Spray Foam Insulated Pipe Compression for Uniform Outer Diameter
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Solution Overview
Problem
Existing piping systems with channels, tubes, or conduits face challenges in applying uniform spray foam insulation due to bulges forming over these attachments, leading to non-circular and non-symmetrical pipe surfaces, and potential gaps that allow moisture penetration.
Innovation Solution
A method involving the application of a compressive force to the spray foam insulation before curing, using a ribbon-shaped member wrapped under tension or a pressure roller, to prevent bulges over channels, tubes, or conduits, ensuring a uniform diameter and preventing moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spray foam insulation is applied to a pipe with channels, tubes or conduits attached to the external surface, then thermal insulation is provided, but protrusions or bulges occur in the applied foam insulation resulting in a non-circular and non-symmetrical outside diameter surface
Solution Approach 1:
A compression element is applied to the pipe surface before the spray foam insulation is applied. This preliminary action prevents the foam from forming bulges over the channels, tubes or conduits during the insulation application process, ensuring a uniform outside diameter surface while maintaining effective thermal insulation.
2Adaptability or versatility
If channels, tubes or conduits are attached onto the external surface of the pipe under the foam insulation, then heat trace cables or electrical wiring can be accommodated, but gaps in the spray foam insulation can develop at the contact points allowing moisture to penetrate
Solution Approach 1:
The compression element is applied before the spray foam insulation to ensure continuous contact and eliminate gaps at the contact points between the pipe and channels/tubes/conduits. This preliminary compression creates a sealed surface that prevents moisture penetration while still allowing the insulation to accommodate the attached components.
3Reliability
If spray foam insulation is applied onto a pipe with channels, tubes or conduits, then insulation is provided, but additional steps of cutting or grinding are required to remove bulges before spraying a second layer or applying insulation jacket
Solution Approach 1:
The compression element is applied to the pipe surface before the first layer of spray foam insulation is applied. This prevents bulge formation during the insulation application process, eliminating the need for subsequent cutting or grinding steps and allowing direct application of additional insulation layers or jackets, thereby improving productivity.
4Manufacturing precision
If a compressive force is applied to spray foam insulation before curing, then uniform diameter and prevention of bulges is achieved, but additional equipment such as ribbon-shaped members or pressure rollers is required
Solution Approach 1:
A ribbon-shaped compression element, which is a flexible thin film structure, is used to apply compressive force to the spray foam insulation before curing. This flexible element can conform to the pipe surface and attached components, providing uniform compression to prevent bulges while maintaining relatively simple equipment requirements.
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 eliminates the need for additional steps to remove bulges and ensures a uniform insulation layer, preventing moisture penetration and maintaining the temperature of the fluid in the piping system effectively.
Implementation Method 1
applying a spray foam insulation to the external surface of the main pipe; prior to a step of curing the spray foam insulation
Implementation Method 2
applying a compressive force against an exposed outer surface of the spray foam insulation to prevent the formation of bulges
Implementation Method 3
The spray foam insulation can be deposited on the surface of the main pipe such that any gaps between the surface of the main pipe and each of the plurality of channels, tubes or conduits are filled with the spray foam insulation
Data Source
AI summary
A length of a main pipe is provided. The main pipe has an internal surface and an external surface. A plurality of channels, tubes or conduits is attached to the external surface of the main pipe and spaced about a circumference thereof. A spray foam insulation is applied to the external surface of the main pipe. Prior to curing the spray foam insulation, a compressive force is applied against an exposed outer surface of the spray foam insulation to prevent a bulge from forming over the channels, tubes or conduits so that the outer surface of the insulation has a uniform radius.