WO2021221497A1 - Improved method for applying insulation material - Google Patents

Improved method for applying insulation material Download PDF

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Publication number
WO2021221497A1
WO2021221497A1 PCT/NL2021/050250 NL2021050250W WO2021221497A1 WO 2021221497 A1 WO2021221497 A1 WO 2021221497A1 NL 2021050250 W NL2021050250 W NL 2021050250W WO 2021221497 A1 WO2021221497 A1 WO 2021221497A1
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WO
WIPO (PCT)
Prior art keywords
adhesive
dimensional
sub
insulation material
layer
Prior art date
Application number
PCT/NL2021/050250
Other languages
French (fr)
Other versions
WO2021221497A4 (en
Inventor
Antonius Gerardus Johannes Henricus HEYMANS
Original Assignee
R. Van Den Hanenberg B.V.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from NL2025466A external-priority patent/NL2025466B1/en
Application filed by R. Van Den Hanenberg B.V. filed Critical R. Van Den Hanenberg B.V.
Priority to EP21720593.9A priority Critical patent/EP4143475A1/en
Publication of WO2021221497A1 publication Critical patent/WO2021221497A1/en
Publication of WO2021221497A4 publication Critical patent/WO2021221497A4/en

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16LPIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00Thermal insulation in general
    • F16L59/14Arrangements for the insulation of pipes or pipe systems
    • F16L59/143Pre-insulated pipes
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16LPIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00Thermal insulation in general
    • F16L59/02Shape or form of insulating materials, with or without coverings integral with the insulating materials
    • F16L59/026Mattresses, mats, blankets or the like
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16LPIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00Thermal insulation in general
    • F16L59/02Shape or form of insulating materials, with or without coverings integral with the insulating materials
    • F16L59/028Composition or method of fixing a thermally insulating material
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16LPIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00Thermal insulation in general
    • F16L59/14Arrangements for the insulation of pipes or pipe systems
    • F16L59/16Arrangements specially adapted to local requirements at flanges, junctions, valves or the like
    • F16L59/168Flexible insulating material or covers for flanges, junctions, valves or the like
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16LPIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L59/00Thermal insulation in general
    • F16L59/14Arrangements for the insulation of pipes or pipe systems
    • F16L59/16Arrangements specially adapted to local requirements at flanges, junctions, valves or the like
    • F16L59/22Arrangements specially adapted to local requirements at flanges, junctions, valves or the like adapted for bends

