COMPOSITE INSULATION SYSTEM

• US 20190329486A1
• Filed: 11/20/2017
• Published: 10/31/2019
• Est. Priority Date: 11/18/2016
• Status: Active Grant

• Current Assignee: Nelson Global Products, Inc. (Nelson Global Holdings LLC)
• Original Assignee: Saprex, LLC
• Inventors: Goulet, Robert Jacque
• Granted Patent: US 11,946,584 B2
• Time in Patent Office: Days
• CPC Class Codes: B29C 53/58 helically
• CPC Class Codes: B29C 53/588 having a non-linear axis, e.g. elbows, toroids
• CPC Class Codes: B29C 63/048 specially adapted for articles having local protrusions, e.g. tubes having a bead weld
• CPC Class Codes: B29C 63/10 around tubular articles
• CPC Class Codes: B29C 70/30 Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
• CPC Class Codes: B29C 70/682 Preformed parts characterised by their structure, e.g. form
• CPC Class Codes: B29K 2101/12 Thermoplastic materials
• CPC Class Codes: B29K 2105/0005 containing compounding ingredients releasing, lubricating or separating agents B29C33/56, fibers B29K2105/08, B29K2105/12; fillers B29K2105/16, recycled material B29K2105/26
• CPC Class Codes: B29K 2105/0809 Fabrics
• CPC Class Codes: B29K 2995/0015 Insulating
• CPC Class Codes: B29L 2023/225 Insulated
• CPC Class Codes: B32B 15/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2305/184 Braided fabrics
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2597/00 Tubular articles, e.g. hoses, pipes
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/026 Knitted fabric
• CPC Class Codes: D02G 3/22 Yarns or threads characterised by constructional features , e.g. blending, filament/fibre piecing of yarns or threads D01H15/00
• CPC Class Codes: D04B 1/225 Elongated tubular articles of small diameter, e.g. coverings or reinforcements for cables or hoses
• CPC Class Codes: D04B 21/205 Elongated tubular articles of small diameter, e.g. coverings or reinforcements for cables or hoses
• CPC Class Codes: D04C 1/06 : Braid or lace serving particular purposes
• CPC Class Codes: D10B 2401/04 : Heat-responsive characteristics
• CPC Class Codes: D10B 2505/02 : Reinforcing materials; Prepregs
• CPC Class Codes: F16L 57/06 : against wear F16L57/04 takes precedence
• CPC Class Codes: F16L 59/027 : Bands, cords, strips or the like for helically winding around a cylindrical object
• CPC Class Codes: F16L 59/028 : Composition or method of fixing a thermally insulating material
• CPC Class Codes: F16L 59/029 : layered
• CPC Class Codes: F16L 59/10 : Bandages or covers for the protection of the insulation, e.g. against the influence of the environment or against mechanical damage integral with the insulation materials F16L59/02
• CPC Class Codes: F16L 59/106 : Flexible covers for flanges, junctions, valves or the like
• CPC Class Codes: F16L 59/14 : Arrangements for the insulation of pipes or pipe systems F16L59/02 - F16L59/12 take precedence
• CPC Class Codes: F16L 59/163 : Branch units in general F16L41/02; Insulation forming a whole with branches
• CPC Class Codes: F16L 59/168 : Flexible insulating material or covers for flanges, junctions, valves or the like
• CPC Class Codes: F16L 59/22 : adapted for bends

Abstract

Embodiments of the present invention provide a self-molding composite system for insulation and covering operations. The self-molding composite system may be cured to form any desired shaped for insulation and covering operations. The composite system comprises one or more layers that may create a rigid layered composite when cured. The one or more layers of the composite system may include a base layer that is a braided, knit, or non-woven fiber based substrate, an interstitial matrix layer, and customizable top coat. The customizable top coat may be a solvent based polymer solution that includes various additives that may include color pigments, additives for additional abrasion protection, additives for thermal protection, and/or additives for creating various textures or visible appearances to the composite system.

