Note: Descriptions are shown in the official language in which they were submitted.
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LOW PERMEANCE INSULATIVE DEVICE AND RELATED KIT
FIELD OF THE INVENTION
[0001] The present invention relates generally to thermal insulation. More
particularly, the present invention relates to insulative padding and related
insulation kit
for reducing thermal and water vapor transfer between pipe couplings, valves,
and other
exposed conduit areas and the surrounding environment.
BACKGROUND OF THE INVENTION
[0002] In the field of thermal insulation, numerous attempts have been made to
insulate conduits to alleviate thermal transfer and thereby reduce related
energy costs.
Such thermal transfer may be due to heat loss from heat bearing systems (e.g.,
steam
distribution pipes) or heat gain to cold systems (e.g., chilled water
distribution pipes).
This is most common within industrial, institutional, and/or commercial
settings that
include thermal energy distribution or cooling systems. Straight sections of
pipes within
the given system are typically completely encased, often permanently, within a
continuous insulation material suitably chosen for high heat tolerance.
However, such
systems often include a variety of pipe components and equipment including,
but not
limited to, flanges, valves, valve stems, and steam traps. These components
often
require some level of maintenance. In turn, this requires some level of
physical access to
the particular component necessitating removal of the thermal insulation
materials.
[0003] Removable/reusable insulation blankets, in the form of two matching,
mirror-image halves, often referred to as "clamshells", have been used to
insulate such
components requiring periodic and/or frequent access. However, most clamshell
type of
removable/reusable component insulation devices are designed to be installed
by skilled
insulation installers and are generally difficult to re-attach by personnel
unskilled in pipe
insulation due in large part to wire lacing which is normally cut and
discarded during
removal. Accordingly, once a maintenance issue occurs at the component site,
it is
common within industrial, institutional, and/or commercial settings to see an
insulation
device lying unused nearby. Several such flawed attempts have been identified
among
previous related devices.
[0004] One previous attempt at providing pipe insulation is found in United
States
Patent No. 4,112,967 issued to Withem on September 12, 1978 for a weatherproof
insulated valve cover. The Withem valve cover is for a pipeline and provided a
flexible
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multi-layered construction shaped to conform to valves having stub pipe-type
valve stem
housings. The valve cover included a waterproof outer layer of Herculite or
the like with
one of the inner layers being insulation. The cover was easily removable by
virtue of
releasable fasteners to permit access to the valve for maintenance.
[0005] Another previous attempt is found in United States Patent No. 4,207,918
issued to Burns et al. on June 17, 1980 for an insulation jacket. The Burns et
al. device is
an insulation jacket for use as a valve cover. The jacket includes a body
portion having a
central section and two lateral sections. Each of the lateral sections
includes an inboard
and outboard belt and each of the belts extends along each of the lateral
sections. The
ends of each of the belts are adapted to interlock whereby the insulation
jacket may be
securely fastened around a valve casting.
[0006] Yet another attempt is found in United States Patent No. 4,556,082
issued
to Riley et al. on December 3, 1985 for a removable thermal insulation jacket
for valves
and fittings. The Riley et al. device is a unitary flexible thermal insulation
jacket for valves
and pipe fittings. The jacket is universal in the sense that it properly fits
valves and pipe
fittings of various manufacturers. It is secured snugly to a valve or pipe
fitting by attached
draw cords, rendering the jacket readily removable and reusable.
[0007] Still another attempt is found in United States Patent No. 4,925,605
issued
to Petronko on May 15, 1990 for a method of forming a heat foam insulation
jacket.
Petronko discloses a unitary removable and reusable jacket for the thermal
insulation of
pipe components. The fully-formed generally-rectangular jacket is composed of
three
layers: a heat and water resistant outer fabric layer, a hardened rigid-cell
polyurethane
middle layer, and a thin flexible heat-shrinkable plastic inner layer. The
inner and outer
layers are joined together by perimeter seams and a transverse center seam
which forms
two pockets adapted to contain the polyurethane foam middle layer. The inner
and outer
layers are formed at time of manufacture while the middle layer is formed
during the
application process. During the application process, an exothermic chemical
reaction is
generated by the combination of the chemicals polyol and isocyanate which are
inserted
between the inner and outer layers through holes contained in the outer layer,
to form a
rapidly expanding and hardening rigid cell polyurethane foam middle layer.
During the
application of the jacket around the accouterment, in response to the
exothermic
chemical reaction, the inner layer shrinks to fit the exact shape of the
underlying pipe, as
does the rigid-cell middle layer which is being formed. When installation is
complete, the
jacket may be removed and reused by using pressure to "crack" the transverse
seam
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dividing the middle layer into two pockets which are positioned on opposite
sides of the
accouterment.
