Insulated Pipe Manufacturing Using Expansion Bag
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Solution Overview
Problem
The existing manufacturing processes for insulated pipes face issues such as insulation material adhering to the mould cavity, making it difficult to open the mould without damaging the material, and achieving sufficient adhesion between the insulation and the casing, leading to inconsistent product quality and increased waste.
Innovation Solution
A method involving a closed bag around the inner pipe, which expands and solidifies within the mould, ensuring the insulation material is covered and preventing adhesion issues, allowing for easier removal and improved bonding with the casing, using a bag that can be made of various materials including diffusion barriers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If liquid insulation material is injected into a closed mould cavity, then the insulation material expands and solidifies to form the insulation layer, but the solidified insulation material adheres to the mould wall making it difficult to open the mould without damaging the material
Solution Approach 1:
A release agent is applied to the inner wall of the mould cavity before injecting the liquid insulation material. This release agent acts as an intermediary layer between the mould wall and the expanding insulation material, preventing adhesion and enabling easy mould opening without damaging the solidified insulation material.
Solution Approach 2:
A flexible bag is placed around the inner pipe inside the mould cavity. This thin film bag allows the insulation material to expand against it while preventing direct contact with the mould wall, facilitating easy removal of the insulated pipe from the mould without damaging the insulation layer.
2Manufacturing precision
If the mould is kept closed during expansion and solidification to maintain dimensions and tolerances, then the insulation material solidifies properly, but the casing cannot adhere sufficiently to the solidified insulation material
Solution Approach 1:
The bag is placed around the inner pipe before injecting the insulation material. This preliminary positioning ensures that when the insulation material expands and solidifies, the bag remains in contact with the insulation layer, creating a surface that the casing can adhere to after the mould is opened.
Solution Approach 2:
The bag serves as an intermediary layer between the solidified insulation material and the casing. It provides a surface that facilitates adhesion between the casing and insulation, eliminating the need for additional adhesives while maintaining reliable bonding.
3Ease of operation
If an open mould technique is used to inspect and control the foaming process, then the expansion can be monitored, but the insulation material may tear when opening the mould and precision in timing the closure is required
Solution Approach 1:
A flexible bag is placed around the inner pipe before injecting the insulation material. This bag contains the expanding insulation material, allowing the mould to be opened for inspection while preventing the insulation material from tearing. The bag maintains the integrity of the insulation layer throughout the process.
Solution Approach 2:
The bag acts as a mediator between the expanding insulation material and the mould wall, allowing the mould to be opened without damaging the insulation material. It enables process inspection while maintaining material integrity.
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 enhances production yield, ensures uniform product quality, and improves the long-term insulation efficiency by preventing oxygen infusion, thus reducing material waste and ensuring consistent adhesion between the insulation and casing.
Implementation Method 1
liquid insulation material is injected into the mould cavity. The liquid insulation material expands until it reaches the wall of the mould cavity and subsequently solidifies
Implementation Method 2
During those processes, the bag is pressed towards the inner wall of the mould. Hence, the expanded and solidified insulation material facing the inner wall of the mould will be covered by the bag
Data Source
AI summary
The present invention relates to a method for manufacturing an insulated pipe comprising an inner pipe, an insulation material and a casing. The manufacturing method of the present invention concerns in particular the process of molding an insulation material onto the inner pipe, comprising the step of covering the inner pipe with a closed bag with open ends and subsequently inserting the bag covered inner pipe into a mold. Hereafter the insulation material is injected in a liquid state into the mold between the inner pipe and the bag. The insulation material in a liquid state will after injection start to expand and finally solidify. During those processes, the bag is pressed towards the inner wall of the mold.