WO2014188192A1

WO2014188192A1 - Polymeric foam pipe instulation

Info

Publication number: WO2014188192A1
Application number: PCT/GB2014/051562
Authority: WO
Inventors: Paul Jacobs; Karl Hewson; Luis CONCEICAO
Original assignee: Zotefoams Plc
Priority date: 2013-05-22
Filing date: 2014-05-21
Publication date: 2014-11-27
Also published as: GB201309244D0; EP2999590A1

Abstract

A G-shaped elongate polymeric foam body is provided for insulating a water pipe, wherein the foam forming the G-shape has a thermal conductivity of less than 0.15 W/mK at 0°C.

Description

POLYMERIC FOAM PIPE INSULATION

FIELD OF THE INVENTION The present invention relates to polymeric foam insulation for in-place pipes and ducts. The foam insulation is provided in the form of a semi-rigid length of foam with a G- shaped cross-section. The shape of the insulation is such that it can easily be installed by firstly opening out the G-shape and then slipping it easily over the pipe or duct to be insulated. Once installed the G-shape causes the insulation to grip the pipe without falling off and acts to provide a closure force that facilitates closure with tape, ties or other fastenings.

BACKGROUND OF THE INVENTION Piping and ducting systems are designed to transport a variety of fluids, some of which may be heated, such as a hot air, hot water or steam, and some of which may be chilled, such as a cold water, or in some instances the temperature of the fluids may alternate between hot and cold. When the fluid transported is at a different temperature to that of the ambient environment, it is desirable to insulate the piping to maintain the temperature of the fluid being transported, and to reduce overall energy losses in the system. In addition to this, the insulation may provide protection against burn or freeze injuries that could occur as a result of contact with uninsulated or insufficiently insulated pipework. Often these piping and ducting systems are in situ before they are insulated or there is a requirement to be able to remove the insulation and replace it, for example, during maintenance. In such circumstances it is highly desirable for the insulation to be installed quickly and easily in order to minimize the installation costs (i.e. labour costs) and keep any downtime of the system to a minimum. In patent US3279503, Carbone et al teach a snap-on insulation where the edges of the insulation overlap to provide a resilient closure. However, because the parts of the Carbone insulation which overlap also touch each other, the snap-on insulation is installed by springing apart the overlap to allow the pipe to be inserted and then closing the insulation to overlap the join, and this action of springing apart the overlap can prove difficult to achieve, particularly when working in confined spaces. In patent application US2003/0234058, Tippins describes a self-closing pipe insulation device that requires accurate preparation of the insulation material in order to facilitate the even joining of the longitudinal edges of the material to form the tubular sleeve configuration.

It is an advantage of the present invention that, unlike the teaching of Carbone et al, it is not necessary to spring apart the overlap of the foam insulation to allow the insulation to be installed. This makes it easier for a single individual to install the insulation and the insulation is easier to install in confined spaces or hard to reach places. It is a further advantage that, unlike the teaching of Carbone et al and Tippins, the internal diameter of the G-shaped semi-rigid foam insulation does not have to be the same or greater than the outside diameter of the pipe to be insulated to provide either an exact match or an overlap along the longitudinal edge of the insulation. In addition, the nature of the G-shaped form of the insulation is such that it grips the pipe once installed and acts to provide a closure force that facilitates closure with tape, ties or other fastenings. It is contemplated that the G-shaped insulation may be overwrapped with further layers of insulation which might be of lower thermal resistance, be of lower cost or have other significantly differentiated properties.

US 5,049,426 (Kimura et al.) discloses a take-up liner for uncured rubber members having a laminate of reinforcing cloth, a flexible foamed layer, a cloth layer and an elastomer layer adhered thereto. The liner has a helical shape.

CA 975279 (The B.F. Goodrich Company) discloses a curved resilient laminate which is made by vulcanizing an elastomer laminar in adhesive contact with a heat formable elastomer laminar. Various configurations are disclosed including a spiral

configuration.

US 1,435,311 (Knight) discloses a flexible tubular clamping jacket comprising a length of flexible tubing split lengthways. US 2006/0237216A1 (Yoshida et al.) discloses a covering member comprising cylindrical or columnar foam having a longitudinal slit line. JP 2011117503 (Panasonic Corp) discloses a covering material for a pipe which is elastically formed so that the cross-section in the direction perpendicular to the axis of the pipe becomes a spiral shape.

