Abstract:
A thermal insulation system for insulating a pipe is disclosed having an upper insulation member engageable with a lower insulation member to collectively surround the pipe. Each of the upper and lower insulation members preferably have a plurality of constant radius relief cuts at each end thereof, wherein the constant radius relief cuts extend from the end of each of the insulation members toward the center of the insulation member. In a preferred embodiment, each insulation member further includes a plurality of radial relief cuts extending radially from the inner surface of each of the insulation members toward the outer surface of the insulation member. The radii of curvature of the insulation members is preferably variable such that, for a portion of the insulation member, a gap exists between the inner surface of the insulation member and the pipe, allowing room for fluctuation in the size and shape of the insulation members.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to thermal insulation systems for piping, and more particularly to a factory jacketed thermal pipe insulation having relief cuts therein to compensate for fluctuations in form resulting from varying environmental factors. 
     BACKGROUND OF THE INVENTION 
     Pipes that convey liquid or gaseous materials from one point to another often require insulation and protection from environmental elements such as heat and cold. Insulation is especially important in industrial and critical process applications. To protect against the elements, one option has been to provide piping with the insulation already installed thereon. Thus, piping and insulation are made available as a combined unit. The purchase of the pipe and insulation as a combined unit ensures that the insulation will fit the pipe perfectly. However, when the pipe needs repair or maintenance, the process of removing and replacing the insulation is difficult and time consuming. 
     To simplify the insulation process, a factory jacketed insulation system is available, separately from the pipes. The factory jacketed insulation system allows the user the option of the installation of a wider variety of piping of various construction and materials without the necessity of purchasing the piping and insulation as a combined unit. The factory jacketed insulation system includes a first semi-circular section that is dimensioned to mate with a second semi-circular section. The two semi-circular sections are permanently bonded to a single exterior jacket to complete the insulation system. The first and second sections have corresponding notches at the ends for easy fit and mating. The factory jacketed insulation system can be installed by simply pressing the first semi-circular section around half of the pipe and wrapping the second section over the remaining pipe thereby joining the first and second sections together. The factory-applied jacket allows for precision mating of the two insulation sections. There is no need to remove the pipe when installing the insulation. Furthermore, the pipe and the insulation need not be purchased together as a combined unit. The slide-over arrangement also allows for simplified testing of the installation for leakage and repair of the pipes. 
     The disadvantage of the factory jacketed insulation system is that the insulation material is sensitive to the moisture content in the ambient air. In a dry environment, the insulation material is at its smallest condition. When the humidity rises, the insulation material expands. A 30% rise in humidity could result in a 3% increase in the size of the material. The fluctuation in the size of the insulation material interferes with the fit around the pipe. The problem is magnified for larger pipes since there is an increase in the surface area. 
     This problem is illustrated in the manufacturing/sale scenario. The manufacturer, located in a first city, cuts the insulation to the customer&#39;s specifications. The insulation is then shipped to a second city having a different ambient air moisture level than the first city. When the insulation arrives at the second city, it will have fluctuated in size and will no longer fit around the pipe. The unsatisfied customer will undoubtedly complain to the manufacturer and return the insulation for evaluation. Upon arrival in the first city, the insulation will return to its original size, evading a negative analysis. The manufacturer is not able to respond to the customer&#39;s complaint. 
     The problem can arise even if the insulation is not shipped to another city. For instance, insulation that is cut in humid temperatures is swollen and contains water. Once the insulation is placed on a hot pipe, the water evaporates causing the insulation to shrink. If a jacket is placed around the insulation, the contraction of the insulation will cause the jacket to wrinkle. 
     Accordingly, there is a need for a thermal insulation system that is easy to install and accommodates fluctuation in size of the insulation resulting from changes in temperature and humidity. 