Definitions

  • the present invention is in the field of an improved method for applying insulation materi al thermal insulation on a 3-dimensional structure and specifically thermal isolation of tubes, flanges, and valves.
  • Insulation in air conditioning, cool installations, process installation, and heating installa tion has become more important over the years.
  • thermal insulation relates to a reduction of heat transfer between objects in thermal contact or in range of radiation influence, such as tubing in a maintenance room.
  • Ther mal insulation can be achieved with suitable object shapes and materials.
  • the heat transfer (flow) is considered as an inevitable consequence of contact between objects of differing temperature.
  • a thermal insulation In order to reduce heat flow, and thus maintaining an object substantially at a same temperature, a thermal insulation is provided.
  • the thermal insulation has a reduced thermal conduction or likewise an insulating action.
  • a thermal conductivity (k) is used to quantify insulating properties. Therein a low thermal conductivity value indicates a high insulating capability (R-value).
  • Other important properties of insulating materials are product density (p) and specific heat capacity (c). It is noted that cooling requires much more energy than heating; so maintaining a low tempera ture is in view of energy consumption quite important.
  • Heating and cooling systems are sources of heat. They distribute heat through buildings, typically by means of pipe or ductwork. In order to reduce energy consumption insulating these pipes using pipe insulation in unoccupied rooms is required. It further prevents condensation occurring on cold and chilled pipework. Preventing the formation of condensation on pipework is important as moisture contributes to corrosion.
  • flexible elastomeric foams For (somewhat) complex piping insulation typically flexible elastomeric foams are used. These foams relate to flexible and closed-cell structures. Examples are rubber foams based on NBR or EPDM rubber. Flexible elastomeric foams exhibit such a high resistance to the passage of water vapor that they do not generally require additional water-vapor barriers. Such high va- por resistance, combined with the high surface emissivity of rubber, allows flexible elastomeric foams to prevent surface condensation formation with comparatively small thicknesses.
  • flexible elastomeric foams are widely used on refrigeration and air- conditioning pipework.
  • Flexible elastomeric foams are also used on heating and hot-water sys tems.
  • these flexible foams still have to be applied on the structures.
  • Such includes cut ting and gluing of parts. If long stretched piping is involved, such cutting and gluing is relatively simple.
  • Thermal insulation is typically applied to a 3-D structure by using an adhesive. Despite great care, often the thermal insulation does not adhere sufficiently to the 3D-structure. Also labor conditions at the site of installation are often at least somewhat difficult, e.g. in terms of limited space, availability of tools, environmental conditions, etc.
  • the present invention therefore relates to an improved method for insulating and products obtained thereby, which overcomes one or more of the above disadvantages, without jeopardiz ing functionality and advantages.
  • the present invention relates in a first aspect to an improved method for applying a ther mal insulation on a 3-dimensional structure according to claim 1, comprising providing the thermal insulation material, providing a first layer of adhesive on the thermal insulation material, pre-drying the first layer of adhesive during a pre-drying time, applying the thermal insulation comprising the pre-dried first layer of adhesive on the 3-dimensional structure, and heating the pre-dried first layer of adhesive during a first period of time at a first heating-temperature, in a second aspect to a 3 -dimensional product according to claim 12, and in a third aspect to a com puter program according to claim 13.
  • the present application is a continuation of Dutch national application 2025466 and 2026387.
  • the three dimensional structure comprises at least two indi vidual tube sections and an outward extending connecting section.
  • insulation still largely relates to applying pieces of insulation material by hand.
  • Such is especially the case for large ductworks, having external diameters ranging from 15 mm - 2 m (similar to DN15 to DN2000, such as DN20, DN50, DN80, DN100, DN200, DN250, etc.), typi cally being used for transport of fluids, like hot and cold water, and gases, like nitrogen and air.
  • Modern ductwork may involve multitudes of 100-10.000 meters or more for a building or build ing complex. For understanding in a typical day 2000 m of ductwork may be isolated, whereas such an isolation may continue for months.
  • the ductwork is typically formed from a metal, such as stainless steel, aluminum, or from plastics.
  • the present method makes use of a panel of substantially flat insulation material, such as a foam plate.
  • the material of the foam plate has an inbuilt, water vapor barrier.
  • the plate is preferably effective in preventing moisture ingress and maintaining a long term thermal efficiency.
  • a dust and fiber free material is used.
  • the material does not rapidly deteriorate and keeps moisture as far from the pipe surface as possible, thereby reducing a risk of expensive under insulation corrosion.
  • the material preferably has a closed cell structure, prefer ably interconnected closed cells. As such water ingress is limited. The material may vary some what in characteristics, e.g. when applied to hot or cold pipe work.
  • the present flat insulation material has a thickness of 0.5 cm-5 cm, such as 1.0 cm, 1.3 cm, 1.6 cm, 1.9 cm, 2.5 cm, 3.2 cm and 5.0 cm.
  • the insulation material may have an adhesive layer.
  • the thickness of the material is selected in view of insulation properties and temperature gradi ent between liquid (gas/fluid) in e.g. ductwork and outside temperature.
  • one or more 2-dimensional elements from the flat insulation material are formed, typically by hand.
  • such an element is referred to as a two-dimensional element as the element forming substantially has a two dimensional shape or form, such as a square or rectangular form, circle section ellipsoid section, a shape according to figures 1 or 2, etc.
  • the element clearly has the thickness of the insulation material and in that sense it is a three-dimensional element.
  • the one or more 2-dimensional elements together are intended to form a closed structure around the pipe work, or part thereof. As such the elements need to fit perfectly with respect to one and another. It is noted that often, despite standardized measures of pipe work, most of the work is done on location, that is where the pipe work is pre sent.
  • the one or more 2-dimensional elements are applied on the 3 -dimensional structure.
