PAS Foam Tubular Assembly for Safer Steam Hose Insulation
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Solution Overview
Problem
Existing steam-carrying tubular assemblies using fiberglass insulation are cumbersome, hazardous to handle, require multiple manufacturing steps, and suffer from thermal performance issues, leading to safety risks and increased costs.
Innovation Solution
A polyarylene sulfide (PAS) foam layer is used to encase a hollow inner tube, offering reduced density, thermal conductivity, and thermal effusivity, eliminating the need for fiberglass and allowing for a single continuous processing step, enhancing safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fiberglass insulation is used in steam-carrying tubular assemblies, then thermal insulation is provided, but handling safety deteriorates and manufacturing complexity increases
Solution Approach 1:
The patent changes the material parameter from fiberglass to polymer foam, transforming the insulation material from a hazardous fibrous material to a safe cellular polymer structure that provides equivalent or superior thermal insulation without the harmful effects of glass fiber exposure
Solution Approach 2:
The patent employs composite material structures where polymer foam is combined with metal tubing and protective layers, creating an integrated assembly that maintains thermal insulation performance while eliminating the need for hazardous fiberglass materials
2Reliability
If fiberglass tape is used for insulation, then thermal protection is achieved, but manufacturing process complexity increases due to discontinuous batch processing
Solution Approach 1:
The patent enables continuous manufacturing by replacing discontinuous fiberglass tape wrapping with a continuous polymer foam extrusion process that can be performed in a single uninterrupted operation, eliminating the need to stop and change reels or tapes
Solution Approach 2:
The patent merges multiple discrete manufacturing steps (fiberglass wrapping, tape application, polymer extrusion) into a single integrated continuous process where polymer foam is extruded directly onto the metal tube in one continuous action
3Reliability
If fiberglass is used in steam hoses, then insulation is provided, but operator safety deteriorates requiring special protective equipment
Solution Approach 1:
The patent extracts and removes the hazardous fiberglass component from the insulation system entirely, replacing it with polymer foam that provides the same thermal protection function without the health and safety risks associated with glass fiber exposure
4Reliability
If polymeric jacket is added to protect fiberglass tape, then protection is improved, but weight increases making tubing heavy and difficult to handle
Solution Approach 1:
The patent changes the density parameter of the insulation material by using cellular polymer foam structure which provides adequate protection and insulation at lower density compared to solid polymeric jackets used with fiberglass, thereby reducing overall weight
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 PAS foam layer provides improved thermal performance, reduced weight, and easier handling, enabling quicker installation, lower costs, and increased productivity while ensuring worker safety and space efficiency.
Implementation Method 1
a foamed thermal insulator surrounding the outer surface of the inner tube, the foamed thermal insulator comprising a foamed polyarylene sulfide polymer material
Implementation Method 2
comprising a foamed polyarylene sulfide polymer material having a foamed density and a foamed thermal effusivity that is foamed from an un-foamed polyarylene sulfide polymer material
Data Source
AI summary
A polyarylene sulfide (PAS) foam layer that circumscribes a hollow inner tube and may have a 50% or greater density reduction relative to the density of an un-foamed PAS polymer material and/or a 50% or greater thermal conductivity reduction relative to the thermal conductivity of an un-foamed PAS polymer material and/or 50% or greater thermal effusivity reduction relative to the thermal effusivity of an un-foamed PAS polymer material. The PAS foam layer may have a low density (e.g., less than 0.67 g/cc) and/or a low thermal conductivity (e.g., anywhere from 0.017 W/(m-K) to 0.145 W/(m-K)) and/or a low thermal effusivity (e.g., less than 316 Ws1/2/m2/K, optionally anywhere from 38 Ws1/2/m2/K to 316 Ws1/2/m2/K) even at high temperatures (e.g., above 400 degrees Fahrenheit (° F.) (about 204 degrees Celsius (° C.)). Such a PAS foam layer may have characteristics appropriate for use as part of a steam hose.