Note: Descriptions are shown in the official language in which they were submitted.
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INSULATION BLANKET SYSTEM
DESCRIPTION
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present invention claims the benefit of U.S. Provisional
Application No.
60/934,384 filed June 13, 2007.
FIELD OF THE INVENTION
[0002] The present invention relates generally to insulating blankets
and more specifically to
insulation blankets for high temperature systems. The blanket can be
selectively manufactured
to encompass turbines, pumps and valves, piping/conduit (straight, elbows,
valves, T's and Y's),
fans and blowers, nuclear components, exchangers, headers and tanks, dryers
and hoppers, and
component parts and specialty equipment used for transporting or storing
different materials in
difficult environments. The thermal insulation blanket of the present
development has an inner
blanket core of aerogel material and is encapsulated by an insulative fabric
cover that includes
one or more drain openings and one or more breather vents.
DESCRIPTION OF THE PRIOR ART
[0003] Blanket-type insulation is frequently used in power plants and
other extreme
conditions requiring protection, insulation and/or acoustical dampening due to
heat, cold and/or
sound. Such blankets are typically removable and reusable and have a
fiberglass core incased or
encapsulated by a fiberglass or glass fabric. The blanket is held around the
component, such as a
vessel or pipe, by connectors, buckles/straps, spring clasps, and hook and
loop type fasteners.
[0004] In some environments, the blankets are covered by metal jackets
to protect the
blankets from moisture. In indoor and outdoor environments wherein blankets
are employed
without a metal or water repellant/water-impervious outer jacket, the blankets
have an inherited
problem, they can absorb and hold moisture. Specifically, the blanket's outer
fabric's weave and
the needle holes in the seam can let moisture pass through the fabric layer to
the inner insulating
core.
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[0005] The resulting wet-blanket becomes heavy, causing the blanket to
sag down. The
ingress and holding of water not only affects the insulating properties of
individual components
of the blanket (cover and core) but the geometry of the blanket relative to
the object being
insulated.
[0006] Blankets used in the manholes and tunnels can become completely
submerged in
water or surrounded by steam for extended periods. Once the water is removed
from the
surrounding environment, these blankets can be difficult, if not impossible,
to remove as they are
holding large amounts of water within. A standard 10" or 12" valve cover can
weigh up to
2001bs.
[0007] The present invention is provided to solve the problems discussed
above and other
problems. A full discussion of the features and advantages of the present
invention is deferred to
the following detailed description, which proceeds with reference to the
accompanying drawings.
SUMMARY OF THE INVENTION
[0008] The present invention is directed to an insulation blanket
system. The insulation
blanket system comprises an insulating core produced from a flexible aerogel,
an outer layer of a
fabric, an inner layer of a fabric, a pair of opposing end layers of a fabric
wherein the insulating
layer is substantially encapsulated by a combination of the inner, outer, and
pair of end layers;
and a plurality of fasteners located adjacent the opposing end layers for
drawing the pair of end
layers together forming a substantially tubular arrangement.
[0009] The flexible aerogel of the insulation blanket system of Paragraph
[0008] may be
hydrophobic.
[0010] The flexible aerogel of the insulation blanket system of
Paragraph [0008] or [0009]
may be doped with a hydrophobic agent.
[0011] The flexible aerogel of the insulation blanket system of any of
Paragraphs [0008] to
[0010] may be selected from the group consisting of: a silica aerogel, a
nanoporous aerogel, and
an aerogel with reinforcing fibers.
[0012] The insulating core of the insulation blanket system of any of
Paragraphs [0008] to
[0011] may have a thickness between 6 mm and 20 mm.
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[0013]
The insulating core of the insulation blanket system of any of Paragraphs
[0008] to [0012] may comprise a first layer of the flexible aerogel and a
second layer
of the flexible aerogel.
[0014]
The first and second layers of the insulation blanket system of Paragraph
[0013] may have a thickness between 6 mm (0.24 ins.) and 10 mm (0.40 ins.)
[0015]
The insulating blanket of any of Paragraphs [0008] to [0014] may further
comprise a drain opening in the outer layer located adjacent the end layers
exposing
a portion of the insulating core.
[0016]
The insulating blanket of any of Paragraphs [0008] to [0015] may further
comprise a breather vent in the outer layer located opposite the opposing end
layers
exposing a portion of the insulating core.
[0017]
The drain of any of Paragraphs [0015] to [0016] may be produced from a
brass grommet.
[0018]
The vent of any of Paragraphs [0015] to [0017] may be produced from a
two-piece brass screen.
[0019]
The insulating blanket of any of Paragraphs [0008] to [0018] may further
comprise a plurality of tuft supports in the outer layer enhancing structural
integrity of
the blanket.
[0020]
The insulating blanket of any of Paragraphs [0008] to [0019] may further
comprise a plurality of tuft supports in the inner layer enhancing structural
integrity of
the blanket.