  • the one or more 2-dimensional elements are typically fixed by applying an adhesive.
  • the method of insulation is characterized e.g. in that in the forming step is motor assisted, preferably an electrical motor, whereas prior art methods typically rely on cutting by hand. In particular burrs are prevented, a perfect fit between parts is achieved, friction or torque are virtu ally absent, especially in non-straight parts, and appearance is as if the 3-dimensional element is one.
  • the motor assisted forming provides many advantages over the prior art and solves the problems mentioned. Further the amount of work per unit time increases significantly, especially for complex structures, by 10-20%, on top of an improved performance. It has also been found that an amount of waste is reduced, by some 5-20%, depending on a type of structure formed.
  • the present method can be applied with easy, without a need for large investment, at any loca- tion, without a need of a complex, big and expensive apparatus.
  • the motor may provide reciprocating motion to a cutting element. It has been found that controlled movement of a cutting element, especially in a reciprocating manner, provides cutting faces with hardly any or no burrs, having a required angle, that can be applied with ease onto 3- dimensional structures.
  • the present method comprises providing a first layer of adhesive on the thermal insulation material, wherein the first layer may be applied partially on the surface of the insulation material, or fully, typically depending on the joints to be formed, as well as on the size of sub-elements of the 3D-structure, pre-drying the first layer of adhesive during a time at a pre-drying-temperature, typically at ambient conditions, such as for at least one hour, preferably for at least 4 hours, more preferably for at least 12 hours, and typi cally at least 36 hours, at ambient workshop temperature, and applying the thermal insulation on the 3 -dimensional structure.
  • a pre-drying-temperature typically at ambient conditions, such as for at least one hour, preferably for at least 4 hours, more preferably for at least 12 hours, and typi cally at least 36 hours, at ambient workshop temperature
  • the adhesive After pre-drying the adhesive has lost most or all of its initial tacki ness, and can therefore be applied without the thermal insulation material being adhered to the 3D structure. It is noted that some insulation materials may be provided already with adhesive, and a thin layer of paper or plastic or the like to protect the adhesive before being used, but these adhesive often do not adhere properly, or not fully, or let go over time. Surprisingly, by pre drying the present adhesive, and thereafter heating the adhesive the adhesive strength is in creased significantly and none of the above problems occur. In addition also slits, at joints where two sides of the insulation material come together, are absent. Such does not only improve ther mal insulation, but also prevents water/moisture from entering, 3-D structure from being deterio rated, and further provides aesthetically very pleasant insulations.
  • the present invention relates to a computer program comprising instruc tions loaded on at least one computer for carrying out the following steps: for a 3-D structure comprising a plurality of sub-elements, such as from the group of straight sections, bends, cou plings, T-junctions, butterfly valves, pipe-couplings, passages through walls and floors, bifurca tions, sensors, controllers, closures, vents, locking wheels, supports, suspensions, flanges and branches, selecting each sub-element individually, as well as the type of said sub-element, select ing at least one preformed 2-dimensional element for each identified sub-element to be insulated, and optionally preparing and/or ordering the at least one preformed 2-dimensional element for each identified sub-element to be insulated, such as by providing instructions to a preparation machine, and/or labelling the at least one preformed 2-dimensional element.
  • a 3-D structure comprising a plurality of sub-elements, such as from the group of straight sections, bends,
  • the present invention relates in a first aspect to an improved method for applying a ther- mal insulation on a 3-dimensional structure according to claim 1.
  • the 3-dimensional structure typically relates to elements of ductwork and piping, such as pipe-couplings, passages through walls and floors, bends, bifurcations, sensors, T-junctions, controllers, closures, vents, locking wheels, supports, suspensions, (butterfly jvalves, flanges and branches.
  • the outward extending connecting section may also relate to a sensor, a controller, a closure, etc.; the term indicates such extensions in general.
  • the present method may comprise providing a second layer of adhesive on the 3 -dimensional structure, and drying the second layer of adhesive during a second period of time at a second drying-temperature.
  • the second layer may be a one- component adhesive as well.
  • the second layer may improve adhering.
  • the second lay er is not required, and a first layer only is found to e sufficient for good adhering.
  • the first period of time may be ⁇ 60 seconds, such as 5-30 seconds, i.e. the adhesive heats and dries relative quickly and provides extra adherence.
  • the first heating-temperature may be ⁇ 120°C (393 K), such as 30-60°C (303-333 K).
  • the drying temperature is preferably not too high, in view of the insulation material, and is preferably high enough to establish drying. Slightly elevated temperatures suffice.
  • the second period of time may be at least one hour, preferably for at least 4 hours, more preferably for at least 12 hours, and typically at least 36 hours.
  • the second drying-temperature may be ⁇ 120°C (393 K), such as 30-60°C (303-333 K), and typically is at ambient conditions.
  • heating may be under application of a heated air flow, such as using a blow dryer. Heating can simply be established by using a con ventional blow dryer.
  • heating may be under application of induction.
  • An advantage thereof is that the insulation material itself does not heat up. In addition no vapor, such as emitted is released from the adhesive.
  • heating may be under application of microwaves.
  • Heating may be applied with an apparatus providing a power of 25-250 kW, typically ap plied over a surface area of 10-100 cm 2 . If microwave or induction is used suitable frequencies are 40 kHz-1 MHz, such as 100-300 kHz.
  • the present method may comprise drying the applied thermal insulation during a period of > 10 minutes, such as > 30 minutes, e.g. > 60 minutes. Drying of the adhesive typically consumes some time.
  • providing a first layer of adhesive and pre-drying the first layer of adhesive may be done at a first location, and wherein applying the thermal insulation on the 3 -dimensional structure may be done at a second location.
