Spiral-Wound Pipe Insulation With Through-Thickness Property Control

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Solution Overview

Problem

Conventional methods for forming pipe insulation require on-site glass manufacturing, leading to inefficiencies and environmental concerns due to continuous operation of melter devices, and lack the ability to vary insulation properties through thickness.

Innovation Solution

A method and system for forming pipe insulation using preformed fibrous materials like mats, felts, or webs, which are spiral wound around a mandrel and fixed with energy, allowing for adjustable thickness and varying properties through the use of different materials and treatments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If glass manufacturing is performed on-site using melter devices, then pipe insulation can be continuously produced, but emissions increase and operational efficiency decreases due to the need for continuous melter operation

Engineering Contradiction:

Improvecontinuous production capabilityVSAvoidemissions from melter devices

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent extracts the glass manufacturing process from the pipe insulation production site by using preformed fiberglass mats as raw material. This eliminates the need for on-site melter devices, thereby removing the source of emissions while maintaining continuous production capability through the availability of premanufactured insulation materials

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The fiberglass mats are preformed and prepared in advance at a separate location before being transported to the pipe insulation production site. This preliminary action allows the melting process to occur off-site, reducing on-site emissions while ensuring continuous supply of raw materials for pipe insulation manufacturing

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If a single insulating material is used throughout the pipe insulation thickness, then manufacturing is simplified, but the ability to optimize thermal performance varies through thickness is lost

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidproperty variation through thickness

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent applies different fiberglass mat densities at different radial positions within the pipe insulation. The inner layer uses a first density and the outer layer uses a second density, allowing each region to have optimized properties for its specific thermal and structural requirements while maintaining manufacturing feasibility through layer-by-layer construction

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The pipe insulation is constructed as a composite structure with multiple fiberglass mat layers of different densities. This composite approach combines materials with different properties to achieve superior overall performance, with the inner layer providing specific characteristics and the outer layer providing complementary characteristics

Inventive Principle:

Principle #40Composite materials

3Object-generated harmful factors

If preformed fiberglass mats are used instead of on-site glass manufacturing, then emissions are reduced and operational flexibility improves, but the process requires additional material handling and storage

Engineering Contradiction:

Improveemissions from glass manufacturingVSAvoidmaterial handling and storage requirements

Core Design Contradiction:

Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The preformed fiberglass mats serve as an intermediary material that bridges the gap between off-site glass manufacturing and on-site pipe insulation production. These mats are manufactured in advance, stored, and then applied to pipes, eliminating the need for continuous on-site melting while providing a practical material handling solution

Inventive Principle:

Principle #24Intermediary (Mediator)

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 approach eliminates the need for on-site glass production, reduces emissions, and enables the creation of pipe insulation with customizable properties by varying the thickness and material composition, enhancing production efficiency and flexibility.

Implementation Method 1

The uncured pelt has a width that approximately corresponds to a circumference of the pipe insulation being made... Hot air is blown through the insulation while it is in the mold to cure the binder

Methodology Applied

Scientific EffectCuring: Phase Change