[0008] Yet still another attempt is found in United States Patent No.
5,025,836
issued to Botsolas on June 25, 1991 for a pipe fitting cover for covering pipe
fitting. The
Botsolas device discloses a rigid or semi-rigid cover for installation over an
insulated pipe
fitting. The cover is pre-cut in the geometric design that enables it to
conform to the
shape of the pipe fitting when installed.
[0009] Still another attempt is found in United States Patent No. 5,713,394
issued
to Nygaard on February 3, 1998 for a reusable insulation jacket for tubing.
The Nygaard
device is a reusable single layer insulation jacket for splicing and
termination of industrial
tubing, fittings, and valves carrying extreme hot and cold materials comprises
a fiberglass
mat. The mat is of a width as to completely wrap the tubing, fitting, or valve
and overlap
itself. Releasable fastening means securely hold the mat in place to insulate
the tubing,
fitting, or valve from fire and to prevent an individual from otherwise being
burned from
contacting the tubing, fitting, or valve.
[0010] Further still another attempt is found in United States Patent No.
5,941,287
issued to Terito, Jr. et al. on August 24, 1999 for a removable reusable pipe
insulation
section. The Terito, Jr. et al. device discloses a removable reusable
insulating unit
suitable for insulating exposed pipe sections forming components of an
insulated pipe
system. The unit includes a hollow body constructed of an insulating material
which is
capable of being easily cut the hollow body defining an interior and an
exterior of the
insulating unit. The interior is sized to envelop an exposed pipe section on
an insulated
pipe system. The body has at least two pipe receptor areas and each is sized
to
accommodate a component of an insulated pipe system.
[0011] As well, another attempt is found in United States Patent No. 6,907,907
issued to Maida on June 21, 2005 for removable pipe valve insulation cover.
The Maida
device discloses a pipe insulation cover including a flexible planar and
generally
rectangular sheet having opposite long and short sides. Gathering structure is
connected
to each of the short sides, and releasably fastening structure is connected
along each of
the long sides of the flexible sheet. The long sides are releasably connected
together
after wrapping the sheet around pipe valve insulation, and the short sides are
gathered
around the pipe valve insulation by the gathering structure. This device does
not address
either use on chilled water pipe nor the exclusion of water vapor through the
use of tightly
sealed, low vapor permeance jacketing on the removable and reusable
insulation.
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[0012] The competing requirements of maintaining an enclosed insulation layer
yet enabling physical access for component maintenance has led to a variety of
insulation
devices to reduce thermal transference between the given insulated device or
apparatus
and the surrounding environment. The common aspect of such existing removable
insulation devices is that they are designed with a particular component in
mind and
shaped accordingly. That is to say, a typical insulative device for example
designed for a
valve is shaped in such a way that the device is rendered unsuitable for, by
example, a
flanged coupling or a steam trap. Oftentimes, in chilled fluid applications,
heat transfer
may be accompanied by undesirable vapor migration into, and condensation
within, the
thermal insulation systems; this can reduce insulative capacity from dampened
insulation
material. All these issues tend to drive up costs to the end user. Moreover,
an industrial,
institutional, and/or commercial user will be required to purchase several
different shapes
and sizes for the variety of components found within their system. This can be
an
unwieldy and costly solution.
[0013] It is, therefore, desirable to provide an insulation device that is
versatile
and cost-effective.
SUMMARY OF THE INVENTION
[0014] It is an object of the present invention to obviate or mitigate at
least one
disadvantage of previous insulation devices.
[0015] The present invention provides a versatile insulation in the form of a
segmented insulative device. Moreover, the segmented insulative device lends
itself to
quick customization on-site, rather than requiring costly off-site manufacture
or pre-
assembly and subsequent quick installation on the pipe component requiring
thermal
insulation. The segmented insulative device is designed for versatility
provided by the
device's embodiment within an installer's kit. The kit to fabricate the
segmented
insulative device includes a large rectangular sheet of segmented insulation,
a roll of
reusable fastening tape (e.g., two-sided "hook-and-loop" type such as Velcro
straps), a
cutting mechanism (e.g., scissors or retractable razor cutter) for cutting
suitably-sized
portions of both the segmented insulation sheet and the reusable fastening
tape, and a
fastener (e.g., stapler or similar fastening means) to connect a section of
the reusable
fastening tape to the custom-cut section of segmented insulation. A stapler
can be used
to attach the hook-and-loop tape to the insulative device to facilitate
installation and so
the two do not become later separated.