  • the present method provides the opportunity to prepare for application of an insulation material at a location different to where the insulation material is applied, such as at a workshop or workplace. At such a workshop conditions are typically much more optimal in view of preparation, such as space, ventilation, temperature, humidity, and so on. Also for forming the substantially 2D-structures equipment is typically available, and well accessible. A worker may for instance prepare a large number of insulation pieces, such as 20-50 pieces, then move to the location of application, and apply the pieces. The process-time is thereby reduced by 20-40%, whereas also the quality is improved, e.g. in terms of adhesive strength (being virtually impossible to remove the insulation material), preciseness, joints, appearance, etc..
  • the three dimensional structure may comprise at least two individual tube sections and an outward extending connecting section.
  • the present method is therewith versatile.
  • the thermal insulation may have a thickness of 0.5 cm-5 cm.
  • the thermal insulation may comprise a substantially flat panel.
  • the present method may comprise forming one or more sub stantially 2-dimensional elements from the flat insulation material, wherein forming is assisted by a motor that provides reciprocating motion to a cutting element.
  • the forming may be performed at a constant angle with respect to the 2-dimensional element, wherein the angle is preferably select ed from 85-95° (perpendicular), 40-50°, 25-35° and 55-65°.
  • a mold may be used to form the one or more substantially 2-dimensional elements.
  • the substantially 2-dimensional ele ments may comprise a first cylindrical like element having a first inner radius, at least one sub stantially flat element, wherein the first cylindrical like element and the at least one substantially flat element are connected at an angle of about 90°.
  • the flat insulation material may be rotated during forming.
  • the insulation material may be a foam.
  • the insulation material may have an inbuilt, water vapor barrier.
  • the insulation material may be a dust and fiber free material.
  • the insulation material may have a closed cell structure, preferably interconnected closed cells.
  • the 3 -dimensional structure may com prise at least one element with a radius of > 100mm, such as > 200 mm.
  • the present method may comprise at a first location, in the 3-D structure identifying a plurality of sub-elements, such as from the group of straight sections, bends, couplings, T-junctions, butterfly valves, pipe-couplings, pas sages through walls and floors, bifurcations, sensors, controllers, closures, vents, locking wheels, supports, suspensions, flanges and branches, for each sub-element individually, identifying the type of sub-element, selecting at least one preformed 2-dimensional element for each identified sub-element to be insulated, and insulating at least one sub-element of the plurality of sub elements, and optionally preparing and/or ordering the at least one preformed 2-dimensional el ement for each identified sub-element to be insulated, preferably at a second location.
  • a plurality of sub-elements such as from the group of straight sections, bends, couplings, T-junctions, butterfly valves, pipe-couplings, pas sages through walls and floors,
  • the present use is for one or more of maintaining a relatively low tempera ture, maintaining a relatively high temperature, such as inside a tubing structure, providing fire safety, limiting corrosion, noise insulation, preventing mold growth, and preventing microbial growth.
  • Fig. la-p show steps in the insulation of a complex 3D structure.
  • Fig. la-p show steps in the insulation of a complex 3D structure.
  • Fig. la shows the to be insulated structure.
  • Fig. lb shows a mold, for e.g. figs le-lf.
  • Fig. lc shows to be folded materi al, fig. Id a cap, fig. le-lf material to be provided on an end of a tube or section with increasing or decreasing diameter, fig. lg shows part of a cap structure, and fig. lh of an partly open struc ture.
  • the insulation material is partly provided with adhesive (white colour).
  • Fig. li shows a partly insulated structure, and fig. lj a subsequent step of insulation.
  • Ik shows a side which is cut under an angle of 45 degrees
  • figs. 11-lm shows cut-out parts.
  • Fig. In shows adhesive material on insulation material may be temporarily covered with paper.
  • Figs lo-lp show a fully insulated structure, wherein insulation material fits perfectly together, leaving no openings or the like, and having no remaining parts or fractions at the joints.
  • plates of Armaflex are used as insulation material.
  • the insulation is made of Armaflex®, such as 13 or 19 mm thick Armaflex®.
  • the Armaflex is cut into the right dimensions, such as by using the exemplary embodiments above.
  • the Armaflex are ready to be applied onto the 3D-objects to be isolated at the location thereof, in terms of structure.
  • a IK adhesive such as Armaflex 520, is applied to one side of the insulation ma terial.
  • the prepared insulation material is now left to dry for at least one hour, preferably for at least 4 hours, more preferably for at least 12 hours, and typically at least 36 hours.
  • the adhesive is then dry, and does not provide much adhesive strength anymore; this can be established easily by applying a piece of paper or the like, and removing said piece of paper; this can be done without much force.
  • an removable protection foil may be provid ed, such as a plastic foil, or paper, but typically there is not much need to do so. This process can be repeated as often is deemed required, such as 10-1000 times, such that all preparations for insulation at the location of the 3D-objects are done.
  • the prepared Armaflex is the transferred to the location of insulation. There the prepared Armaflex is applied to the 3D-object to be insulated.
  • a simple heater such as a hair dryer, is used to heat the adhesive, to a temperature of 40-60 °C, during a period of time of typically less than 60 sec, such as less than 30 sec, before applying the Armaflex.
  • an insulation material that can withstands temperature of up to 100 °C, prefera bly up to 120 °C, such as the Armaflex used.
  • a HU serie inductive heater of RF Heating Consult is used. The inductive heater is steadily moved over the Armaflex, typically with a slow forward and backward movement, as well as over joints and the like.
  • the adhesive strength is so high, that it is virtually impossible to remove the applied insulation, at least not by human force/body weight.
  • a much better quality of insulation is achieved, such as more constant, independent of the person applying the insulation material, in a shorter period of (overall) time, and with virtually no gaps/fissures, providing a fluid-tight insulation over the surface of the 3D-object and aesthetic appearance.
  • the present method is especially suited for more complex 3D-objects and/or with a larger diameter, such as couplings.