SUMMARY OF THE INVENTION

In a first aspect of the present invention, there is provided an elongate polymeric foam body for insulating a water pipe, wherein in transverse cross-section at least part of the body is in the form of spiral defining a space within the spiral, wherein the foam forming the spiral has a thermal conductivity of less than 0.15 W/mK at 0°C and is sufficiently flexible to be able to move from a first configuration having a first diameter to a second configuration having a second diameter, the second diameter being greater than the first diameter, and wherein the spiral is resiliently biased into the first configuration, and wherein in the first configuration the outermost part of the spiral circumferentially overlaps an inner part of the spiral and wherein there is a gap between said outermost part and said inner part through which gap said space within the spiral can be accessed, whereby in use the foam body can be moved from the first

configuration to the second configuration to enable a water pipe to be disposed in the space within the spiral, the resilient bias of the spiral causing the body to grip the water pipe.

The main advantage of the present invention is that by using a low thermal conductivity foam to form the G-shaped semi-rigid foam insulation a reduced thickness of foam can be used to achieve the required level of thermal insulation or personal protection than if a higher thermal conductivity material were used. This reduction in the thickness of the insulation will make it easier to handle, install and maintain, particularly where the pipe or duct to be insulated is in a confined space, and it may also be accompanied by a reduction in weight. Any reduction in the weight of the insulation will reduce the overall weight of the pipe or ducting system and might allow the use of lighter weight brackets, hangers, fixings and the like. This would have significant benefits for pipe or ducting systems in mass transport applications, such as aircraft and trains, where weight savings can reduce fuel consumption, thereby reducing the environmental impact and making a significant contribution to reducing the operating costs over the lifetime of the vehicle.

The present invention is preferably a semi-rigid polymeric foam insulation with a G- shaped cross-section that can be used for the thermal or thermal acoustic insulation of pipework and ducting. The G-shaped insulation can be fabricated from sheets, blocks or rolls, using techniques such as cutting, slitting, cold-forming, moulding,

thermoforming or any other technique known to those skilled in the art. The foam can be heat welded or laminated by standard techniques to form insulation of any desired length or thickness. Where thermal processes are used, as in the case of thermoforming for example, the surface of the foam may be provided with a closed skin due to a healing effect of the outermost cell walls, however, where cold-forming processes are used the surface of the foam may have a proportion of open cells from the cutting and slitting processes used to fabricate the material. As regards the polymeric foam, polymeric foam insulation materials may be

thermoplastic or thermoset and may have an open or a closed cell structure. Examples of polymeric foams used for pipe insulation include polyethylene, EPDM, polyurethane, polyisocyanurate, melamine, polyamide and polyvinylidene fluoride. They are typically characterised by their low density and low thermal conductivity, i.e. less than 0.04 W/mK at 0°C, although in certain specific applications thermal conductivities of up to 0.15 W/mK may be considered. In the present invention it is desirable for the foam to have sufficient rigidity to form a self-supporting G-shape while retaining sufficient flexibility to allow it to be installed easily on the pipe or duct to be insulated. It is contemplated that the semi-rigid G-shape could also be formed from a composite structure of various layers, selected from any number of polymeric foams, films, foils, textiles, reinforcements and other materials known to those skilled in the art. Such a composite structure could be prepared by heat lamination, adhesive bonding, sewing or other techniques known to those skilled in the art. Individual layers could have different functional characteristics such as thermal conductivity, temperature resistance, weatherability, fire performance, colour or identification markings. It is further contemplated that the semi-rigid G-shape could be used in combination with insulation in any of the other format known to those skilled in the art, including semi-circular half sections, tubes, strips, rolls and sheets.

In a second aspect of the invention, there is provided a method for insulating a water pipe comprising the steps of

(i) providing an elongate polymeric foam body wherein the polymeric foam has a thermal conductivity of less than 0.15 W/mK at 0°C,

wherein in transverse cross-section at least part of the body is in the form of spiral defining a space within the spiral,

wherein the foam forming the spiral is sufficiently flexible to be able to move from a first configuration having a first diameter to a second configuration having a second diameter, the second diameter being greater than the first diameter, and

wherein the spiral is resiliently biased into the first configuration,

and wherein in the first configuration the outermost part of the spiral

circumferentially overlaps an inner part of the spiral,

(ii) moving said foam body from the first configuration to the second configuration,