     SUMMARY OF THE INVENTION 
     The thermal insulation system of the present invention includes an upper insulation member engageable with a lower insulation member to collectively surround and insulate a pipe. The ends of the upper and lower insulation members are preferably configured to form shiplap joints when the insulation members are wrapped around the pipe and connected together. In a preferred embodiment, the first end of the upper insulation member preferably has a projection that is dimensioned to fit into a groove in the first end of the lower insulation member to form a shiplap joint. Similarly, the second end of the lower insulation member has a projection that is dimensioned to fit into a groove in the second end of the upper insulation member forming a second shiplap joint. The projections on the first end of the upper insulation member and the second end of the lower insulation member preferably have a dome-shaped cross-section and extend across the entire length of the upper and lower insulation members. Correspondingly, the grooves in the second end of the upper insulation member and in the first end of the lower insulation member have a dome-shaped cross section to accommodate the respective projections. 
     The upper and lower insulation members are preferably made of a flexible foam material and, more preferably, made of TECHLITE®, an open melamine foam. Foam material tends to fluctuate in size and shape depending on the environmental conditions. To compensate for the fluctuations in size and shape, relief cuts are made in the foam material to minimize the variance in the insulation. Specifically, a series of constant radius relief cuts are provided on the first and second ends of each of the insulation members. The cuts preferably extend from the ends of the insulation members toward the center portion. In a preferred embodiment, the radius of each of the cuts remains constant. 
     In addition to the constant radius relief cuts, radial relief cuts are made on the inner surface of the upper and lower insulation members. The cuts extend axially along the length of insulation members and radially advance from the inner surface toward the outer surface of each of the insulation members. In a preferred embodiment, three radial relief cuts are provided on each of the upper and lower insulation members. On each insulation member, one radial relief cut is preferably positioned at the center of the insulation member and the second and third radial relief cuts are provided on either side of the first radial relief cut, equidistant therefrom. 
     In a preferred embodiment of the present invention, the upper and lower insulation members are arc-shaped and the inner surface of the insulation members have variable radii of curvature. The radius of curvature at the center of the insulation members is preferably greater than the radius of curvature at the first and second ends of the insulation members such that a gap is created between the inner surface and the pipe at the center portion of each of the insulation member. The gap accommodates the variation in the size and shape of the insulation members resulting from varying environmental conditions. The various forms of relief cuts and gaps that accommodate size fluctuations allow the foam material of the insulation members to fluctuate while still preserving the connection at the shiplap joints of the insulation members and maintaining the fit of the insulation members around the pipe. 
     This invention, together with the additional features and advantages thereof, which was only summarized in the foregoing passages, will become more apparent to those of skill in the art upon reading the description of the preferred embodiments, which follows in the specification, taken together with the following drawings. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of one embodiment of the thermal insulation system of the present invention; 
     FIG. 2 is a perspective view of the lower insulation member of one embodiment of the thermal insulation system of the present invention; and 
     FIG. 3 is an end view of one embodiment of the thermal insulation system of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The object of the present invention is to provide a thermal insulation system that is easy to install and that accommodates variations in the size of the insulation material resulting from varying environmental conditions. 
     As shown in FIG. 1, the thermal insulation system  10  of the present invention includes an upper insulation member  12  and a lower insulation member  14 . The upper and lower insulation members  12 ,  14  are dimensioned to wrap around a pipe (not shown) and join each other forming a pair of shiplap joints  26 , best shown in FIG.  3 . Specifically, the first end  16  of the upper insulation member  12  preferably has a projection  26  that is dimensioned to fit into a groove  28  in the first end  20  of the lower insulation member  14 . Similarly, the second end  22  of the lower insulation member  14  has a projection  30  that is dimensioned to fit into a groove  32  in the second end  18  of the upper insulation member  12 . In the preferred embodiment of the invention, the projections  26  and  30  preferably have a dome-shaped cross-section. The insulation system is installed onto a pipe by covering half of the pipe with the upper insulation member  12  and the other half of the pipe with the lower insulation member  14  and coupling the members together forming the shiplap joints  26 . 