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[0016] An alternative embodiment of the present invention further includes a
low
permeance layer on the outer surface of the segmented insulation in
combination with a
low permeance, pressure-sensitive adhesive fastening tape in lieu of reusable
"hook-and-
loop" fastening tape. The insulation is segmented by way of internal stitching
arranged
throughout the underlying composite structure of the segmented insulative
device.
Moreover, such stitching does not penetrate either the low permeance layer on
the outer
surface of the segmented insulation or the low permeance adhesive fastening
tape.
Accordingly, the low permeance outer surface is adhered to the underlying
composite
structure of the segmented insulative device and, in turn, the low permeance
adhesive
fastening tape is adhered to any exposed outer surfaces of the segmented
insulative
device such that the low permeance characteristics of the overall segmented
insulative
device is not compromised by the stitching forming the segmenting.
[0017] In a first aspect, the present invention provides a segmented
insulative
device including: a first layer and a second layer each formed from a flexible
material, the
flexible material being resistant to moisture and heat; an inner layer of
flexible insulation
held between the first and second layers by way of stitching, the stitching
forming a cut-
site for separating the segmented insulative device into multiple sections;
and one or
more fastening mechanisms for securing one or more of the multiple sections to
a
component of a thermal distribution system.
[0018] In a further embodiment, there is provided a kit for on-site
fabrication of a
segmented insulative device, the kit including: a sheet of segmented
insulation capable of
separation into multiple sections; a reusable fastening tape capable of
securing one or
more of the multiple sections upon a component of a thermal distribution
system and later
being capable of being removed without damaging or altering the insulation
sheet; a
cutting mechanism capable of separating the sheet of segmented insulation into
the
multiple sections and resizing the reusable fastening tape; and a fastener
such as a
stapler capable of readily affixing the reusable fastening tape to a
corresponding one of
the multiple sections at the site.
[0019] In still a further embodiment, the fastening tape included is of a low
permeance, pressure-sensitive self-adhesive nature such that no further
fastener (e.g.,
either Velcro or stapler) is required. In this further embodiment, there is
provided a
segmented insulative device including: a first layer and a second layer each
formed from
a flexible material; an inner layer of flexible insulation held between the
first and second
layers by way of stitching, the stitching forming a cut-site for separating
the segmented
insulative device into multiple sections; one or more fastening mechanisms for
securing
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one or more of the multiple sections to a component of a thermal distribution
system, and
wherein at least one of the first or second layers and the one or more
fastening
mechanisms are fabricated from a material having low permeance sufficient to
substantially preclude water vapor penetration there through.
[0020] In this further embodiment, the stitching is precluded from penetrating
both
the outside low permeance layer and the one or more fastening mechanisms such
that
low permeance characteristics of the device is not compromised by the
stitching.
[0021] In the further embodiment, there is also provided a kit for on-site
fabrication of a segmented insulative device, the kit including: a sheet of
segmented
insulation including at least a first layer fabricated from a first material
having low
permeance sufficient to substantially preclude water vapor penetration there
through, the
sheet of segmented insulation capable of separation into multiple sections; a
pressure-
sensitive, adhesive fastening tape fabricated from a second material having
low
permeance sufficient to substantially preclude water vapor penetration there
through, the
adhesive fastening tape capable of both securing the multiple sections upon a
component
of a thermal distribution system and sealing the multiple sections against
water vapor
ingress; and a cutting mechanism capable of separating the sheet of segmented
insulation into the multiple sections and resizing the adhesive fastening
tape.
[0022] Other aspects and features of the present invention will become
apparent
to those ordinarily skilled in the art upon review of the following
description of specific
embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Embodiments of the present invention will now be described, by way of
example only, with reference to the attached Figures.
[0024] FIGURE 1 is an illustration showing one embodiment of the kit
components in accordance with the present invention.
[0025] FIGURE 2A illustrates a standard sized sheet of segmented insulation
and
detailing sewing patterns in accordance with the present invention.
[0026] FIGURE 2B is a cross-section taken across line 2B-2B in FIGURE 2A
showing composite layering.
[0027] FIGURE 3A is an illustration showing the segmented insulation sheet
cutting step using the kit elements as shown in FIGURE 1.
[0028] FIGURE 3B is an illustration showing the fastening tape cutting step
using
the kit elements as shown in FIGURE 1.
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[0029] FIGURE 3C is an illustration showing the fastening tape connection step
using the kit elements as shown in FIGURE 1.
[0030] FIGURE 3D is an illustration showing the fastening tape tab-creation
step
using the kit elements as shown in FIGURE 1.
[0031] FIGURE 3E is an illustration showing three custom assemblies of
differently-sized segmented insulative devices in accordance with the present
invention.
