Polyimide Foam Pipe Heater Insulation
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Solution Overview
Problem
Conventional pipe heaters have poor heat insulating properties due to their structural limitations, particularly with heat insulating layers made of felt, which restrict improvements in thermal insulation even with increased thickness.
Innovation Solution
A pipe heater design incorporating a tubular heat insulating layer with a polyimide foam layer and a protection layer formed by coating polyimide resin on woven polyimide fiber cloth, interposed between the foam layer and the heating wire to prevent bubble dissipation and enhance thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the heat insulating layer is made of felt, then the structure is simple and easy to manufacture, but the heat insulating property is poor and cannot be improved by increasing thickness
Solution Approach 1:
The patent applies composite materials by combining polyimide foam (providing excellent heat insulation) with woven polyimide fiber cloth (providing structural support and bubble prevention). This composite structure resolves the contradiction by achieving superior heat insulating properties while maintaining manufacturability through a systematic multi-layer construction approach.
Solution Approach 2:
The patent utilizes porous polyimide foam as the core heat insulating material. The foam structure provides high heat insulation performance due to its porous nature that traps heat, while the interconnected bubbles provide structural integrity. This resolves the contradiction by delivering excellent thermal insulation without requiring excessive thickness.
2Reliability
If the thickness of the heat insulating layer is increased to improve heat insulation, then the heat insulating property improves, but the structural integrity deteriorates due to bubble dissipation from heat transfer
Solution Approach 1:
The patent introduces a protection layer made of woven polyimide fiber cloth as an intermediary between the heating wire and the polyimide foam layer. This protection layer acts as a barrier that prevents direct heat transfer to the foam bubbles, preventing bubble dissipation and maintaining structural integrity while allowing the foam layer to provide excellent heat insulation.
Solution Approach 2:
The protection layer is positioned beforehand between the heat source and the foam structure to cushion against thermal damage. This preventive measure protects the foam bubbles from dissipation before it can occur, enabling the use of thicker foam layers for improved insulation without compromising structural stability.
3Reliability
If a protection layer is added to prevent bubble dissipation, then the heat insulating property is improved, but the device complexity increases
Solution Approach 1:
The protection layer utilizes the porous structure of woven fiber cloth, which naturally provides both mechanical strength and thermal barrier properties. This material choice enhances heat insulation while avoiding excessive complexity by using a straightforward textile structure rather than complex multilayer assemblies.
Solution Approach 2:
The patent creates a composite structure where the protection layer (woven polyimide fiber cloth) and heat insulating layer (polyimide foam) work together synergistically. This composite approach improves heat insulation performance while maintaining relatively simple manufacturing processes, as both layers can be applied using standard industrial techniques.
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 improved pipe heater achieves enhanced heat insulating properties through the foam structure and the protection layer, allowing for easier enhancement by increasing thickness without damaging the insulation, and reduces heat transfer to the polyimide foam layer.
Implementation Method 1
a polyimide foam layer (11) formed of polyimide foam
Implementation Method 2
the protection layer (44) interposed between the heat insulating layer (10) and the heating wire (21) so as to prevent bubbles distributed in the polyimide foam layer (11) from dissipating due to heat transferred from the heating wire (21)
Data Source
AI summary
Disclosed is a pipe heater comprising a tubular heat insulating layer having a pair of separating surfaces formed over the entire length thereof, an external cover bonded to the outer surface of the heat insulating layer to enclose the heat insulating layer, a heating layer provided inside the heat insulating layer and including a heating wire therein, and an internal cover provided inside the heating layer to enclose the heating layer, wherein the heat insulating layer includes a polyimide foam layer formed of polyimide foam, and a protection layer is interposed between the heat insulating layer and the heating wire to prevent bubbles distributed in the polyimide foam layer from dissipating due to heat transferred from the heating wire.