Double-Layer Insulated Pipe Assembly for Water Ingress Containment
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Solution Overview
Problem
Thermally insulated pipe arrangements in heat distribution systems are prone to damage, leading to water penetration and loss of thermal insulation, resulting in system failure and high renovation costs.
Innovation Solution
A thermally insulated pipe arrangement featuring a corrugated outer shell with two distinct insulation layers, where the second layer is fluid-tightly connected to the corrugated pipe, preferably using welding or adhesive, and comprising PUR foam and PE foam film to prevent water spread, ensuring robustness and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-layer insulation design is used, then the device complexity is reduced, but the reliability decreases due to quick damage and water penetration
Solution Approach 1:
The insulation system is divided into two distinct layers: a first insulating layer (e.g., PUR foam) providing thermal insulation, and a second insulating layer (e.g., PE foam) providing water barrier protection. This segmentation allows each layer to specialize in its primary function, with the second layer specifically preventing water spread in case of outer jacket damage.
Solution Approach 2:
The patent uses composite material construction with two different insulating materials having distinct properties. The first layer uses materials like PUR foam for thermal insulation, while the second layer uses materials like PE foam with closed-cell structure for water resistance. This composite approach combines the advantages of different materials to achieve both thermal efficiency and water protection.
2Reliability
If the second insulating layer is extensively connected to the corrugated pipe, then the fluid-tightness is improved, but the manufacturing complexity increases
Solution Approach 1:
The second insulating layer is connected to at least 30% of the inner surface of the corrugated pipe, which is sufficient to achieve the fluid-tightness goal without requiring 100% surface coverage. This partial connection approach provides adequate protection while simplifying the manufacturing process compared to full-surface bonding.
Solution Approach 2:
The connection between the second insulating layer and corrugated pipe is concentrated in specific areas (at least 30% of the inner surface, preferably in corrugated troughs) rather than uniformly distributed. This local quality approach ensures fluid-tightness at critical locations while reducing overall manufacturing complexity.
3Reliability
If robust protection measures are implemented, then the reliability is improved, but the flexibility of the pipe arrangement deteriorates
Solution Approach 1:
The patent uses flexible foam materials for both insulating layers that can bend and conform to the pipe's curvature while maintaining their protective functions. The corrugated pipe structure itself provides flexibility, and the insulation layers are designed to accommodate this flexibility without compromising their water barrier or thermal insulation properties.
Solution Approach 2:
The outer corrugated pipe jacket serves as a sacrificial protective element that can be damaged without causing system failure. The underlying double-layer insulation system provides redundant protection, allowing the outer jacket to be replaced if damaged while the core insulation structure remains intact and functional.
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
The solution effectively prevents uncontrolled water spread and maintains thermal insulation, enhancing the pipe's robustness and flexibility, thereby reducing renovation costs and ensuring system reliability.
Implementation Method 1
the second insulating layer is connected on its outer surface facing away from the first insulating layer to at least 30% of the inner surface of the corrugated pipe, preferably in the area of the corrugated troughs, in a fluid-tight manner
Implementation Method 2
a first insulating layer (130) that completely surrounds the at least one media pipe (110) radially
Implementation Method 3
The foam can be closed-cell and, by virtue of this alone, already impedes the further transport of water in the event of damage to the thermally insulated pipe assembly
Data Source
Figure 1
AI summary
The present invention relates to a thermally insulated pipe arrangement (100) comprising at least one media pipe (110) for receiving, storing or conveying a fluid, a corrugated pipe (120) surrounding the at least one media pipe (110) as an outer shell, wherein the corrugated pipe (120) has corrugated troughs (124) and corrugated crests (125), a first insulating layer (130) which radially completely surrounds the at least one media pipe (110), a second insulating layer (140) which is different from the first insulating layer (130) and radially completely surrounds the first insulating layer (130), wherein the second insulating layer (140) is connected at its outer surface (143) facing away from the first insulating layer (130) to at least 30% of the inner surface (112) of the corrugated pipe (110), preferably in the region of the corrugated troughs (124), in a fluid-tight manner.