Claims

1. A fiber-reinforced composite insulation system that is configured to be applied to a component comprising:

one or more structural reinforcement layers, the one or more structural reinforcement layers being configured to conform to the component;

a self-molding fiber cover comprising a spring-like structure configured to provide compression around the component; and

one or more liquid polymer matrix solutions configured to be applied to the one or more structural reinforcement layers and/or the self-molding fiber cover positioned on the component to form the fiber-reinforced composite insulation system when cured.

2. The composite insulation system of claim 1, wherein the one or more structural reinforcement layers comprise structural fibers, resin fibers and/or elastic fibers, wherein:

structural fibers comprise glass, carbon, polymer, ceramic, metallic, mineral and/or natural fibers; and

resin fibers comprise polyethylene terephthalate (PET), polyamide (PA), polyphenylene sulfide (PPS), polyphenylene oxide ether (PPE), polyethylenimine (PEI), polyether ether ketone (PEEK), fluoric polymers such as polytetrafluoroethylene (PTFE), ethylene-tetrafluoroethylene (ETFE), polyvinylidenefluoride (PVDF), and/or ethylene-tetrafluoroethylene (ETFE) based fibers.

3. The composite insulation system of claim 1, wherein the one or more structural reinforcement layers comprise braided fiber materials, knit fiber materials, woven fiber materials, and/or non-woven fiber materials.

4. The composite insulation system of claim 1, wherein the one or more structural reinforcement layers comprise polymeric films, metal films, metalized polymeric films, foils, fiber reinforced films and/or fiber reinforced foils.

5. The composite insulation system of claim 1, wherein the self-molding fiber cover comprises braided fiber materials, knit fiber materials, woven fiber materials, and/or non-woven fiber materials.

6. The composite insulation system of claim 1, wherein the self-molding fiber cover comprises structural fibers, resin fibers and/or elastic fibers, wherein:

structural fibers comprise glass, carbon, polymer, ceramic, metallic, mineral and/or natural fibers; and

resin fibers comprise polyethylene terephthalate (PET), polyamide (PA), polyphenylene sulfide (PPS), polyphenylene oxide ether (PPE), polyethylenimine (PEI), polyether ether ketone (PEEK), fluoric polymers such as polytetrafluoroethylene (PTFE), ethylene-tetrafluoroethylene (ETFE), polyvinylidenefluoride (PVDF), and/or ethylene-tetrafluoroethylene (ETFE) based fibers.

7. The composite insulation system of claim 1, wherein the one or more liquid polymer matrix solutions comprise a dispersion of ground thermoplastic polymer in an organic or non-organic solvent.

8. The composite insulation system of claim 1, wherein the one or more liquid polymer matrix solutions comprise one or more additives chosen from a group comprising surfactants, emulsifiers, dispersants, rheology modifiers, and functional additives.

9. The composite insulation system of claim 1, wherein the one or more liquid polymer matrix solutions comprise a thermoset polymer, wherein thermoset polymer comprises alkyd, amino, epoxy, phenolic, polyimide, polyurethane or silane polymers.

10. The composite insulation system of claim 1, wherein the one or more liquid polymer matrix solutions are configured to flow within and at least partially infuse the self-molding fiber cover to create a fiber-reinforced composite.

11. The composite insulation system of claim 1, wherein the one or more liquid polymer matrix solutions are configured to flow within and at least partially infuse the one or more structural reinforcement layers to form a multi-layer, fiber-reinforced composite.

12. The composite insulation system of claim 1, further comprising one or more metal foil or fiber reinforced metal foil layers chosen from a group comprising aluminum, fiberglass reinforced aluminum, stainless steel, nickel, and tin.

13. The composite insulation system of claim 1 further comprising a customizable topcoat configured to be applied to the self-molding fiber cover, the customizable top coat comprising one or more dry ground polymers dissolved in a solvent and an emulsifier.

14. The composite insulation system of claim 1, wherein heat is applied to cure the composite system into a rigid layered composite around the component.

15. The composite insulation system of claim 14, wherein the curing is configured to cause the one or more liquid polymer matrix solutions to flow between the one or more structural reinforcement layers and the self-molding fiber cover to create a mechanical and chemical bond between layers of the composite system.

16. The composite insulation system of claim 1 further comprising a localized insulation mat positioned between the component and the one or more structural reinforcement layers, configured to be provide localized insulation to the component.