     The shape of the upper and lower insulation members  12 ,  14  is not limited to a semi-circular shape. Rather, the upper and lower insulation members can have any arc shape as long the two members, when connected to each other, fully surround the pipe to be insulated. The upper and lower insulation members  12 ,  14  are made of insulative material to maintain the temperature of the pipes and protect the pipes from environmental elements. In the preferred embodiment, the members  12 ,  14  are made of TECHLITE®. TECHLITE® is a flexible foam produced from melamine resin, a thermoset of the amino-plastics group. TECHLITE® is a precision-machined and mechanical insulation system developed specifically as a lightweight non-fibrous alternative to conventional fibrous and elastomeric products. The benefits of TECHLITE® are that it has high temperature resistance, low bacterial growth, 25/50 fire rating and outstanding fabrication qualities. Accordingly, TECHLITE® is safe, durable, efficient, and relatively maintenance free. Melamine foam is manufactured and sold by BASF in Ludwig Shafer, Germany. 
     The problem with any insulative material, and particularly TECHLITE®, is that, as discussed above, it is sensitive to the moisture content in the ambient air and fluctuates in size and shape when exposed to varying temperatures and levels of humidity. If the insulation members  12 ,  14  are cut in humid conditions and then transferred to a dry area, the members will shrink and will no longer fit around the pipe. Similarly, insulation members that have swelled with moisture from the humidity of the ambient air will shrink from the heat emanating from the piping and will no longer fit around the piping. 
     The thermal insulation system of the present invention minimizes the fluctuation in shape and size of the insulation members by providing various relief cuts in the insulation members. Two types of relief cuts are shown in FIGS. 1 through 3. First, a series of constant radius relief cuts are made beginning in the first and second end of each insulation member. As described in more detail below, constant radius cuts  34  are made in the first end  20  and second end  22  of the lower insulation member  14 . Similarly, constant radius cuts are made in the first end  16  and the second end  18  of the upper insulation member  12 . The cuts  34  are radial and extend from the ends of the insulation members toward the center portion. The radius of curvature of each of the cuts  34  is preferably constant. 
     In a preferred embodiment, the upper insulation member  12  has a pair of constant radius relief cuts  34  in its first end  16 . The cuts  34  in the first end  16  are radial and extend from the first end  16  of the upper insulation member  12  toward the center portion  36  of the upper insulation member  12 . The pair of constant radius relief cuts  34  on the first end  16  of the upper insulation member  12  are preferably spaced apart, and more preferably, each cut  34  extends from an edge  40  of the dome-shaped projection  26  toward the center portion  36 . Another pair of constant radius relief cuts  34  are preferably made in the second end  18  of the upper insulation member  12 . The cuts  34  in the second end  18  of the upper insulation member  12  are preferably spaced apart and, more preferably, each cut  34  extends from an edge of the groove  32  in the second end  18  toward the center portion  36  of the upper insulation member  12 . The number of cuts, the depth of each cut, and the space between the cuts depend upon the specific application, including factors such as the size of the pipe, size of the insulation, insulative material used, the environmental conditions, etc. 
     Similarly, in a preferred embodiment, the lower insulation member  14 , as shown in FIGS. 1 and 2, has a pair of constant radius cuts  34  at its first end  20  and a pair of constant radius cuts  34  at its second end  22 . The pair of constant radius relief cuts  34  on the first end  20  of the lower insulation member  14  are preferably spaced apart, and more preferably, each cut  34  extends from an edge  42  of the dome-shaped projection  30  toward the center portion  38  of the lower insulation member  24 . The second pair of constant radius cuts  34 , made in the second end  22  of the lower insulation member  14  are preferably spaced apart and more preferably, each cut  34  extends from an edge  46  of the groove  28  in the second end  20  toward the center portion  38  of the lower insulation member  14 . 
