Open-Cell Polyurethane Foam Pipe Connection
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Solution Overview
Problem
Existing methods for connecting tubes, especially those used for underwater gas transport, face challenges in meeting mechanical requirements for impact resistance and buoyancy while avoiding toxic liquid modifiers and improving processability, with current solutions being costly and inefficient in production and processing.
Innovation Solution
The connection area between tubes is covered with open-cell rigid polyurethane foam containing polyisocyanurate structures, using a polyurethane system that reacts an isocyanate component with a polyol mixture, filled under high pressure to create a sleeve that meets mechanical and buoyancy requirements without toxic modifiers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid polyurethane foam is used to cover tube connections for impact protection, then mechanical strength and impact resistance are improved, but buoyancy increases which is undesirable for underwater pipelines
Solution Approach 1:
The patent employs open-cell rigid polyurethane foam with a porosity of 80-95%, creating a lightweight porous structure that provides impact protection while minimizing buoyancy. The open-cell structure allows the foam to achieve high impact resistance through energy absorption during compression while maintaining low density (20-80 kg/m³) to reduce buoyant forces on underwater pipelines.
Solution Approach 2:
The invention creates a composite structure by combining the porous polyurethane foam with the tube surface, forming an integrated protective sleeve. This composite material system merges the structural integrity of the tube with the energy-absorbing properties of the foam, achieving both impact protection and controlled buoyancy characteristics suitable for underwater applications.
2Reliability
If liquid modifiers are added to polyurethane systems to improve foam properties, then foam quality is improved, but toxicity increases due to harmful chemicals
Solution Approach 1:
The patent removes toxic liquid modifiers from the polyurethane formulation entirely, achieving foam production through alternative mechanisms. The system uses water as a blowing agent and relies on the natural expansion characteristics of the foam reaction, eliminating the need for harmful chemical additives while maintaining foam quality and structural properties.
Solution Approach 2:
The invention changes the chemical parameters of the foam system by using different blowing agents and formulation ratios that do not require toxic liquid modifiers. By adjusting the isocyanate index and using environmentally friendly additives, the system achieves desired foam properties through parameter optimization rather than harmful substances.
3Productivity
If polyurethane systems are formulated for rapid foam formation, then production speed is improved, but processability deteriorates due to phase separation
Solution Approach 1:
The patent employs a dynamic formulation approach where the polyurethane system is designed to progress through different stages of reaction control. The system allows for extended mixing and processing time in the initial phase, then accelerates foam formation during application. This dynamic behavior enables both good processability during handling and rapid foam formation when needed, avoiding premature phase separation.
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 solution allows for faster, more cost-effective production of tube connections that withstand impact tests and have low buoyancy, with improved processability and reduced toxicity, enabling efficient and stable foam formation even in large tube diameters.
Implementation Method 1
a polyol mixture (b) and an isocyanate component (a), wherein the polyol mixture (b) reacts with the polyisocyanate (a) to form a rigid polyurethane foam containing isocyanurate structures
Implementation Method 2
open-cell rigid foam, which is a rigid polyurethane foam containing isocyanurate structures
Data Source
Figure 1~2
AI summary
The invention relates to cladding for a connection of at least two pipes or parts thereof using an open cell rigid foam material, to the production of such cladding, and to the use of an open cell rigid foam material for protecting the connection of two pipes.