[0020a]
Therefore, in accordance with the present invention, there is provided
an insulation blanket system comprising:
an insulating core produced from a flexible hydrophobic aerogel;
an outer layer of a fabric;
an inner layer of a fabric;
a pair of opposing end layers of a fabric wherein the insulating layer is
substantially
encapsulated by a combination of the inner, outer, and pair of end layers;
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a plurality of fasteners located adjacent the opposing end layers for drawing
the pair
of end layers together forming a substantially tubular arrangement; and
a drain opening passing through the outer layer and terminating at the
insulating
core, exposing a portion of the insulating core and located adjacent the end
layers.
[0020b] Also, in
accordance with the present invention, there is provided an
insulation blanket system comprising:
an insulating core produced from a flexible hydrophobic aerogel;
an outer layer of a fabric;
an inner layer of a fabric;
a pair of opposing end layers of a fabric wherein the insulating layer is
substantially
encapsulated by a combination of the inner, outer, and pair of end layers;
a plurality of fasteners located adjacent the opposing end layers for drawing
the pair
of end layers together forming a substantially tubular arrangement;
a breather vent opening in the outer layer of fabric in fluid communication
with and
terminating at the insulating core for permitting liquids entering into the
substantially encapsulated core to escape the insulating core in the form or a
steam or a vapor.
[0021] The
present invention is an improvement on existing systems and tries to
alleviate the above problems. The improved blanket of the present development
includes an inner blanket core of an aerogel material, preferably Pyrogel
6350
insulation or Pyrogel 10350 insulation, and is encapsulated by an insulative
fabric
cover that includes one or more drain openings and one or more breather vents.
The
stitching is preferably Teflon or like material and the hardware is pure
brass.
[0022] Other
features and advantages of the invention will be apparent from the
following specification taken in conjunction with the following drawings.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0023] To understand the present invention, it will now be described by
way of example,
with reference to the accompanying drawings in which:
[0024] FIG. 1 is a perspective view (cross-section) of thermal
insulation blanket made in
accordance with the teachings of the present invention;
[0025] FIG. lA is a section view along line A-A of FIG. 1;
[0026] FIG. 1B is a sectional view along line B-B of FIG. 1;
[0027] FIG. 2 is a detail drawing of the grommet used for the drain
opening;
[0028] FIG. 3 is a detail drawing of the breather vent;
[0029] FIG. 4 is a perspective view of a grommet used in association with
the drain opening;
and
[0030] FIG. 5 is a perspective view of a vent used in association with
the breather vent.
DETAILED DESCRIPTION
[0031] While this invention is susceptible of embodiments in many
different forms, there is
shown in the drawings and will herein be described in detail preferred
embodiments of the
invention with the understanding that the present disclosure is to be
considered as an
exemplification of the principles of the invention and is not intended to
limit the broad aspect of
the invention to the embodiments illustrated.
[0032] A blanket made in accordance with the teaching of the present
invention is shown in
FIG. 1 by the general reference number 10. Blankets of this type are typically
used in sections of
piping/conduit having a valve connected thereto. Specifically, a front portion
21 of the blanket
10 covers a portion of the conduit going to the valve (not shown), a rear
portion 22 of the blanket
10 covers a portion of the conduit leaving the valve, and an upper portion 23
of the blanket
covers the valve, leaving an opening 24 for the valve control, such as a
turning knob. In the
construction of FIG. 1, the blanket 10 is constructed of two (2) halves, a
right blanket portion 25
and a left blanket portion 26. The two blanket portions 25,26 are mated or
placed in confronting
relationship with their butt surfaces 33 abutting one another.
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[0033] The blanket 10 has an outer fabric or skin 31, an inner fabric or
skin 32, and a butt-
end fabric or skin 33 encapsulating the insulating core 41. The fabric/skin is
sewn together. A
plurality of tuft supports 35,36 are sewn into the blanket 10 to enhance the
structural integrity of
the blanket and prevent shifting. A plurality of fasteners 37,38 are employed
to secure the
5 blanket in place around the component to be insulated. D-rings and straps
are shown, however,
it is recognized by those in the field that other fasteners can be used, such
as hook and loop type
fasteners, laces, etc.
[0034] As noted, once the blanket 10 halves 25,26 are put around the
object to be insulated,
the butt ends 33 of the blanket are pressed against one another in abutting
relationship and the
fasteners 37,38 are mated and locked to ensure the blanket stays in its
desired location and
position.
[0035] The blanket 10 includes one or more breather vents 50 in the
upper portion of the
blanket and one or more drain openings 60 in the lower portion of the blanket.
[0036] The drain opening 60 provides an opening through the outer fabric
31 to the core 41.
In the preferred embodiment, the opening 60 is supported or fixed by a two
piece grommet 61,62
(FIG. 4), specifically a pure brass #1 grommet. It has been learned that pure
brass is important
as it does not corrode like stainless steel. The drain opening 60 permits
liquids, such as water
entering into the enclosed core to drain out of the system.