Abstract

The present invention is in the field of thermal insulation and specifically thermal isolation of tubes, flanges, and valve. Insulation in air conditioning, cool installations, process installation, and heating installation has become more important over the years. In this respect, thermal insulation relates to a reduction of heat transfer between objects in thermal contact or in range of radiation influence, such as tubing in a maintenance room. Thermal insulation can be achieved with suitable object shapes and materials. The present invention provides an improved method of insulation and an improved insulation.

Description

Improved method for applying insulation material
FIELD OF THE INVENTION
The present invention is in the field of an improved method for applying insulation materi al thermal insulation on a 3-dimensional structure and specifically thermal isolation of tubes, flanges, and valves.
BACKGROUND OF THE INVENTION
Insulation in air conditioning, cool installations, process installation, and heating installa tion has become more important over the years.
In this respect, thermal insulation relates to a reduction of heat transfer between objects in thermal contact or in range of radiation influence, such as tubing in a maintenance room. Ther mal insulation can be achieved with suitable object shapes and materials. The heat transfer (flow) is considered as an inevitable consequence of contact between objects of differing temperature.
In order to reduce heat flow, and thus maintaining an object substantially at a same temperature, a thermal insulation is provided. The thermal insulation has a reduced thermal conduction or likewise an insulating action. A thermal conductivity (k) is used to quantify insulating properties. Therein a low thermal conductivity value indicates a high insulating capability (R-value). Other important properties of insulating materials are product density (p) and specific heat capacity (c). It is noted that cooling requires much more energy than heating; so maintaining a low tempera ture is in view of energy consumption quite important.
Heating and cooling systems are sources of heat. They distribute heat through buildings, typically by means of pipe or ductwork. In order to reduce energy consumption insulating these pipes using pipe insulation in unoccupied rooms is required. It further prevents condensation occurring on cold and chilled pipework. Preventing the formation of condensation on pipework is important as moisture contributes to corrosion.
Likewise chemicals, water, air, electrical cables, can run through pipe work.
An example of a document relating to isolation is US 2007/0131300 which recites a pipe insulating fitting cover for insulating a pipe joint, the cover having a first insulating cover for insulating the body of the pipe joint and a second insulating cover for enclosing and insulating the bonnet of the pipe joint. The application recites use of an abrasion apparatus. As a result thereof parts of said cover are abraded to obtain a specific shape. Such abrasion requires a rigid insulation material and a substantial chance of burr formation at the edge of abraded regions. In addition no good insulation is obtained at the edges. It is noted that a curvature of the abrasion apparatus limits the application to specific pipe diameters. Shaping an insulation cover using an abrasive would result in burr formation and an uneven sealing of both the insulation cover itself and the to-be-covered material. The covers used are curved.
For (somewhat) complex piping insulation typically flexible elastomeric foams are used. These foams relate to flexible and closed-cell structures. Examples are rubber foams based on NBR or EPDM rubber. Flexible elastomeric foams exhibit such a high resistance to the passage of water vapor that they do not generally require additional water-vapor barriers. Such high va- por resistance, combined with the high surface emissivity of rubber, allows flexible elastomeric foams to prevent surface condensation formation with comparatively small thicknesses.
As a result, flexible elastomeric foams are widely used on refrigeration and air- conditioning pipework. Flexible elastomeric foams are also used on heating and hot-water sys tems. However these flexible foams still have to be applied on the structures. Such includes cut ting and gluing of parts. If long stretched piping is involved, such cutting and gluing is relatively simple. For complex structures, such as bends, couplings, flanges, T-junctions, and butterfly valves, craftsmanship is required. It is especially relevant that insulation pieces and parts fit well together in order to prevent condensation, mold growth, microbial growth and corrosion. For durability, fire safety, noise reduction and appearance it is important that no burrs are present. Cutting should be performed with relatively high precision and without forming burrs.
Complex structures, such as pipe-couplings, passages through walls and floors, bends, bi furcations, sensors, T-junctions, controllers, closures, vents, locking wheels, supports, suspen sions, (butterfly)valves, flanges and branches, are especially difficult to insulate.
In order to reduce noise and to improve fire safety similar considerations as above apply.
Thermal insulation is typically applied to a 3-D structure by using an adhesive. Despite great care, often the thermal insulation does not adhere sufficiently to the 3D-structure. Also labor conditions at the site of installation are often at least somewhat difficult, e.g. in terms of limited space, availability of tools, environmental conditions, etc.
Some documents refer to methods of applying thermal insulation. For instance US 5,421,371 A, US 4,660,861 A, US 3,117,902 A, US 6,530,603 Bl, US 2,890,739 A, US 2010/330316 Al, the applicants EP 3 262 332 Al, and US 2007/131300 A1 recite such methods.
The present invention therefore relates to an improved method for insulating and products obtained thereby, which overcomes one or more of the above disadvantages, without jeopardiz ing functionality and advantages.
SUMMARY OF THE INVENTION
The present invention relates in a first aspect to an improved method for applying a ther mal insulation on a 3-dimensional structure according to claim 1, comprising providing the thermal insulation material, providing a first layer of adhesive on the thermal insulation material, pre-drying the first layer of adhesive during a pre-drying time, applying the thermal insulation comprising the pre-dried first layer of adhesive on the 3-dimensional structure, and heating the pre-dried first layer of adhesive during a first period of time at a first heating-temperature, in a second aspect to a 3 -dimensional product according to claim 12, and in a third aspect to a com puter program according to claim 13. The present application is a continuation of Dutch national application 2025466 and 2026387. The three dimensional structure comprises at least two indi vidual tube sections and an outward extending connecting section.
Despite that many tasks in nowadays society may be highly automated or machine sup ported, insulation still largely relates to applying pieces of insulation material by hand. Such is especially the case for large ductworks, having external diameters ranging from 15 mm - 2 m (similar to DN15 to DN2000, such as DN20, DN50, DN80, DN100, DN200, DN250, etc.), typi cally being used for transport of fluids, like hot and cold water, and gases, like nitrogen and air. Modern ductwork may involve multitudes of 100-10.000 meters or more for a building or build ing complex. For understanding in a typical day 2000 m of ductwork may be isolated, whereas such an isolation may continue for months. The ductwork is typically formed from a metal, such as stainless steel, aluminum, or from plastics.
The present method makes use of a panel of substantially flat insulation material, such as a foam plate. Preferably the material of the foam plate has an inbuilt, water vapor barrier. The plate is preferably effective in preventing moisture ingress and maintaining a long term thermal efficiency. Preferably a dust and fiber free material is used. Also the material does not rapidly deteriorate and keeps moisture as far from the pipe surface as possible, thereby reducing a risk of expensive under insulation corrosion. The material preferably has a closed cell structure, prefer ably interconnected closed cells. As such water ingress is limited. The material may vary some what in characteristics, e.g. when applied to hot or cold pipe work.
