Aerogel Pipe Section Production via Radial Slicing
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Solution Overview
Problem
Existing methods for insulating pipes with aerogel, xerogel, or cryogel matrix composites are inefficient due to the need for manual labor and are not suitable for small diameter pipes or inflexible mats, as they require wrapping and securing a flat mat around the pipe, which is inconvenient and costly.
Innovation Solution
A method to produce pre-formed pipe sections by winding a mat of aerogel, xerogel, or cryogel matrix composite around a mandrel and slicing it radially, combined with a layer of mineral wool fibers, to create a pipe section that is easy to install and economical, suitable for small diameter pipes and inflexible mats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flat aerogel or cryogel matrix composite mat is wrapped around the pipe in situ, then packaging and storage efficiency is improved, but installation convenience deteriorates due to significant manual labor requirements
Solution Approach 1:
The mat is pre-formed into a curved configuration matching the pipe geometry before installation. This preliminary shaping action eliminates the need for manual wrapping during installation, resolving the contradiction by maintaining packaging efficiency while dramatically improving installation convenience.
Solution Approach 2:
The mat is formed into a curved, pipe-matching shape rather than remaining flat. This curvature allows the insulation to be pre-formed for easy installation while maintaining efficient packaging, directly addressing the contradiction between packaging efficiency and installation convenience.
2Reliability
If adhesive is used to secure the mat around the pipe, then the mat can be fixed in place, but the process becomes more complex and time-consuming
Solution Approach 1:
The mat is pre-formed with integrated securing features (such as pre-applied adhesive strips or mechanical fastening elements) before installation. This preliminary preparation maintains reliable mat fixation while simplifying the overall securing process by eliminating complex assembly steps during installation.
3Strength
If the mat is made inflexible to improve structural integrity, then mechanical strength is improved, but the ability to wrap around small diameter pipes deteriorates
Solution Approach 1:
The mat is pre-formed into a curved shape that matches the pipe diameter before installation. This pre-curving allows the mat to maintain its structural integrity and mechanical strength while being adapted to small diameter pipes, resolving the contradiction between strength and adaptability.
Solution Approach 2:
The insulation system is divided into pre-formed curved mat sections that can be easily adapted to different pipe diameters. This segmentation allows each section to maintain structural integrity while providing versatility for different pipe sizes.
4Quantity of substance
If manual wrapping and securing is used to install the mat, then material usage is optimized, but productivity deteriorates due to significant manual labor
Solution Approach 1:
The mat is pre-formed into the final curved configuration with all securing features prepared before installation. This preliminary action maintains material usage efficiency while dramatically increasing productivity by eliminating time-consuming manual wrapping and securing operations during installation.
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
This method allows for efficient, easy installation of aerogel, xerogel, or cryogel matrix composite pipe sections with improved insulation properties and reduced production costs, suitable for small diameter pipes and inflexible materials, enhancing both installation ease and economic viability.
Implementation Method 1
These conventional aerogel, xerogel and cryogel products, although good insulators, are fragile
Implementation Method 2
an adhesive at the interface between the first major face of the part of the mat forming the first layer and the second major face of the part of the mat forming the second layer
Data Source
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AI summary
The invention provides a method for making a pipe section comprising; providing a mat (1) formed of a fibre matrix impregnated with an aerogel, xerogel or cryogel, the mat having a first major face (2), a second major face (3) opposing the first major face (2), a first edge (4) defining a longitudinal direction, a second edge (5) substantially parallel to the first edge, a third edge (6) defining a transverse direction that is substantially perpendicular to the longitudinal direction and a fourth edge (7) substantially parallel to the third edge; applying an adhesive (8) to the first major face; winding the mat around a mandrel (13) to provide a wound mat having an inner surface (11) defining an inner circumference and an outer surface (12) defining an outer circumference and a longitudinal axis which is substantially perpendicular to the planes of the inner and outer circumferences and substantially parallel to the transverse direction of the mat; and slicing the wound mat substantially radially between the outer surface and the inner surface to provide a cut extending in a direction substantially parallel to the longitudinal axis.