[0037] In the preferred embodiment, there are two (2) drain opening 60
per blanket on each
side of the blanket (e.g., the right side and the left side of the blanket or
the right blanket portion
and the left blanket portion 26). The preferred locations of the openings 60
are at the bottom
of the valve (not shown), in the center and on each side of the valve.
[0038] The purpose of the breather vent 50 is to permit air to enter the
outer fabrics or skins
31 of the blanket to the core 41 and to let moisture escape in the form of
steam or vapor. It has
25 been found that to the extent residual moisture stays inside the skins
31,32,33 or on the core 41
and/or inner skin surfaces 32, mold can occur. The breather vent 50 is a pure
brass vent #D3926.
In the preferred embodiment, the opening vent 50 is supported or fixed by a
two piece
construction 51,52 (FIG. 5). At least one of the two pieces 51,52 includes a
mesh, e.g., surface
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with a plurality openings therein with a mesh or particle size. The breather
vent 50 is installed
just like a standard grommet.
[0039] It should be noted that preferably all hardware associated with
the blankets of the
present invention (such as tags, hooks, D-rings, etc.) are made of pure brass
and the treading
used to sew/stitch the blankets is pure Teflon or similar material.
[0040] As to core insulation 41, it is preferably made with Pyrogel
insulation, produced by
Aspen Aerogels, Inc., Northborough, MA (USA). This material is a flexible
aerogel, nanoporous
insulation specifically designed for high temperature applications. Generally,
aerogels are
nanoporous solids created when silica is gelled in a solvent. When the solvent
is removed, the
remaining product is a puffed-up, sand-like substance with up to 99% porosity.
The
nanoporosity slows heat and mass transport, providing very low thermal
conductivity. It has
some of the following characteristics: very low thermal conductivity, high
temperature
resistance, good flexibility, and relative ease of use. The material combines
a silica aerogel with
reinforcing fibers (non-woven, carbon- and glass-fiber batting). It can be cut
using conventional
textile cutting tools, including scissors, electric scissors and razor knives.
The material can be
stitched to high temperature cloth and encapsulated as with the present
product.
[0041] The material is preferably used in two (2) thicknesses, that
being 6mm (0.24")
(Pyrogel 6350 insulation) and lOmm (0.40") (Pyrogel 10350 insulation). These
sizes can be
stacked together to obtain thicknesses of 12mm (0.48"), 20mm (0.8"), 16mm
(0.64"), etc. Silica
aerogels possess the lowest thermal conductivity of any known solid. For
example, such
aerogels can be used up to 725 F (385 C), are hydrophobic, and have a density
of about 10.7
lb/ft3 (0.17 g/cc). They are roughly 2 to 8 times better than other insulating
products, and can be
used with a smaller or reduced thickness or profile. They can be easily cut
and conformed to
complex shapes, tight curvatures, and spaces with restricted access. They are
physically robust,
soft and flexible but with excellent springback. For example, the material
recovers its thermal
performance even after compression events as high as 50 psi. It has been found
that the material
has equal or better fire protection characteristics than mineral wool and/or
calcium silicate. And,
significantly, the material repels liquid but allows vapor to pass through. In
addition, if the
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material is doped with a hydrophobic agent, it will help make the material
resistant to moisture.
Water ingression can be desorbed when the material is exposed to a heated
environment.
[0042] See Table 1 below.
TABLE 1 Product Specifications
Product Nominal Thermal Conductivity Density
Max. Use Temp.
, Thickness
Pyrogel 6350 6 mm 15.5 mW/m-K 0.17 g/cc 385 C
0.24 in 0.107 Btu-in/hr-ft2- F 10.7 lb/ft3 725
F
Pyrogel 10350 10.0 mm 15.5 mW/m-K O.17g/cc 385 C
0.40 in 0.107 Btu-in/hr-ft2- F 10.7 lb/ft3 725
F
[0043] In experiments, it has been found that with the lower K factor
(thermal conductivity),
two inches (2") of traditional Tem-Mat 91b./cu,ft density insulation can be
replaced by one layer
of the 6mm and one layer of the lOmm aerogel (approx. 16mm or 3/4"). It has
been observed that
for lower temperature environments, only one layer of the Pyrogel insulation
needs to be used,
such as the 6mm or the lOmm sizes.
[0044] The terms "first," "second," "upper," "lower," "front," "back,"
etc. are used for
illustrative purposes only and are not intended to limit the embodiments in
any way. The term
"plurality" as used herein is intended to indicate any number greater than
one, either
disjunctively or conjunctively as necessary, up to an infinite number. The
terms "joined" and
"connected" as used herein are intended to put or bring two elements together
so as to form a
unit, and any number of elements, devices, fasteners, etc. may be provided
between the joined or
connected elements unless otherwise specified by the use of the term
"directly" and supported by
the drawings.
[0045] Many modifications and variations of the present invention are
possible in light of the
above teachings. It is, therefore, to be understood within the scope of the
appended claims the
invention may be protected otherwise than as specifically described.