The present flat insulation material has a thickness of 0.5 cm-5 cm, such as 1.0 cm, 1.3 cm, 1.6 cm, 1.9 cm, 2.5 cm, 3.2 cm and 5.0 cm. The insulation material may have an adhesive layer. The thickness of the material is selected in view of insulation properties and temperature gradi ent between liquid (gas/fluid) in e.g. ductwork and outside temperature.
In a next step one or more 2-dimensional elements from the flat insulation material are formed, typically by hand. In the context of the present invention such an element is referred to as a two-dimensional element as the element forming substantially has a two dimensional shape or form, such as a square or rectangular form, circle section ellipsoid section, a shape according to figures 1 or 2, etc. The element clearly has the thickness of the insulation material and in that sense it is a three-dimensional element. The one or more 2-dimensional elements together are intended to form a closed structure around the pipe work, or part thereof. As such the elements need to fit perfectly with respect to one and another. It is noted that often, despite standardized measures of pipe work, most of the work is done on location, that is where the pipe work is pre sent.
In a next step the one or more 2-dimensional elements are applied on the 3 -dimensional structure. The one or more 2-dimensional elements are typically fixed by applying an adhesive.
The method of insulation is characterized e.g. in that in the forming step is motor assisted, preferably an electrical motor, whereas prior art methods typically rely on cutting by hand. In particular burrs are prevented, a perfect fit between parts is achieved, friction or torque are virtu ally absent, especially in non-straight parts, and appearance is as if the 3-dimensional element is one. The motor assisted forming provides many advantages over the prior art and solves the problems mentioned. Further the amount of work per unit time increases significantly, especially for complex structures, by 10-20%, on top of an improved performance. It has also been found that an amount of waste is reduced, by some 5-20%, depending on a type of structure formed.
The present method can be applied with easy, without a need for large investment, at any loca- tion, without a need of a complex, big and expensive apparatus.
The motor may provide reciprocating motion to a cutting element. It has been found that controlled movement of a cutting element, especially in a reciprocating manner, provides cutting faces with hardly any or no burrs, having a required angle, that can be applied with ease onto 3- dimensional structures.
Details of the above method may be found in European Patent Application EP 16 722 400.5, of the same applicant, which document and its contents are incorporated by reference.
In addition to the above, or as an alternative, the present method comprises providing a first layer of adhesive on the thermal insulation material, wherein the first layer may be applied partially on the surface of the insulation material, or fully, typically depending on the joints to be formed, as well as on the size of sub-elements of the 3D-structure, pre-drying the first layer of adhesive during a time at a pre-drying-temperature, typically at ambient conditions, such as for at least one hour, preferably for at least 4 hours, more preferably for at least 12 hours, and typi cally at least 36 hours, at ambient workshop temperature, and applying the thermal insulation on the 3 -dimensional structure. After pre-drying the adhesive has lost most or all of its initial tacki ness, and can therefore be applied without the thermal insulation material being adhered to the 3D structure. It is noted that some insulation materials may be provided already with adhesive, and a thin layer of paper or plastic or the like to protect the adhesive before being used, but these adhesive often do not adhere properly, or not fully, or let go over time. Surprisingly, by pre drying the present adhesive, and thereafter heating the adhesive the adhesive strength is in creased significantly and none of the above problems occur. In addition also slits, at joints where two sides of the insulation material come together, are absent. Such does not only improve ther mal insulation, but also prevents water/moisture from entering, 3-D structure from being deterio rated, and further provides aesthetically very pleasant insulations.
In a further aspect the present invention relates to a computer program comprising instruc tions loaded on at least one computer for carrying out the following steps: for a 3-D structure comprising a plurality of sub-elements, such as from the group of straight sections, bends, cou plings, T-junctions, butterfly valves, pipe-couplings, passages through walls and floors, bifurca tions, sensors, controllers, closures, vents, locking wheels, supports, suspensions, flanges and branches, selecting each sub-element individually, as well as the type of said sub-element, select ing at least one preformed 2-dimensional element for each identified sub-element to be insulated, and optionally preparing and/or ordering the at least one preformed 2-dimensional element for each identified sub-element to be insulated, such as by providing instructions to a preparation machine, and/or labelling the at least one preformed 2-dimensional element.
Thereby the present invention provides a solution to one or more of the above mentioned problems and drawbacks, without jeopardizing beneficial effects. Advantages of the present de scription are detailed throughout the description.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates in a first aspect to an improved method for applying a ther- mal insulation on a 3-dimensional structure according to claim 1. The 3-dimensional structure typically relates to elements of ductwork and piping, such as pipe-couplings, passages through walls and floors, bends, bifurcations, sensors, T-junctions, controllers, closures, vents, locking wheels, supports, suspensions, (butterfly jvalves, flanges and branches. The outward extending connecting section may also relate to a sensor, a controller, a closure, etc.; the term indicates such extensions in general.
In an exemplary embodiment the present method may comprise providing a second layer of adhesive on the 3 -dimensional structure, and drying the second layer of adhesive during a second period of time at a second drying-temperature. The second layer may be a one- component adhesive as well. The second layer may improve adhering. Generally the second lay er is not required, and a first layer only is found to e sufficient for good adhering. However when a size or diameter of the 3-dimensiaonl structure becomes larger, such as larger than a diameter of 100 mm, it is preferred to also apply the second layer of adhesive.
In an exemplary embodiment of the present method the first period of time may be < 60 seconds, such as 5-30 seconds, i.e. the adhesive heats and dries relative quickly and provides extra adherence.
In an exemplary embodiment of the present method the first heating-temperature may be < 120°C (393 K), such as 30-60°C (303-333 K). The drying temperature is preferably not too high, in view of the insulation material, and is preferably high enough to establish drying. Slightly elevated temperatures suffice.
In an exemplary embodiment of the present method the second period of time may be at least one hour, preferably for at least 4 hours, more preferably for at least 12 hours, and typically at least 36 hours.
In an exemplary embodiment of the present method the second drying-temperature may be < 120°C (393 K), such as 30-60°C (303-333 K), and typically is at ambient conditions.
In an exemplary embodiment of the present method heating may be under application of a heated air flow, such as using a blow dryer. Heating can simply be established by using a con ventional blow dryer.
In an exemplary embodiment of the present method heating may be under application of induction. An advantage thereof is that the insulation material itself does not heat up. In addition no vapor, such as emitted is released from the adhesive.
In an exemplary embodiment of the present method heating may be under application of microwaves.
Heating may be applied with an apparatus providing a power of 25-250 kW, typically ap plied over a surface area of 10-100 cm2. If microwave or induction is used suitable frequencies are 40 kHz-1 MHz, such as 100-300 kHz.
Typically all forms of heating do not damage the insulation material.
In an exemplary embodiment the present method may comprise drying the applied thermal insulation during a period of > 10 minutes, such as > 30 minutes, e.g. > 60 minutes. Drying of the adhesive typically consumes some time.