(iii) locating a water pipe having an outer diameter in said space within the spiral,

wherein the outer diameter of the pipe is such that, when the pipe is located in said space, said outermost part of the spiral does not circumferentially overlap said inner part of the spiral, and wherein the resilient bias of the spiral causes the body to grip the water pipe. Although the present invention has been described with particular emphasis on the thermal or thermal acoustic insulation of pipework and ducting, there are many other applications wherein the inherent benefits of polymeric foam combined with ease of installation would be advantageous. For example, the cushioning properties of the foam make it suitable for impact protection on pipes, posts, barriers, handrails, scaffolding poles and the like. In addition to those examples given above, transportation applications including the protection of ship's railings and roll-bars and cages in vehicles are contemplated, and further applications include impact protection and cushioning on animal stalls, pens, cages and the like. The present invention can also be used on the support poles of swings, trampolines and other playground equipment to protect children from accidental injury. Sporting applications include impact protection on rugby and American football posts and the support poles of basketball hoops and the like. On a smaller scale, grips for bats, racquets, handlebars and other sporting equipment are also contemplated. Further applications include grips for canoe and kayak paddles and rowing oar handles, where the selection of a closed cell foam would impart additional buoyancy, and the handles of rowing machines and other gym equipment.

The present invention has use in medical applications as a wrap to provide localized support and impact protection, in planned or emergency situations, particularly in the area of orthopedics and fractures. It could find similar applications in veterinary medicine, for example, in the protection or treatment of the legs of animals such as horses. In such applications the selection of a closed cell foam would provide a barrier to liquids, micro-organisms and dirt, and, if the polymer was selected from those known to those skilled in the art as breathable, for example a polyether block amide (PEBA), it would also allow sweat and moisture to pass through.

Another use of the present invention is that it can be used to provide protection to the trunks of newly planted trees and saplings that might otherwise be subject to attack by insects or animals. The nature of the present invention is such that it is easily installed and, once installed, it allows for some expansion of the trunk as the tree grows. It can also be designed such that the young tree or sapling can flex in the wind allowing the development of a strong root system. Further horticultural applications include grips for long handled tools and other gardening equipment. The inherent insulation properties of the present invention also make it suitable for use as a beverage can, cup or bottle holder, commonly known as a koozie. In such applications the present invention could be decorated with advertising or promotional information. It is also contemplated that in this application the present invention might be considered disposable, for example at sporting events, concerts or festivals, and in such cases it would be advantageous if the polymer were selected from those known to be biodegradable or compostable. Further applications of the present invention include packaging, and in particular returnable packaging, for tubes, rods, bottles, cylinders and the like. The present invention can also be used to cover the framework of cages, stillages or racks to prevent the contents being scratched or damaged in some other way. The present invention can also find use in cable management and can further be used as an electrical insulation. Where the polymeric foam of the invention is closed cell, the present invention can also be used to impart buoyancy to an object as mentioned previously with regard to watersports. A semi-rigid foam insulation may be provided with a G-shaped cross-section that can be used for the thermal or thermal acoustic insulation of pipework and ducting. The insulation can be fabricated from sheets, blocks or rolls, using a variety of hot or cold forming techniques. The foam can be heat welded, laminated or adhesively bonded by standard techniques to form insulation of any desired length or thickness. The G- shaped cross-section allows the foam to be easily installed around the pipe or duct to be insulated without the need for specialist tools.

In a third aspect of the invention, there is provided an elongate polymeric foam body for insulating a water pipe, wherein in transverse cross-section at least part of the body is in the form of spiral defining a space within the spiral, wherein the foam forming the spiral is sufficiently flexible to be able to move from a first configuration having a first diameter to a second configuration having a second diameter, the second diameter being greater than the first diameter, and wherein the spiral is resiliently biased into the first configuration, and wherein in the first configuration the outermost part of the spiral circumferentially overlaps an inner part of the spiral and wherein there is a gap between said outermost part and said inner part through which gap said space within the spiral can be accessed, whereby in use the foam body can be moved from the first configuration to the second configuration to enable a water pipe to be disposed in the space within the spiral, the resilient bias of the spiral causing the body to grip the water pipe. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of the semi-rigid polymeric foam G-shaped insulation of the present invention prior to installation. FIG. 2 shows a cross-section of the semi-rigid polymeric foam G-shaped insulation of the present invention installed on a length of pipe.

EXAMPLE A 300mm length of 25mm diameter galvanized steel pipe was placed in an oven at 240°C and allowed to reach the same temperature as the oven. A 140mm x 140mm x 7mm piece of Zotek NB50 (Zotefoams) polyamide foam, thermal conductivity 0.036 W/m.K at 0°C, was then placed in the same oven at 240°C and allowed to heat up. Once the foam had reached 240°C both the pipe and the foam were removed from the oven and the foam was wound tightly around the steel pipe and held there. The foam and pipe were allowed to cool to room temperature and the pipe was then removed to leave a self-supporting semi-rigid polyamide foam spiral with a G-shaped cross-section.

