Multi-Walled Pipe Insulation via Additive Segmentation

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Solution Overview

Problem

Existing double-walled tubular components for fluid flow lines face challenges in achieving consistent thermal and electrical insulation due to thermally induced distortion from welding, which leads to electrical or thermal bridges and limited insulation effectiveness, especially in complex geometries.

Innovation Solution

A multi-walled tubular component manufactured using additive processes with inner and outer walls that are not connected, featuring a hollow space filled with insulating material and part-circular bulges for improved accessibility and fillability, allowing for the use of various materials like ceramics or ductile metals to enhance insulation and prevent crack propagation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If welding is used to connect inner and outer walls for stabilization, then structural stability is improved, but thermal and electrical insulation deteriorates due to thermal distortion and formation of thermal bridges

Engineering Contradiction:

Improvestructural stabilityVSAvoidthermal and electrical insulation

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The component is divided into inner and outer wall segments that are not welded together. Instead, temporary connecting elements are used during manufacturing to maintain spacing, and these are removed afterward to create a complete insulating barrier, eliminating thermal bridges while maintaining structural integrity during production.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Temporary connecting elements serve as intermediaries during the manufacturing process to maintain the required spacing between inner and outer walls. These elements are removed after manufacturing to eliminate thermal bridges, having served their purpose only during production.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If welding is used to join individual tubes or segments, then component assembly is simplified, but manufacturing precision deteriorates due to thermally induced distortion

Engineering Contradiction:

Improvecomponent assemblyVSAvoidannular gap consistency

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The inner and outer walls are manufactured with pre-formed geometric features (such as protrusions and recesses) that enable precise positioning and spacing before final assembly. This preliminary preparation ensures consistent annular gaps without requiring welding-induced deformation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The welding process is replaced with a mechanical assembly system using temporary connecting elements and geometric interlocking features. This substitution eliminates thermal distortion while achieving precise positioning and consistent spacing between walls.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If additive manufacturing is used to produce complex geometries, then design versatility is improved, but manufacturing time increases

Engineering Contradiction:

Improvecomplex geometry capabilityVSAvoidmanufacturing time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

Multiple manufacturing operations are merged into a single additive manufacturing process. The inner wall, outer wall, and temporary connecting elements are all produced in one continuous build process, eliminating the need for separate machining, assembly, and finishing operations that would extend manufacturing time.

Inventive Principle:

Principle #5Merging (Combining)

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 enables efficient thermal and electrical insulation with reduced risk of thermal distortion, allowing for complex geometries and improved stability, while eliminating the need for metallic connections and minimizing manufacturing steps for cost and time savings.

Implementation Method 1

a hollow space which is filled with a filling material... efficient thermal and electrical insulation

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

efficient thermal and electrical insulation... necessary to achieve good electrical and thermal insulation

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentEP3284996B1Multi-walled pipe component and method for producing the same

Publication Date: 2019.08.28 KARLSRUHER INST FUR TECH

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AI summary

The present invention provides a multi-walled pipe component (1) for fluid-carrying conduits or pressure-bearing bodies and a manufacturing method for it. According to the invention, the pipe component (1) is a bent, angled, or forked pipe component (1) manufactured by additive manufacturing processes and is composed of nested, one-piece, and unconnected walls (2, 3). An outer wall (2) circumferentially encloses at least one inner wall (3), so that a cavity (4) is formed between the outer wall (2) and the at least one inner wall, which is filled with a filling material, either directly during or after the additive manufacturing process.