In an exemplary embodiment of the present method providing a first layer of adhesive and pre-drying the first layer of adhesive may be done at a first location, and wherein applying the thermal insulation on the 3 -dimensional structure may be done at a second location. The present method provides the opportunity to prepare for application of an insulation material at a location different to where the insulation material is applied, such as at a workshop or workplace. At such a workshop conditions are typically much more optimal in view of preparation, such as space, ventilation, temperature, humidity, and so on. Also for forming the substantially 2D-structures equipment is typically available, and well accessible. A worker may for instance prepare a large number of insulation pieces, such as 20-50 pieces, then move to the location of application, and apply the pieces. The process-time is thereby reduced by 20-40%, whereas also the quality is improved, e.g. in terms of adhesive strength (being virtually impossible to remove the insulation material), preciseness, joints, appearance, etc..
In an exemplary embodiment of the present method the three dimensional structure may comprise at least two individual tube sections and an outward extending connecting section. The present method is therewith versatile.
In an exemplary embodiment of the present method the thermal insulation may have a thickness of 0.5 cm-5 cm.
In an exemplary embodiment of the present method the thermal insulation may comprise a substantially flat panel.
In an exemplary embodiment the present method may comprise forming one or more sub stantially 2-dimensional elements from the flat insulation material, wherein forming is assisted by a motor that provides reciprocating motion to a cutting element.
In an exemplary embodiment of the present method the forming may be performed at a constant angle with respect to the 2-dimensional element, wherein the angle is preferably select ed from 85-95° (perpendicular), 40-50°, 25-35° and 55-65°.
In an exemplary embodiment of the present method a mold may be used to form the one or more substantially 2-dimensional elements.
In an exemplary embodiment of the present method the substantially 2-dimensional ele ments may comprise a first cylindrical like element having a first inner radius, at least one sub stantially flat element, wherein the first cylindrical like element and the at least one substantially flat element are connected at an angle of about 90°.
In an exemplary embodiment of the present method the flat insulation material may be rotated during forming.
In an exemplary embodiment of the present method the insulation material may be a foam.
In an exemplary embodiment of the present method the insulation material may have an inbuilt, water vapor barrier.
In an exemplary embodiment of the present method the insulation material may be a dust and fiber free material. In an exemplary embodiment of the present method the insulation material may have a closed cell structure, preferably interconnected closed cells.
In an exemplary embodiment of the present method the 3 -dimensional structure may com prise at least one element with a radius of > 100mm, such as > 200 mm.
In an exemplary embodiment the present method may comprise at a first location, in the 3-D structure identifying a plurality of sub-elements, such as from the group of straight sections, bends, couplings, T-junctions, butterfly valves, pipe-couplings, pas sages through walls and floors, bifurcations, sensors, controllers, closures, vents, locking wheels, supports, suspensions, flanges and branches, for each sub-element individually, identifying the type of sub-element, selecting at least one preformed 2-dimensional element for each identified sub-element to be insulated, and insulating at least one sub-element of the plurality of sub elements, and optionally preparing and/or ordering the at least one preformed 2-dimensional el ement for each identified sub-element to be insulated, preferably at a second location.
In an example the present use is for one or more of maintaining a relatively low tempera ture, maintaining a relatively high temperature, such as inside a tubing structure, providing fire safety, limiting corrosion, noise insulation, preventing mold growth, and preventing microbial growth.
The invention is further detailed by the accompanying example and figures, which are ex emplary and explanatory of nature and are not limiting the scope of the invention. To the person skilled in the art it may be clear that many variants, being obvious or not, may be conceivable falling within the scope of protection, defined by the present claims.
SUMMARY OF THE FIGURES
Fig. la-p show steps in the insulation of a complex 3D structure.
DETAILED DESCRIPTION OF THE FIGURES
Fig. la-p show steps in the insulation of a complex 3D structure. Fig. la shows the to be insulated structure. Fig. lb shows a mold, for e.g. figs le-lf. Fig. lc shows to be folded materi al, fig. Id a cap, fig. le-lf material to be provided on an end of a tube or section with increasing or decreasing diameter, fig. lg shows part of a cap structure, and fig. lh of an partly open struc ture. The insulation material is partly provided with adhesive (white colour). Fig. li shows a partly insulated structure, and fig. lj a subsequent step of insulation. Fig. Ik shows a side which is cut under an angle of 45 degrees, and figs. 11-lm shows cut-out parts. Fig. In shows adhesive material on insulation material may be temporarily covered with paper. Figs lo-lp show a fully insulated structure, wherein insulation material fits perfectly together, leaving no openings or the like, and having no remaining parts or fractions at the joints.
Example
In an example plates of Armaflex are used as insulation material. Preferably the insulation is made of Armaflex®, such as 13 or 19 mm thick Armaflex®. In the workshop, that is off-site of a location of application, typically at the home office of the applicant, the Armaflex is cut into the right dimensions, such as by using the exemplary embodiments above. As such the Armaflex are ready to be applied onto the 3D-objects to be isolated at the location thereof, in terms of structure. Then a IK adhesive, such as Armaflex 520, is applied to one side of the insulation ma terial. The prepared insulation material is now left to dry for at least one hour, preferably for at least 4 hours, more preferably for at least 12 hours, and typically at least 36 hours. The adhesive is then dry, and does not provide much adhesive strength anymore; this can be established easily by applying a piece of paper or the like, and removing said piece of paper; this can be done without much force. For protection of the adhesive an removable protection foil may be provid ed, such as a plastic foil, or paper, but typically there is not much need to do so. This process can be repeated as often is deemed required, such as 10-1000 times, such that all preparations for insulation at the location of the 3D-objects are done.
The prepared Armaflex is the transferred to the location of insulation. There the prepared Armaflex is applied to the 3D-object to be insulated. A simple heater, such as a hair dryer, is used to heat the adhesive, to a temperature of 40-60 °C, during a period of time of typically less than 60 sec, such as less than 30 sec, before applying the Armaflex. In view of the heating it is preferred to use an insulation material that can withstands temperature of up to 100 °C, prefera bly up to 120 °C, such as the Armaflex used. In an alternative a HU serie inductive heater of RF Heating Consult is used. The inductive heater is steadily moved over the Armaflex, typically with a slow forward and backward movement, as well as over joints and the like. The advantage is amongst others that no vapour is released from the adhesive. In both cases an extremely good adhesion is obtained; the Armaflex can not be removed with human force/human weight any more. Also the insulation is complete and tight and good joints are obtained, without abrading.
After applying the Armaflex insulation material it is found that the adhesive strength is so high, that it is virtually impossible to remove the applied insulation, at least not by human force/body weight. In addition it is found that by preparing the insulation material at the work shop a much better quality of insulation is achieved, such as more constant, independent of the person applying the insulation material, in a shorter period of (overall) time, and with virtually no gaps/fissures, providing a fluid-tight insulation over the surface of the 3D-object and aesthetic appearance. The present method is especially suited for more complex 3D-objects and/or with a larger diameter, such as couplings.

