Metal Foil Insulating Assembly for Storage Vessels
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Solution Overview
Problem
Existing methods for insulating tanks are inefficient, as fibrous materials lose insulating properties when wet and rigid foams require time-consuming shaping and protective foils, leading to limited temperature stability and gaps in insulation.
Innovation Solution
A process involving a mold covered with metal foils, where a foam forming composition is introduced to form a rigid polyurethane foam between the foils, ensuring the foam contacts the metal directly, resulting in a stable insulating element with metal foil coverage that maintains shape and insulating properties under temperature changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fibrous insulation materials are used, then they can easily fill space and adapt to tank shape, but they lose insulating properties when wet and are difficult to dry
Solution Approach 1:
The patent uses a composite structure combining rigid foam insulation with metal foil protective layers. The foam provides the insulating properties while the metal foil protects against moisture and provides structural stability, creating a composite material system that overcomes the limitations of pure fibrous materials.
Solution Approach 2:
The metal foil acts as a thin film protective layer that wraps around the foam insulation. This thin film barrier prevents moisture penetration and provides a protective surface that maintains the insulating properties of the foam even in wet conditions.
2Reliability
If rigid foam insulation is used, then insulating properties are maintained when wet, but the preparation process is time-consuming and requires additional protective foils
Solution Approach 1:
The patent merges the insulation function and protective function into a single integrated process. The metal foil is applied directly to the foam during the foam formation process itself, combining the insulation and protection steps into one operation, thereby reducing overall preparation time.
Solution Approach 2:
The metal foil is applied to the mold surfaces before the foam is formed. This preliminary action ensures that the protective layer is already in place and will be directly contacted by the foam during formation, eliminating the need for subsequent separate protective layer application steps.
3Strength
If insulating elements are cut from large foam blocks, then rigid foam structure is achieved, but gaps are created and temperature stability is limited
Solution Approach 1:
The patent changes the physical state of the foam from solid cut pieces to a formed-in-place structure. By injecting the foam forming composition into the mold and allowing it to expand and cure directly in the desired shape, the material transitions from a rigid block that must be cut to a formed structure that inherently fits the tank geometry, eliminating gaps and improving temperature stability.
4Reliability
If multiple insulating elements are placed around the vessel, then gaps are reduced, but the process becomes more complex
Solution Approach 1:
The patent segments the insulation process into modular elements that can be independently formed and then assembled around the tank. Each insulating element is formed in a separate mold and can be pre-prepared with metal foil coverage, then assembled around the vessel to create continuous insulation with minimal gaps.
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 process produces insulating elements with high adhesive strength and closed-cell foam structure, maintaining insulating properties and shape integrity through repeated temperature cycles, reducing gaps and improving temperature stability.
Implementation Method 1
introducing a foam forming composition in the mold; and allowing a foam to form between the metal foils
Implementation Method 2
The foam comes in direct contact with the metal foil directly after the formation of the foam, and wherein all surfaces of the insulating element are covered with a metal foil
Data Source
AI summary
The present invention relates to a process for preparing an insulating element for a tank comprising the steps of covering at least two surfaces of a mold with a metal foil; introducing a foam forming composition in the mold; and allowing a foam to form between the metal foils. The present invention further relates to the insulating element as such, an insulating assembly for a tank comprising insulating elements which are designed to fit closely to the periphery of the tank, wherein the insulating element is obtained or obtainable according to the process of the present invention; and also the use of said insulating assembly to insulate a tank, a tank wagon or a container.