during its manufacture. This allows the heating element to be attached to the component housed within the substrate layer when the substrate layer is attached to the component (a one-step installation process). Thus, integrating the heating element (and associated infrastructure) into the substrate layer reduces the technical skills required during installation, including the need for an electrician.

[0044] (6) In some embodiments, one or more electrical conductors may be disposed within the insulation or within grooves or pockets in the insulation, and the one or more electrical conductors may be coupled to the first heating element.

[0045] (7) Multiple insulation pieces can be modularly joined to cover pipes of varying lengths, angles, bends, and even valves. The insulation moldings can be physically and electrically joined in a modular fashion, with each section of pipe (or other component to be protected) covered by the insulation and the heating elements within each insulation section powered by a continuous electrical path. In these embodiments, the process involves coupling one or more electrical conductors in the first insulation to one or more electrical conductors in the second insulation and a second heating element integrated into the second insulation via a first coupler embedded in the first insulation and a second coupler embedded in the second insulation. The couplers not only physically connect and conduct electricity, but also electrically connect the components. The one or more electrical connections can include power, ground, data, signals, communications, and the like.

[0046] (8) The embodiments of the present disclosure are described for purposes of illustration and not limitation. Alternative embodiments that do not depart from the scope of the present disclosure will be apparent to those skilled in the art. It goes without saying that those skilled in the art may develop alternative means for implementing the above-described improvements without departing from the scope of the present disclosure.

[0047] (9) It will be understood that certain elements or subcombinations thereof are useful alone and can be used without depending on other elements or combinations, and are within the scope of the claims. Furthermore, the steps depicted in the figures do not necessarily have to be performed in the order depicted.

[0048] [Conclusion] (10) Although the embodiments of the present disclosure are described using particular structural features and method steps, they are not limited to these. These features and steps are presented merely as example methods for implementing the claims.

Claims

1. a first heating element (102) that is adhered or fixed to an outer surface (109) or an inner surface (107) of the insulation layer (106) or that is embedded within the insulation layer (106).

2. 10. The protective insulation system of claim 1, further comprising one or more heating elements electrically coupled in series or parallel with the first heating element.

3. 10. The protective insulation system of claim 1, further comprising a protective layer (108) surrounding the substrate layer.

4. 4. The protective insulation system of claim 3, wherein the protective layer is adhered to an outer surface of a substrate layer.

5. 4. The protective insulation system of claim 3, wherein the protective layer is adhered to an inner surface of the substrate layer.

6. 4. The protective insulation system of claim 3, wherein the protective layer comprises a polyurea material capable of being sprayed in a liquid state and cured to a solid state.

7. 10. The protective insulation system of claim 1, further comprising a first protective polymer layer 108A covering at least a portion of the interior surface of the insulation.

8. 8. The protective insulation system of claim 7, wherein the first heating element is adhered or fixed to the first protective polymer layer.

9. 10. The protective insulation system of claim 8, wherein the first heating element is coated with a second protective polymer layer (108B).

10. 10. The protective insulation system of claim 1, wherein the first heating element is coated with a protective polymer layer (108).

11. 10. The protective insulation system of claim 1, further comprising one or more electrical connectors (1000) embedded in said substrate layer.

12. 10. The protective insulation system of claim 1, further comprising one or more electrical connectors (1000) disposed within grooves (1002) or pockets (1004) of the substrate layer.

13. 10. The protective insulation system of claim 1, further comprising one or more electrical conductors (402, 404) embedded in the substrate layer.

14. 10. The protective insulation system of claim 1, further comprising one or more electrical conductors disposed within grooves or pockets in the substrate layer.

15. 10. The protective insulation system of claim 1, wherein the insulation layer comprises a lightweight foam material having a density between 1 pound and 10 pounds per cubic foot.

16. A protective insulation system comprising an insulating foam substrate (106) having a predetermined thickness and a predetermined density, the substrate (106) having an outer surface (109) and an inner surface (107) that defines the thickness of the substrate (106), or a first heating element (102) integral with the outer surface (109) or the inner surface (107) of the substrate (106), or a protective polymer layer (108) covering the substrate (106) and the first heating element (102).

17. 17. The protective insulation system of claim 16, further comprising one or more electrical conductors (112, 402, 404) disposed within the insulation (106) and configured to be accessible to an exterior of the insulation.

18. 17. The protective insulation system of claim 16, further comprising one or more electrical connectors 402, 404 disposed within the insulation or within grooves or pockets in the insulation.

19. 17. The protective insulation system of claim 16, wherein the first heating element is bonded or secured to the insulation.

20. 17. The protective insulation system of claim 16, wherein the first heating element is embedded within the insulation.

21. The method includes providing a protective insulation system (100) including an insulating substrate layer (106) having a predetermined thickness and a predetermined density, the substrate layer (106) having an outer surface (109) and an inner surface (107) that defines a thickness of the substrate layer (106), and adhering or fastening a first heating element (102) to the outer surface (109) or the inner surface (107) of the substrate layer (106) or embedding the first heating element (102) within the substrate layer (106).

22. 22. The method of claim 21, comprising molding the substrate layer such that an inner surface thereof conforms to a component housed within the substrate layer.

23. 22. The method of claim 21, further comprising applying a first protective polymer layer 108B over the insulation and first heating element.

24. 24. The method of claim 23, further comprising applying a second protective polymer layer 108A between the insulation and the first heating element.

25. 22. The method of claim 21, further comprising disposing one or more electrical conductors 402, 404 within the insulation or within grooves 1002 or pockets 1004 in the insulation, and coupling the one or more electrical conductors to the first heating element.

26. 26. The method of claim 25, wherein the insulating material is a first insulating material, comprising providing a second insulating material therein, and coupling one or more electrical conductors of the first insulating material to one or more electrical conductors of the second insulating material and to a second heating element integrated into the second insulating material via a first coupler 408 embedded in the first insulating material and a second coupler 408 embedded in the second insulating material.

Images