Claims

1. Method for applying a thermal insulation on a 3-dimensional structure, comprising providing the thermal insulation material, providing a first layer of adhesive on the thermal insulation material, characterized in pre-drying the first layer of adhesive during a pre-drying time, applying the thermal insulation comprising the pre-dried first layer of adhesive with the pre-dried first layer on the 3 -dimensional structure, and optionally heating the pre-dried first layer of adhesive during a first period of time at a first heating-temperature.
2. Method according to claim 1, comprising providing a second layer of adhesive on the 3- dimensional structure, and drying the second layer of adhesive during a second period of time at a second drying- temperature.
3. Method according to any of claims 1-2, wherein the first period of time is < 60 seconds, such as 5-30 seconds, and/or wherein the first heating-temperature is < 120°C (393 K), such as 30-60°C (303-333 K), and/or wherein the second period of time is at least one hour, preferably for at least 4 hours, more preferably for at least 12 hours, and typically at least 36 hours,, and/or wherein the second drying-temperature is < 120°C (393 K), such as 30-60°C (303-333 K), and/or wherein heating is under application of a heated air flow, such as by using a blow dryer, and/or wherein heating is under application of induction, and/or wherein heating is under application of microwaves.
4. Method according to any of claims 1-3, comprising drying the applied thermal insulation during a period of > 10 minutes, such as > 30 minutes, e.g. > 60 minutes.
5. Method according to any of claims 1-4, wherein providing the first layer of adhesive and pre-drying the first layer of adhesive is done at a first location, and wherein applying the thermal insulation on the 3 -dimensional structure is done on a second location.
6. Method according to any of claims 1-5, wherein the three dimensional structure com prises at least two individual tube sections and an outward extending connecting section, and/or wherein the thermal insulation has a thickness of 0.5 cm-5 cm, and/or wherein the thermal insulation comprises a substantially flat panel, and/or further comprising forming one or more substantially 2-dimensional elements from the flat insulation material, preferably wherein forming is assisted by a motor that provides reciprocating motion to a cutting element.
7. Method according to claim 6, wherein the forming is performed at a constant angle with respect to the 2-dimensional element, wherein the angle is preferably selected from 85-95° (per pendicular), 40-50°, 25-35° and 55-65°, and/or wherein a mold is used to form the one or more substantially 2-dimensional elements.
8. Method according to any of claims 6-7, wherein the substantially 2-dimensional ele ments comprise a first cylindrical like element having a first inner radius, at least one substantial ly flat element, wherein the first cylindrical like element and the at least one substantially flat element are connected at an angle of about 90°, and/or wherein the flat insulation material is rotated during forming, and/or wherein the insulation material is a foam, and/or wherein the insulation material has an inbuilt, water vapor barrier, and/or wherein the insulation material is a dust and fiber free material, and/or wherein the insulation material has a closed cell structure, preferably interconnected closed cells.
9. Method according to any of claims 1-8, wherein the 3-dimensional structure comprises at least one element with a radius of > 100mm, such as > 200 mm.
10. Method according to any of claims 1-9, wherein the adhesive is a one- or two- component adhesive, such as an aqueous or solvent-based adhesive, such as comprising one or more of a polychloroprene dispersion, a polyurethane dispersion, a natural rubber dispersion, a styrene-butadiene-styrene copolymer dispersion, a nitrile-butadiene rubber dispersion, a polyvi nyl butyral dispersion, a styrene-butadiene rubber dispersion, and combinations thereof, the dis persion comprising 30-80 wt.% solids.
11. Method according to any of claims 1-10, comprising at a first location, in the 3-D structure identifying a plurality of sub-elements, such as from the group of straight sections, bends, couplings, T-junctions, butterfly valves, pipe-couplings, passages through walls and floors, bifurcations, sensors, controllers, closures, vents, locking wheels, supports, suspensions, flanges and branches, for each sub-element individually, identifying the type of sub-element, selecting at least one preformed 2-dimensional element for each identified sub-element to be insulated, and insulating at least one sub-element of the plurality of sub-elements, and optionally preparing and/or ordering the at least one preformed 2-dimensional element for each iden tified sub-element to be insulated, preferably at a second location.
12. Insulated 3D-structure obtained by a method according to any of claims 1-11.
13. Computer program comprising instructions loaded on at least one computer for carry ing out the following steps: for a 3-D structure comprising a plurality of sub-elements, such as from the group of straight sections, bends, couplings, T-junctions, butterfly valves, pipe-couplings, passages through walls and floors, bifurcations, sensors, controllers, closures, vents, locking wheels, sup- ports, suspensions, flanges and branches, selecting each sub-element individually, as well as the type of said sub-element, selecting at least one preformed 2-dimensional element for each identified sub-element to be insulated, and optionally preparing and/or ordering the at least one preformed 2-dimensional element for each iden tified sub-element to be insulated, such as by providing instructions to a preparation machine, and/or labelling the at least one preformed 2-dimensional element.
PCT/NL2021/050250 2020-04-30 2021-04-19 Improved method for applying insulation material WO2021221497A1 (en)

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Citations (8)

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US3117902A (en) 1958-10-20 1964-01-14 Fastab Insulations Inc Insulating coverings for enclosures
US4660861A (en) 1983-12-28 1987-04-28 Hutchinson S.A. Heat insulating means for piping subjected to thermal, hydrostatic and mechanical stresses, positioning thereof and processes for forming said insulating means
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US20070131300A1 (en) 2005-11-12 2007-06-14 Richard Lounders Pipe joint insulation, apparatus and method
US20100330316A1 (en) 2009-06-25 2010-12-30 Nomaco Inc. Self-adjusting insulation, including insulation particularly suited for pipe or duct
EP3262332A1 (en) 2015-02-26 2018-01-03 R. Van Den Hanenberg B.V. Isolation method and isolation equipment

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2890739A (en) 1954-11-30 1959-06-16 Armstrong Cork Co Segmented insulation and method of installing the same
US3117902A (en) 1958-10-20 1964-01-14 Fastab Insulations Inc Insulating coverings for enclosures
US4660861A (en) 1983-12-28 1987-04-28 Hutchinson S.A. Heat insulating means for piping subjected to thermal, hydrostatic and mechanical stresses, positioning thereof and processes for forming said insulating means
US5421371A (en) 1993-04-19 1995-06-06 Nmc Of North America, Inc. Multi-layered bonded closure system for foam tubes or profiles
US6530603B1 (en) 1998-02-17 2003-03-11 Industrial Thermo Polymers Limited Self-covering element
US20070131300A1 (en) 2005-11-12 2007-06-14 Richard Lounders Pipe joint insulation, apparatus and method
US20100330316A1 (en) 2009-06-25 2010-12-30 Nomaco Inc. Self-adjusting insulation, including insulation particularly suited for pipe or duct
EP3262332A1 (en) 2015-02-26 2018-01-03 R. Van Den Hanenberg B.V. Isolation method and isolation equipment

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