Corrugated Insulated Conduit Pipe with Post-Formed Foam Filling
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Solution Overview
Problem
Existing methods for producing thermally insulated, corrugated pipes with deep corrugation are complex and lengthen the production process, while achieving flexibility and space-efficient manufacturing remains a challenge.
Innovation Solution
The outer jacket is formed separately from the inner tube in a corrugator, where thermal insulation foam is introduced after the outer jacket has been formed, allowing for independent corrugation and easy shaping without defects, using a two-component foam mixture with adjustable reactivity and a protective tube with friction-reducing coating to prevent adhesion and control foam formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the outer jacket and thermal insulation are formed together in sequence, then the production process is simpler, but the corrugation depth is reduced and flexibility is compromised
Solution Approach 1:
The production process is divided into two independent stages: first forming the corrugated outer jacket structure, then separately introducing and foaming the thermal insulation material. This segmentation allows the corrugation to be formed to full depth before insulation is added, avoiding the compromise that occurs when both processes are combined.
Solution Approach 2:
The outer jacket is pre-formed with deep corrugation in the corrugator before the thermal insulation is introduced. By completing the shaping action first, the jacket achieves its final corrugation depth and flexibility characteristics, and subsequent insulation foaming does not interfere with this pre-established geometry.
2Manufacturing precision
If the thermal insulation is introduced before the outer jacket is formed, then the insulation can expand freely, but the outer jacket develops defects and improper shaping
Solution Approach 1:
The outer jacket is completely formed in the corrugator with all corrugations and shaping completed before the thermal insulation material is introduced. This preliminary formation ensures the jacket has proper geometry and no defects, and the subsequent insulation foaming occurs in a stable, pre-formed structure rather than interfering with jacket formation.
Solution Approach 2:
The film tube acts as an intermediary container that holds the liquid foam mixture in place during the extrusion and corrugation processes. It allows the foam to be positioned correctly within the formed jacket and ensures uniform distribution during expansion, while not interfering with the outer jacket's independent formation in the corrugator.
3Shape
If a deep corrugation is achieved by closing the line pipe with additional molding tools, then flexibility is improved, but the production plant becomes more complex and longer
Solution Approach 1:
The corrugation formation is separated from the insulation process and performed in a dedicated corrugator unit that processes only the outer jacket material. This segmentation eliminates the need for complex multi-functional molding tools that would be required to simultaneously form both deep corrugations and accommodate insulation, thereby simplifying the overall production plant design.
Solution Approach 2:
Instead of forming the pipe structure and then adding insulation (conventional approach), the invention inverts the sequence by first forming the corrugated jacket structure and then introducing the insulation material into the already-formed structure. This inversion allows deep corrugation to be achieved with simpler equipment, as the corrugator only needs to handle the jacket material without coordinating with insulation processes.
4Productivity
If the foam formation occurs during extrusion, then the process is continuous, but the outer jacket cannot be properly formed without defects
Solution Approach 1:
The continuous production process is segmented into distinct functional zones: the extruder forms and extrudes the outer jacket material continuously, while the corrugator separately and continuously forms the corrugation pattern. The foam formation is segmented as a subsequent independent step that occurs after the jacket is formed. This segmentation maintains overall production continuity while ensuring each step can be optimized for its specific function without interference.
Solution Approach 2:
The film tube serves as an intermediary that carries the liquid foam mixture through the extrusion and corrugation zones without premature expansion. It maintains the foam in a controlled liquid state during the continuous production process, allowing the outer jacket to be fully formed first, then enables foam expansion to occur in the correct position and timing after the jacket structure is established.
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 enables the production of pipes with deep corrugation and high flexibility, simplifying the process by allowing the outer jacket to be formed before foaming, reducing defects, and ensuring stable shaping, while maintaining the flexibility and thin insulation required.
Implementation Method 1
In order to form the outer casing in the corrugator, a vacuum corrugator is used in particular, in which the shaping takes place by means of a vacuum acting between the mold parts of the corrugator and the outer casing to be formed.
Implementation Method 2
a mixture of starting materials is used to form the insulating foam, the reactivity of which is adjusted in such a way that, depending on the speed of the production line for the duct and the temperature conditions, the foaming reaction only takes place in the corrugator.
Implementation Method 3
Additionally or alternatively, the foam formation of the starting material in the film tube is influenced by cooling taking place as it is passed through the extruder.
Data Source
Figure 1~2
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AI summary
The invention relates to a method for continuously producing a heat-insulated corrugated conduit pipe (1) comprising at least one inner pipe (2). A corrugated outer casing of the conduit pipe is first produced using an extruder (27) and a corrugator (28), and the inner pipe arranged in a film tube together with a foam-forming starting material is guided into the corrugator, in which the previously corrugated outer casing of the conduit pipe is filled with the heat-insulating foam. The device (10) provided for carrying out the method has a protective pipe (26), by means of which the inner pipe surrounded by the film tube can be guided into the corrugator in a separate manner from the extrusion and corrugation process of the outer casing.