Insulated Pipe Production via Continuous Corrugation
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Solution Overview
Problem
Existing methods for manufacturing flexible pre-insulated pipes are limited by the length of the production line, leading to cumbersome assembly processes for longer pipes and difficulty in producing flexible pipes with sharp corrugation edges, while also requiring large production spaces.
Innovation Solution
A continuous method involving covering an inner pipe with a film, dispensing expandable insulation material, extruding an outer casing before the insulation expands fully, and passing the assembly through a corrugator to create a flexible pipe with a corrugated casing, allowing for longer pipe lengths and reduced production space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a discontinuous method is used to manufacture flexible pre-insulated pipes, then the production process is simpler and more flexible, but the length of the produced pipe is limited to up to 100 m requiring multiple pipes to be assembled
Solution Approach 1:
The patent applies continuous manufacturing where the pipe assembly moves continuously through the production line without interruption. The inner pipe, insulation material, and outer casing are applied in a continuous process, enabling production of pipes longer than 100 meters without discontinuous assembly operations.
2Length of moving object
If a continuous process is used to manufacture flexible pre-insulated pipes, then longer pipe lengths can be produced, but a long production line is needed which takes up a large amount of space
Solution Approach 1:
The patent employs a nested structure where the inner pipe is surrounded by insulation material which is in turn surrounded by the outer casing. This nested arrangement allows all components to be applied in a compact sequential manner around the pipe axis, reducing the lateral space required for production equipment.
3Productivity
If a continuous process is used with curing inside moulds, then insulated pipes can be produced, but it is difficult to produce sharp corrugation edges as the casing does not easily fill into the corrugation recesses
Solution Approach 1:
The patent applies preliminary corrugation to the outer casing before the insulation material is applied. By pre-forming the corrugated shape on the outer casing surface, sharp edges and well-defined corrugation recesses are created before the insulation process, eliminating the difficulty of filling recesses during or after curing.
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 very flexible pipes with corrugated casings of varying diameters, overcoming length limitations and space requirements, while allowing for the combination of different insulation materials for enhanced properties.
Implementation Method 1
dispensing an expandable insulation material in a liquid state between the inner pipe assembly and the film thereby preparing an initial pipe assembly comprising a layer of expanding insulation material
Data Source
AI summary
A method for producing an insulated pipe in corrugated casing (100) comprising the steps of: covering an inner pipe assembly (105) comprising at least one inner pipe (101) with a film (106); dispensing an expandable insulation material (102) in a liquid state between the inner pipe assembly (105) and the film (106) thereby preparing an initial pipe assembly (107) comprising a layer of expanding insulation material (102a) positioned between the film (106) and the inner pipe assembly (105); extruding a layer of outer casing (104) onto the initial pipe assembly (105) before the insulation material has expanded completely, thereby creating a still expanding insulated pipe assembly (118); and leading the still expanding insulated pipe assembly (118) through a corrugator (205) having an inner corrugated surface giving the casing (104) a corrugated shape as the at least one layer of expanding insulation material (118) continues to expand.