Corrugated Thermoplastic Insulated Pipe for Bendability and Heat Retention
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Solution Overview
Problem
Existing thermally insulated pipes face challenges in achieving optimal insulation values, bending radius, and maintaining small outside diameters while meeting industry standards, with composite systems offering superior insulation but limited flexibility and non-composite systems being more bendable but less insulative.
Innovation Solution
The development of thermally insulated pipes featuring a medium pipe surrounded by thermal insulation and a corrugated outer jacket made of thermoplastic materials, with a foam insulation that is 60% closed-cell and a thermoplastic jacket with a modulus of 300-1400 MPa, allowing for a combination of stability, flexibility, and effective thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If composite systems with PUR/PIR foam insulation are used, then thermal insulation performance is improved, but bendability and flexibility deteriorate
Solution Approach 1:
The patent changes the physical-chemical parameters of the insulation material by using thermoplastic foam instead of cross-linked PUR/PIR foam. The thermoplastic material has a lower modulus of elasticity and can be heated above its melting point, fundamentally changing its mechanical properties from rigid to flexible, thereby enabling bending while maintaining insulation performance
Solution Approach 2:
The patent utilizes the phase transition property of thermoplastic materials. When heated above the melting point of the thermoplastic jacket material, the material transitions from a rigid solid state to a flexible molten state, allowing the pipe to be bent. After cooling, it returns to its rigid state, maintaining both flexibility during installation and structural integrity during operation
2Ease of operation
If non-composite systems with thermoplastic foam insulation are used, then bendability is improved, but thermal insulation performance deteriorates
Solution Approach 1:
The patent optimizes the parameters of thermoplastic foam insulation by selecting materials with specific density ranges (30-80 kg/m³) and closed-cell structures (at least 60% closed cells). These parameter adjustments enhance the thermal insulation properties of thermoplastic materials while maintaining their inherent bendability advantage
Solution Approach 2:
The patent creates a composite structure combining the medium pipe, thermoplastic foam insulation layer, and thermoplastic jacket. This multi-layer composite design allows each layer to contribute its specific properties: the insulation layer provides thermal performance while the outer thermoplastic jacket provides flexibility and protection, achieving both good insulation and bendability
3Ease of manufacture
If pipes with smooth jackets are used, then manufacturing simplicity is improved, but bending forces increase
Solution Approach 1:
The patent applies a corrugated (wave-shaped) structure to the outer jacket surface. This curvature modification increases the moment of inertia of the jacket cross-section, significantly reducing bending forces required during installation while still allowing the pipe to be bent to required radii when heated
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 provides pipes with high ring stiffness, improved bendability, and consistent thermal insulation performance, meeting standards for district and local heating applications with reduced bending forces and smaller diameters.
Implementation Method 1
the outer jacket (2) comprises a thermoplastic material (21) which has a waveform (22), in particular having a corrugated structure
Implementation Method 2
at least one thermal insulation (3), which is arranged around the medium pipe, wherein the thermal insulation (3) comprises a foam (31) which has a density of 30-80 kg/m3 according to ISO 845:2006
Implementation Method 3
a foam insulation that is 60% closed-cell
Data Source
AI summary
Thermally insulated pipes including thermal insulation, outer jacket and medium pipes, wherein the thermal insulation includes a foam having a density of 30-80 kg/m3, the outer jacket includes a thermoplastic plastic (21) having a modulus of 300-1400 MPa and having a corrugated shape. The invention further relates to the use as well as the manufacture of such tubes. Furthermore, the invention relates to composite materials, their use for thermal insulation, as well as their manufacture.