17. The composite insulation system of claim 1 further comprising a localized insulation sleeve positioned between the component and the one or more structural reinforcement layers, configured to be provide localized insulation to the component.

18. The composite insulation system of claim 1 further comprising a localized reinforcement layer, configured to prevent creation of gaps between the component and the one or more structural reinforcement layers due to differential thermal expansion.

19. The composite insulation system of claim 1 further comprising a localized reinforcement layer, configured to be prevent localized abrasion of the component.

20. A method for providing the fiber-reinforced composite insulation system that is configured to be applied to a component, the method comprising:

providing one or more structural reinforcement layers, the one or more structural reinforcement layers being configured to conform to the component;

providing a self-molding fiber cover comprising a spring-like structure configured to provide compression around the component;

sliding the one or more structural reinforcement layers over the component;

sliding the knit cover over the one or more structural reinforcement layers;

securing the knit cover with one or more clamping devices;

applying one or more liquid polymer matrix solutions to the one or more structural reinforcement layers and/or the self-molding fiber cover positioned on the component; and

curing the composite insulation system at a predetermined temperature.

21. A conforming, fiber-reinforced composite insulation system that is configured to be applied to a component comprising:

one or more structural reinforcement layers, the one or more structural reinforcement layers being configured to provide structural support, insulation or protection to the component; and

one or more liquid polymer matrix solutions configured to be applied to the one or more structural reinforcement layers positioned on the component to form the fiber-reinforced composite insulation system.

22. A conforming, fiber-reinforced composite insulation system that is configured to be applied to a component comprising:

a self-molding fiber cover comprising a spring-like structure configured to provide compression around the component; and

one or more liquid polymer matrix solutions configured to be applied to the self-molding fiber cover positioned on the component to form the fiber-reinforced composite insulation system when cured.

23. A composite insulation system that is configured to be applied to a component comprising:

a braided tape, the braided tape being configured to conform to the component;

a self-molding fiber cover comprising a spring-like structure configured to provide compression around the component; and

one or more composite matrix solutions configured to be applied to the braided tape and/or the self-molding fiber cover positioned on the component to form the composite insulation system.

24. The composite insulation system of claim 23, wherein the braided tape comprises at least one of glass fibers, thermoplastic fibers, and elastic fibers.

25. The composite insulation system of claim 23, wherein the braided tape is configured to wrapped around the component such that the braided tape forms an abutment with at least a portion of an adjacent braided tape, wherein the abutment is a tight junction.

26. The composite insulation system of claim 23, wherein the braided tape is configured to wrapped around the component and secured without external clamps.

27. The composite insulation system of claim 23, wherein the braided tape is configured to be opened to receive flanges in the component.

28. The composite insulation system of claim 23, wherein the braided tape comprises elastic longitudinal tows and inelastic oblique tows.

29. The composite insulation system of claim 23, wherein the braided tape is a fiber based substrate comprising interweaving multiple fibers, at least one fiber selected from a group comprising e-glass, s-glass, basalt, quartz, polytetrafluoroethylene (PTFE), meta-aramid, para-aramid, melamine, polybenzimidzole, polyimide, silica, oxidized polyacrylonitrile, carbon fiber, and/or ceramic.

30. The composite insulation system of claim 23, wherein the composite matrix comprises vermiculite, colloidal silica, potassium silicate, bitumen, calcium aluminate.

31. The composite insulation system of claim 23, wherein the composite matrix comprises one or more additives selected from a group consisting of thermoplastic polymers, thermoset polymers.

32. The composite insulation system of claim 23, wherein the composite matrix comprises a biocide.

33. The composite insulation system of claim 23, wherein the composite matrix is incorporated into the braided tape prior to wrapping the component.

34. A method for producing a composite insulation system for a component, the method comprising:

providing a braided tape, wherein the braided tape configured to conform to the component;

wrapping the braided tape around the component such that the braided tape forms an abutment with at least a portion of an adjacent braided tape wrap, wherein the braided tape and the adjacent braided tape wrap do not overlap;

wrapping and tucking ends of the braided tape into adjacent wraps of the braided flat tape; and

applying a composite matrix to at least a portion of the braided flat tape.