     In addition to the constant radius relief cuts  34 , radial relief cuts  50  are made on the inner surface  52  of the upper insulation member  12  and the inner surface  54  of the lower insulation member  14 . The radial relief cuts  50  begin at the inner surfaces  52 ,  54  of the upper and lower insulation members, respectively, and advance toward the outer surfaces  56 ,  58  of the upper and lower insulation members  12 ,  14 , respectively. The radial relief cuts  50  preferably do not reach the outer surfaces  56 ,  58  of the insulation members  12 ,  14 . The length of the radial relief cuts  50  preferably extends across the entire length of the insulation member  12 ,  14 . The depth of each cut, the number of the cuts, and the space between the cuts depend upon the specific application, including factors such as the size of the pipe, size of the insulation, insulative material used, and the environmental conditions. In a preferred embodiment of the present invention, three radial relief cuts  50  are made on each of the upper and lower insulation members  12 ,  14 . A center relief cut  5   b  is preferably made in the center portion  36 ,  38  of each of the upper and lower insulation members  12 ,  14 , respectively. Side radial relief cuts  50   a  and  50   c  are preferably made on either side of the center relief cut  50   b  and, more preferably, are equidistant from the center relief cut  50   b.    
     The constant radius relief cuts  34  and the radial relief cuts  50  minimize the fluctuation in the shape and size of the insulation members resulting from a change in the moisture content of the ambient air by interrupting the path of the fluctuation. For example, if the insulation members are expanding as a result of an increase in humidity, the relief cuts  34 ,  50  are positioned in the expansion path and interrupt the growth of the insulation members. Accordingly, the insulation members are able to maintain substantially the same size. 
     As shown in FIG. 3, in a preferred embodiment of the present invention, the inner surfaces  52 ,  54  of the upper and lower insulation members, respectively, are arc-shaped. The radii of curvature of the inner surfaces  52 ,  54 , preferably, are not constant. Rather, the radius of curvature at the center portion  36 ,  38 , designated as Rc in FIG. 3, is greater than the radius of curvature at the ends  16 ,  18 ,  20 , and  22  of the insulation members, designated as Re in FIG.  3 . The radius of curvature at the ends  16 ,  18 ,  20  and  22 , Re, is preferably equal to the radius of the pipe, designated as Rp in FIG.  3 . Since Rc is greater than Rp, a gap  60  is created between the pipe and the insulation members  12 ,  14 . The gap  60  further accommodates any expansion of the insulative material. Accordingly, when the upper or lower insulation members expand as a result of varying environmental conditions, the upper and lower members  12 ,  14  expand into the gap  60 . This design allows for the thermal insulation system to be fitted around the pipe while still allowing some room for expansion of the insulative material. 
     In a preferred embodiment, the thermal insulation system  10  also includes a jacket  62 , shown in FIG.  1 . The jacket  62  is dimensioned to wrap around the upper and lower insulation members  12 ,  14 . The jacket  62  is preferably attached to the insulation members by attaching the first end  63  of the jacket to one of the insulation members. In FIG. 1, the first end  63  of the jacket  62  is shown attached to the upper insulation member  12 . The jacket wraps around both of the upper and lower insulation members  12 ,  14  after the insulation members have been installed on the pipe. A second end  64  of the jacket  62  is placed over the first end  63  of the jacket such that the second end  64  overlaps the first end  63 . The second end  64  can be attached to the first end  64  using an adhesive or other fixing aids known in the art. 
     The jacket  62  is preferably made of a one-piece, continuous foil material. When there is a change in the shape or size of the insulation members, the jacket will bubble or otherwise deform. The deformation in the jacket allows a user to observe any change in the insulation members from the exterior of the thermal insulation system. In the conventional insulation systems, a factory jacketed jacket is used. The disadvantage of the factory jacketed system is that it does not allow the user to observe the fluctuations in the insulation from the exterior of the system. The one-piece jacket is an improvement over the prior insulation systems in that it deforms to alert the user of a change in the insulation members. 
     While the invention is disclosed in conjunction with specific embodiments thereof, it is to be evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as falling within the spirit and broad scope of the appended claims.