Thermoplastic-Coated U-Bolt for Pipe Insulation and Corrosion Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing U-bolts fail to provide effective insulation and prevent contact between the metal piece and the element to be fixed, leading to issues such as corrosion, vibration transmission, and the need for frequent replacement, especially in outdoor installations and long pipelines.
Innovation Solution
A U-bolt with a metal piece of 'U'-shape configuration featuring an over-moulded thermoplastic coating on the central portion, which provides a permanent insulation and contact surface oriented perpendicularly to the metal piece, preventing direct contact and enhancing grip and hold without the need for additional insulation materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flexible plastic hose is placed on the central portion of the U-bolt to provide insulation, then insulation between the metal piece and the pipe is achieved, but the hose folds during installation making the operation slow and complicated, and cracks form over time causing contact between metal and pipe
Solution Approach 1:
The patent merges the insulation function with the U-bolt structure itself by integrating a plastic coating directly onto the metal piece. This eliminates the need for separate flexible hoses that require installation and maintenance, combining the structural and insulating functions into a single integrated component.
Solution Approach 2:
The plastic coating is applied in advance during manufacturing, before installation. This preliminary action ensures the insulation is already in place and properly positioned, eliminating the need for complex installation procedures and subsequent maintenance of separate insulation components.
2Reliability
If plastic material is stuck on the inner part of the U-bolt to provide insulation, then insulation between metal piece and pipe is achieved, but damp and rain cause the material to come unstuck and fail its function
Solution Approach 1:
The patent combines the metal piece and plastic coating into a single integrated structure where the coating is permanently bonded to the metal substrate. This merging eliminates the adhesion problems associated with separately applied plastic materials that can detach under environmental stress.
Solution Approach 2:
The patent uses a composite structure consisting of a metal piece with an overmolded plastic coating. This composite material approach creates a durable, weather-resistant insulation layer that remains firmly attached despite exposure to damp and rain, overcoming the limitations of simple adhesive applications.
3Reliability
If a sheet of polymer or neoprene is used to line the pipeline area where the U-bolt is installed to provide insulation, then insulation is attempted, but proper insulation between the sheet and the pipe is not achieved and the sheet breaks causing contact between U-bolt and pipe
Solution Approach 1:
The patent integrates the insulation function directly into the U-bolt structure through an overmolded plastic coating on the metal piece. This eliminates the need for separate sheets that require proper installation and can break, creating a more reliable and durable insulation solution.
Solution Approach 2:
The plastic coating is applied during manufacturing before installation, ensuring proper insulation is already in place. This preliminary action prevents the installation errors and material failures that occur with separately applied sheets, guaranteeing consistent insulation performance.
4Ease of operation
If the central portion of the metal piece is flattened to improve settlement in the shape of the pipe or element, then grip and hold are improved, but direct contact between metal bar and pipe occurs causing corrosion and vibration transmission
Solution Approach 1:
The patent combines the flattened metal structure with an overmolded plastic coating, merging the mechanical grip function with the insulation function. The flattened shape provides settlement and grip, while the plastic coating prevents direct metal-to-pipe contact, eliminating corrosion and vibration transmission issues.
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 thermoplastic coating ensures acoustic, electrical, and thermal insulation, reduces corrosion risks, and improves the grip and hold of the element, eliminating the need for excessive tightening and frequent replacements, while maintaining insulation and preventing direct contact with the metal piece.
Implementation Method 1
The thermoplastic nature of said coating, as well as a physical separation between the metal piece and the element to be fixed is a vibration-proof, electrical and thermal insulation
Implementation Method 2
The thermoplastic nature of said coating, as well as a physical separation between the metal piece and the element to be fixed is a vibration-proof, electrical and thermal insulation
Implementation Method 3
an over-moulded coating (2) of thermoplastic material which covers the central portion (11) of the metal piece (1) and defines on the inner side a contact surface (21) of said coating with the pipe or element to be fixed
Implementation Method 4
reduces corrosion risks, and improves the grip and hold of the element
Data Source
Figure 1~2
Figure 3~4
AI summary
A U-bolt, comprising a metal piece (1) of general "U"-shaped configuration, with a central portion (11) intended to laterally embrace an element (E) to be fixed, and extended in two straight sections (12) intended to be introduced into holes in a cradle (4) and/or a support (S); said straight sections (12) having a threaded section (13) for mounting tightening nuts (4) for the U-bolt and for the cradle (4) and/or the support (S) against opposite sides of the element (E) to be fixed, the metal piece (1) comprising a coating (2) of thermoplastic material.