Claims

CLAIMS 1. An elongate polymeric foam body for insulating a water pipe, wherein in transverse cross-section at least part of the body is in the form of spiral defining a space within the spiral,

wherein the foam forming the spiral has a thermal conductivity of less than 0.15 W/mK at 0°C and is sufficiently flexible to be able to move from a first configuration having a first diameter to a second configuration having a second diameter, the second diameter being greater than the first diameter, and

wherein the spiral is resiliently biased into the first configuration,

and wherein in the first configuration the outermost part of the spiral

circumferentially overlaps an inner part of the spiral and wherein there is a gap between said outermost part and said inner part through which gap said space within the spiral can be accessed,

whereby in use the foam body can be moved from the first configuration to the second configuration to enable a water pipe to be disposed in the space within the spiral, the resilient bias of the spiral causing the body to grip the water pipe.

2. A foam body as claimed in claim 1 comprising a first layer of polymeric foam which has a thermal conductivity of less than 0.15 W/mK at 0°C and one or more additional layers selected from foams, films, foils, textiles and reinforcing material.

3. A foam body as claimed in Claim 1 or 2, wherein the polymeric foam has a thermal conductivity of less than 0.04 W/mK at 0°C.

4. A foam body as claimed in Claim 1 or 2, wherein the polymeric foam has a thermal conductivity of less than 0.15 W/mK at 150°C.

5. A foam body as claimed in Claim 4, wherein the polymeric foam has a thermal conductivity of less than 0.07 W/mK at 150°C.

6. A foam body as claimed in Claim 5, wherein the polymeric foam has a thermal conductivity of less than 0.055 W/mK at 150°C.

7. A foam body as claimed in any preceding claim, wherein the polymer is a thermoplastic.

8. A foam body as claimed in any preceding claim, wherein the polymeric foam has a density of less than 200kg/m³.

9. A foam body as claimed in Claim 8, wherein the polymeric foam has a density of less than 100kg/m³.

10. A foam body as claimed in Claim 9, wherein the polymeric foam has a density of less than 60kg/m³.

11. A foam body as claimed in any preceding claim, wherein the polymeric foam is closed cell.

12. A foam body as claimed in any preceding claim, wherein the polymeric foam is crosslinked.

13. A method for insulating a water pipe comprising the steps of

wherein the spiral is resiliently biased into the first configuration, and wherein in the first configuration the outermost part of the spiral circumferentially overlaps an inner part of the spiral,

wherein the outer diameter of the pipe is such that, when the pipe is located in said space, said outermost part of the spiral does not circumferentially overlap said inner part of the spiral, and wherein the resilient bias of the spiral causes the body to grip the water pipe.

14. The preparation of the multilayer structure according to Claim 2 by heat lamination or adhesive bonding.

15. The transformation of the polymeric foam insulation according to Claim

1 or 2 into a continuous or semi-continuous spiral of any desired length by welding, laminating or adhesive bonding.

16. The use of a foam body as claimed in any of claims 1 to 12 as insulation for rigid or flexible pipes and ducts in industrial process equipment and installations.

17. The use of a foam body as claimed in any of claims 1 to 12 as insulation for rigid or flexible oil and gas pipelines.

18. The use of a foam body as claimed in any of claims 1 to 12 as insulation for rigid or flexible pipes and ducts in buildings.

19. The use of a foam body as claimed in any of claims 1 to 12 as insulation for rigid or flexible pipes and ducts in vehicles.

20. The use of a foam body as claimed in any of claims 1 to 12 to protect sapling or tree trunks or branches from damage.

21. The use of a foam body as claimed in any of claims 1 to 12 as an impact protector for a bar, pipe or section of scaffolding, or on animal stalls, pens or cages, to reduce the risk of impact damage.

22. The use of a foam body as claimed in any of claims 1 to 12 as a grip for canoe or kayak paddles or rowing oar handles.

23. The use of a foam body as claimed in any of claims 1 to 12 as a wrap to provide localized support and impact protection in a medical or veterinary application.

24. The use of a foam body as claimed in any of claims 1 to 12 as a grip for tools or gardening equipment.

25. The use of a foam body as claimed in any of claims 1 to 12 as a beverage can, cup or bottle holder.

26. The use of a foam body as claimed in any of claims 1 to 12 as packaging.

27. The use of a foam body as claimed in any of claims 1 to 12 for cable management.

28. The use of a foam body as claimed in any of claims 1 to 12 as an electrical insulator.

29. A pipe having a foam body as claimed in any of claims 1 to 12 fitted thereon.