Two-Layer Recycled Thermoplastic Pipe Insulation
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Solution Overview
Problem
Existing thermal insulating materials for pipes, such as porous foam insulation made of synthetic resins, suffer from phase shift phenomena, temperature dissipation, and vulnerability to external damage, requiring improved performance for industrial applications.
Innovation Solution
A thermal insulating complex comprising at least two layers of different densities, with an extruded cellular layer having progressive density and an external protective layer made from recycled thermoplastic polymers like PVC, which are coextruded without adhesives, providing enhanced durability and insulation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If porous foam insulation made of synthetic resins is used, then thermal insulation performance is improved, but resistance to external physical degradation worsens
Solution Approach 1:
The patent applies composite materials by combining a cellular insulating layer (made of expanded thermoplastic polymer) with an external protective layer (made of different thermoplastic polymer). This composite structure provides both thermal insulation properties from the cellular layer and resistance to external physical degradation (UV rays, shocks, weather) from the protective layer, resolving the contradiction between insulation performance and durability.
Solution Approach 2:
The patent applies local quality by giving different regions of the insulating complex different properties: the cellular layer has low density and high insulation value, while the external protective layer has higher density and resistance to environmental factors. Each layer is optimized for its specific function, allowing the overall structure to simultaneously achieve good thermal insulation and high resistance to external degradation.
2Loss of energy
If high density insulating material is used, then temperature dissipation is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by varying the density parameter across different layers: the cellular layer has low density (0.03-0.06 g/cm³) for optimal insulation, while the external protective layer has higher density for durability. The progressive density transition within the cellular layer (from 0.03 g/cm³ at center to 0.06 g/cm³ at periphery) optimizes thermal performance without requiring complex multi-material assembly processes.
Solution Approach 2:
The patent merges the insulating function and protective function into a single integrated insulating complex manufactured by coextrusion. This combining of multiple functions into one component reduces manufacturing complexity compared to assembling separate insulation and protection layers, while still achieving the desired thermal performance through the progressive density design.
3Loss of energy
If progressive density cellular layer is used, then insulation efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent implements progressive density changes within the cellular layer, transitioning from lower density (0.03 g/cm³) at the center to higher density (0.06 g/cm³) at the periphery. This parameter change optimizes thermal insulation by creating a density gradient that reduces heat transfer while maintaining structural integrity. The coextrusion manufacturing process achieves this gradient through controlled material formulation and processing parameters.
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 insulating complex effectively reduces temperature dissipation, withstands external damage, and is easy to install and recycle, offering improved thermal insulation and protection for pipes in various environments.
Implementation Method 1
a thermal insulating complex for insulating a pipe, made of thermoplastic polymer and comprising at least two insulating layers of different densities, in which each of said layers is integrally bonded to the adjacent layer
Implementation Method 2
which is expanded and extruded
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The invention proposes a thermal insulation complex, preferably for tubes or pipes, comprising at least two insulating layers of different densities, in which each of said layers is integrally bonded to the adjacent layer, characterized in that said complex comprises: - An extruded cellular layer having cells whose density is progressively increasing from the center of the cellular layer towards its periphery. - An external layer peripherally surrounding and substantially enveloping said cellular layer, providing it with an external protective surface, and having cells having a density of between approximately 1.10 g/cm³ and 1.4 g/cm³, preferably between 1.15 g/cm³ and 1.3 g/cm³.