Insulated Pipe Foaming With Adhesion Promoter for Uniform Density
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Solution Overview
Problem
The production of insulated pipes often faces challenges in achieving uniform bulk density and homogeneous foam structure, leading to insufficient adhesion and reduced axial shear strength, particularly in continuous production processes for large diameters or high bulk densities.
Innovation Solution
A process involving a media pipe and a jacketing pipe with an adhesion promoter applied to the media pipe surface, followed by introducing a polyurethane system comprising an isocyanate component, polyol component, and catalyst into the slot between the pipes before the adhesion promoter is fully cured, and then foaming and curing the polyurethane system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If polyurethane foam is applied to insulate pipes in continuous production processes, then productivity is improved, but manufacturing precision deteriorates leading to non-uniform bulk density and inconsistent foam structure
Solution Approach 1:
The adhesion promoter is applied to the media pipe surface before the polyurethane foam is introduced. This preliminary action ensures that the surface is properly prepared for foam adhesion before the foaming process begins, which is critical for maintaining consistent axial shear strength in continuous production where process parameters can vary
Solution Approach 2:
The invention introduces specific parameter controls including the adhesion promoter application timing (before foam introduction), the polyurethane system composition (isocyanate component, polyol component, catalyst ratios), and introduces these parameters within specific ranges to ensure uniform foam structure and bulk density while maintaining continuous production capability
2Device complexity
If traditional insulation methods are used, then the production process is simpler, but the thermal conductivity is higher and insulation performance is reduced
Solution Approach 1:
The invention uses a composite system consisting of three distinct layers: the media pipe, the adhesion promoter layer, and the polyurethane foam insulation layer. This composite structure leverages the specific properties of each material - the adhesion promoter provides bonding, the polyurethane provides low thermal conductivity insulation - achieving superior thermal performance compared to traditional single-material insulation methods
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 process significantly increases axial shear strength, often doubling it compared to traditional methods, while ensuring uniform density and low thermal conductivity, making it suitable for large diameter and high bulk density insulation applications.
Implementation Method 1
an adhesion promoter is applied to the surface of the media pipe facing the film hose or the jacketing pipe
Implementation Method 2
foaming and curing the polyurethane system
Implementation Method 3
foaming and curing the polyurethane system
Implementation Method 4
polyurethane foams can be used as insulation material
Data Source
AI summary
Described herein is a process for producing insulated pipes including providing a media pipe and a film hose continuously formed from a film or a media pipe and a jacketing pipe, wherein the media pipe is arranged inside the film hose or the jacketing pipe and a slot is formed between the media pipe and the film hose or jacketing pipe, wherein an adhesion promoter is applied to the surface of the media pipe facing the film hose or the jacketing pipe, introducing a polyurethane system at least including an isocyanate component (a) including at least one isocyanate, a polyol component (b), and at least one catalyst into the slot before the adhesion promoter is fully cured, and foaming and curing the polyurethane system. Also described herein are insulated pipes obtainable or obtained by such a process.