Composite Refrigeration Pipe Structure for High Burst Pressure
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Solution Overview
Problem
Current multilayer composite pipes face challenges in achieving high burst pressure and temperature resistance, particularly in refrigeration applications, due to limitations in material thickness and single-point failures in metal layers, which affect their performance and reliability.
Innovation Solution
The development of a composite refrigeration line set featuring an inner polyethylene tube, adhesive layers, an AL 3004-O aluminum layer with specific thickness ranges, and an outer polyethylene layer, along with optional low-emissivity and reinforcement layers, to enhance burst pressure and temperature resistance, and prevent single-point failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single metal layer is used in composite pipes, then the structure is simpler and manufacturing is easier, but the pipe is susceptible to single-point failures and cannot achieve high burst pressure
Solution Approach 1:
The metal layer is segmented into multiple separate layers (first metal layer and second metal layer) instead of using a single continuous metal layer. This segmentation prevents single-point failures from propagating through the entire structure and enables the pipe to withstand higher burst pressures by distributing stress across multiple discrete metal barriers.
Solution Approach 2:
The pipe employs a composite structure combining multiple materials including plastic layers and multiple metal layers separated by adhesive layers. This composite material approach creates a multi-functional structure where each layer contributes specific properties: plastic provides flexibility and corrosion resistance, metal provides strength and barrier properties, and adhesive provides bonding between layers, collectively achieving high burst pressure resistance.
2Strength
If metal layer thickness is increased to improve burst pressure resistance, then strength improves, but the pipe becomes more prone to single-point failures and manufacturing becomes more difficult
Solution Approach 1:
Instead of using one thick metal layer that is vulnerable to single-point failures, the metal barrier is segmented into multiple thinner layers. This segmentation ensures that a defect or failure in one metal layer does not compromise the entire pipe structure, as other metal layers continue to provide barrier and strength functions.
Solution Approach 2:
The structure incorporates adhesive layers between metal layers that act as cushioning elements. These adhesive layers prevent stress concentration and crack propagation between metal layers, providing a buffer that protects against single-point failures before they can compromise the overall pipe integrity.
3Reliability
If multiple metal layers are added to prevent single-point failures and increase burst pressure, then reliability improves, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
Multiple metal layers and plastic layers are merged into a single integrated composite structure through adhesive bonding. This merging approach allows the pipe to be manufactured as a unified component rather than assembling separate parts, simplifying the manufacturing process while maintaining the reliability benefits of multiple metal layers for preventing single-point failures.
Solution Approach 2:
The use of composite materials with adhesive bonding creates a integrated multi-layer structure that combines the advantages of multiple metal layers (reliability, burst pressure resistance) with the benefits of a unified construction (ease of manufacture, structural integrity). The adhesive layers facilitate manufacturing by providing a simple bonding mechanism between layers.
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 solution achieves burst pressures in excess of 1950 pounds per square inch and improved temperature resistance, addressing the limitations of existing pipes by distributing stress and preventing single-point failures through the use of multiple metal layers and reinforcement.
Implementation Method 1
a first adhesive layer positioned about the inner plastic tube; an aluminum layer positioned about the first adhesive layer and coupled to the inner plastic tube via the first adhesive layer; a second adhesive layer positioned about the aluminum layer; and an outer plastic layer positioned about the aluminum layer coupled to the aluminum layer via the second adhesive layer
Implementation Method 2
The composite refrigeration line set can further include a low-emissivity layer positioned about the outer plastic layer. The low-emissivity layer can include low-emissivity aluminum.
Implementation Method 3
The composite refrigeration line set can further include a low-emissivity layer positioned about the outer plastic layer
Data Source
AI summary
One aspect of the invention provides a composite refrigeration line set including at least one selected from the group consisting of: a suction line and a return line, characterized in that one or more of the suction line and the return line are a composite refrigeration line set tube include: an inner plastic tube; a first adhesive layer positioned about the inner plastic tube; an aluminum layer positioned about the first adhesive layer and coupled to the inner plastic tube via the first adhesive layer; a second adhesive layer positioned about the aluminum layer; and an outer plastic layer positioned about the aluminum layer coupled to the aluminum layer via the second adhesive layer. The inner plastic tube is polyethylene of raised temperature. The outer plastic tube is polyethylene of raised temperature. The aluminum layer comprises AL 3004-O.