Aerogel Pipe Coating for Corrosion Under Insulation

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Solution Overview

Problem

Corrosion under insulation (CUI) occurs due to moisture condensation in voids between pipes and insulation, which is difficult to address without removing the sheathing material, and existing solutions do not effectively prevent this phenomenon.

Innovation Solution

A method involving a paste composed of silica aerogel particles, a water-based solvent, and a binder resin with a combination of cellulose-based and acrylic acid-based resins, where the second binder resin has lower solubility, applied to form a coating film that suppresses condensation and enhances adhesion and strength, allowing for effective insulation and corrosion prevention on complex pipe surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional insulation materials are used, then thermal insulation is provided, but voids are generated between the pipe and insulation causing moisture condensation and corrosion

Engineering Contradiction:

Improveheat energy lossVSAvoidcorrosion under insulation

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

The patent applies a coating film composed of aerogel particles and binder resin directly to the pipe surface. This thin film structure eliminates voids between the pipe and insulation while providing both thermal insulation and corrosion protection, resolving the contradiction between energy conservation and corrosion prevention.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent uses a composite material system consisting of aerogel particles (for thermal insulation), binder resin (for adhesion and flexibility), and optional reinforcing fibers. This composite structure provides both thermal insulation performance and mechanical adhesion to eliminate voids, simultaneously addressing energy loss and corrosion issues.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If sheathing materials are added to suppress corrosion, then corrosion protection is improved, but device complexity and additional materials are required

Engineering Contradiction:

Improvecorrosion protectionVSAvoidadditional sheathing materials

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The coating film of the present invention performs multiple functions simultaneously: it provides thermal insulation (reducing heat loss), prevents corrosion (by eliminating voids and providing a protective barrier), and ensures mechanical adhesion (through the binder resin). This multi-functional coating eliminates the need for separate sheathing materials, reducing device complexity while maintaining comprehensive protection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If aerogel particles are used in low content, then paste applicability is improved, but thermal insulation performance is insufficient

Engineering Contradiction:

Improvepaste applicabilityVSAvoidthermal insulation performance

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent optimizes the aerogel particle content parameter to 5% or more by mass in the paste composition. This parameter change ensures sufficient thermal insulation performance while maintaining paste applicability. The binder resin content and composition are also adjusted to achieve the right balance between coating film strength and aerogel particle distribution, resolving the contradiction between manufacturability and performance.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method effectively prevents corrosion under insulation by forming a strong, adhesive coating film that reduces moisture condensation and enhances thermal insulation, suitable for various pipe shapes, including flanges and bends, without the need for additional sheathing materials.

Implementation Method 1

the binder resin comprises a first binder resin and a second binder resin, both dissolved in the liquid medium and wherein the second binder resin has a lower solubility to the liquid medium than the first binder resin

Methodology Applied

Scientific EffectSolubility difference:

Implementation Method 2

a paste comprising silica aerogel particles... applied to form a coating film that suppresses condensation

Methodology Applied

Scientific EffectHydrophobic effect: Hydrophobe

Implementation Method 3

aerogel particles include aerogel, xerogel and/or cryogel particles... enhances thermal insulation

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP3783076B1Method for suppressing corrosion under heat-insulating material, and paste for suppressing corrosion under heat-insulating material

Publication Date: 2022.12.28 RESONAC CORP

Figure 1

AI summary

The present invention relates to a method for suppressing corrosion under insulation, including a step of applying a paste containing aerogel particles and a liquid medium to a target surface to form a coating film. The present invention also relates to a paste for suppressing corrosion under insulation, containing aerogel particles and a liquid medium.