Continuous Insulated Pipe Production with Multi-Nozzle Injection
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Solution Overview
Problem
Existing methods for producing insulated pipes with polyurethane foam face challenges in achieving uniform density distribution and preventing the polyurethane system from running out of the pipe, leading to inconsistent quality and increased costs due to the need for multiple socket connections.
Innovation Solution
A continuous process involving a carrier pipe, a jacket pipe, and a film tube with a polyurethane layer, where a multiple nozzle bent to match the annular gap's radius is used to fill a polyurethane system comprising an isocyanate and polyol mixture, ensuring even distribution and application of a thermoplastic jacket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If discontinuous tube-in-tube production with star-shaped spacers is used, then pipe segments can be manufactured, but uniform density distribution of polyurethane foam is not achieved and production efficiency is reduced
Solution Approach 1:
The patent implements continuous production by eliminating the discontinuous steps of manual assembly and welding. The carrier pipe and jacket pipe are continuously fed through the production line, and polyurethane foam is continuously injected and cured, allowing the process to run without interruption and achieve both high productivity and uniform foam density
Solution Approach 2:
The patent divides the pipe production into distinct continuous segments: carrier pipe formation, jacket pipe formation, polyurethane foam injection, and curing zones. This segmentation allows each zone to be optimized independently while maintaining overall continuous production flow
2Ease of manufacture
If longer individual pipe segments are used to reduce socket connections, then installation costs are reduced, but production becomes more difficult and quality control decreases
Solution Approach 1:
The continuous production process allows for consistent quality control across long pipe segments by maintaining stable processing conditions throughout the entire production line, eliminating the quality variations that occur with discontinuous batch production
Solution Approach 2:
The patent replaces manual operations (mechanical assembly and welding) with automated continuous processes, including automated polyurethane injection systems and continuous curing zones, which provide more consistent quality control over long production runs
3Reliability
If polyurethane system is filled into annular gap, then thermal insulation is achieved, but material may run out of pipe leading to inconsistent quality
Solution Approach 1:
The patent pre-forms the carrier pipe and jacket pipe with precise dimensions before the polyurethane injection process, ensuring the annular gap has consistent geometry throughout. This preliminary preparation prevents material loss by ensuring proper fit and containment before the insulation material is applied
Solution Approach 2:
The continuous injection and curing process ensures that polyurethane material is consistently applied throughout the entire pipe length without interruption, preventing gaps or deficiencies in the insulation layer that would occur with discontinuous application 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 ensures a low and evenly distributed polyurethane foam density, preventing material loss and achieving a uniform density distribution along the pipe length, resulting in improved thermal insulation and reduced thermal conductivity.
Implementation Method 1
foaming and allowing the polyurethane system to harden
Implementation Method 2
a polyurethane system comprising at least one isocyanate component (a) and at least one polyol mixture (b)
Implementation Method 3
applying a layer of at least one thermoplastic to the film tube by extrusion in order to form the jacket tube
Data Source
Figure 1
AI summary
The invention relates to a continuous method for producing insulated pipes comprising a medium pipe (3), a casing pipe, a layer of at least one polyurethane between the medium pipe and the casing pipe, and a film tube (5) between the at least one polyurethane and the casing pipe, comprising at least the steps of (A) providing a medium pipe and a film tube, which is continuously formed from a film, in a jaw conveyor, wherein the medium pipe is arranged within the film tube in such a way that an annular gap is formed between the medium pipe and the film tube, (B) injecting a polyurethane system comprising at least one isocyanate component (a) and at least one polyol mixture (b) into the annular gap, (C) foaming and curing the polyurethane system, and (D) applying a layer of at least one thermoplastic plastic to the film tube by means of extrusion in order to form the casing pipe, wherein the injection as per step (B) is performed by means of a multi-nozzle bent according to the radius of the annular gap.