[0032] FIGURES 4A through 4E illustrate the step-by-step, on-site installation
of
the three differently-sized assemblies shown in FIGURE 3E as applied to a
valve
component.
[0033] FIGURE 5 is an illustration showing a low permeance embodiment of the
kit components in accordance with the present invention useful for a chilled
fluid
application.
[0034] FIGURE 6A is a cross-section similar to that of FIGURE 2B but shown in
terms of the low permeance embodiment of FIGURE 5.
[0035] FIGURE 6B is a cross-section of the dotted close-up portion of FIGURE
6A.
[0036] FIGURE 7 is an illustration showing a section of low permeance
segmented insulation during sizing of related pressure-sensitive adhesive
fastening tape
in accordance with the low permeance embodiment of FIGURE S.
[0037] FIGURE 8 is a simplified illustration showing a partially installed
custom
assembly of a low permeance segmented insulative device in accordance with the
alternative kit embodiment shown in FIGURE 5.
DETAILED DESCRIPTION
[0038] Generally, the present invention provides a segmented insulative device
and related kit for insulating certain serviceable components of a thermal
energy
distribution system. Although the invention will be described in terms of
insulation in high
temperature settings, it should be understood that the present invention is
equally useful
and suitable for insulating against heat loss from heat bearing systems (e.g.,
steam
distribution pipes) or heat gain to cooling systems (e.g., chilled water
distribution pipes).
The present invention provides a versatile, reusable, and cost-effective
insulative device
useful for a variety of pipe serviceable components and equipment including,
but not
limited to, flanges, valves, valve stems, and water circulation pumps. During
typical
maintenance of such components, the present invention ensures easy physical
access to
the particular component.
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[0039] With reference to FIGURE 1, there are illustrated the kit elements 10,
11,
11a, 12, and 13 in accordance with the segmented insulative device. The kit
shown is
used by an installer to fabricate the segmented insulative device on site and
typically
within an industrial, institutional, and/or commercial setting. The inventive
kit includes a
standard sized sheet of segmented insulation 10, a supply (e.g., roll 11) of
reusable
fastening tape 11a, a cutting mechanism 12, and a fastening device 13. More
specifically, the supply of reusable fastening tape is a roll 11 of suitably
dimensioned
(e.g., 1/2" to 2" wide and 10' to 20' long) two-sided hook-and-loop type
fastening tape 11a
such as, but not limited to, Velcro straps with the hooks on one side and the
loops on
the other. By use of the term "reusable," it should be understood that the
tape 11 a is self-
sealing or self-adhering in such a manner that it can be fastened, unfastened,
and
refastened many times over.
[0040] The cutting mechanism 13 may be a pair of scissors, retractable razor
cutter, utility knife, or any similarly durable cutting device suitable for
cutting both the
supply of fastening tape 11a and the sheet of segmented insulation 10. The
fastening
device 13 can be a stapler, rivet gun, or any similarly durable fastening
device suitable for
connecting a section of the reusable fastening tape 11a to a custom-cut
section of
segmented insulation 10. For illustrative clarity, a specific stapler 13, pair
of scissors 12,
and roll of hook-and-loop tape 11a are shown in FIGURE 1 though any suitable
substitutions may be made for these particular kit elements without straying
from the
intended scope of the present invention.
[0041] With regard to FIGURES 2A and 2B, detailed illustrations of the
segmented insulation are shown. FIGURE 2A is a top view of a standard sized
sheet 20
of the segmented insulation. The sheet 20 of segmented insulation resembles in
some
regard a quilted blanket in that uniform squares or rectangles are formed in a
grid pattern
across the sheet surface. Although a particular sized sheet is shown having
six grids in
width and twelve grids in length, it should be readily understood that any
particular width
and length may be produced without straying from the intended scope of the
present
invention.
[0042] Typically, the whole sheet 20 would be provided within the kit in a
rolled up
fashion. Limiting factors in terms of whole sheet dimensions may include the
length and
weight of any given rolled sheet of segmented insulation. Indeed, smaller
rolls may be
less difficult for an installer to carry through cramped quarters among
thermal piping,
though larger rolls may afford the installer more sizing variations.
Accordingly, ease of
use and portability are factors in determining a standard size for the rolled
sheet of
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segmented insulation and such standard may vary according to any given
industrial,
institutional, and/or commercial application. FIGURE 2A is therefore only one
example of
a standard size such that the sheet may alternatively be 4' x 8, 2' x 8' or
any desired
dimension. When considering the whole sheet and the given weight constraints
for any
particular application, it should also be understood that, for example, a 2' x
16' sheet
would weigh the same as 4' x 8'. Therefore, it should be readily apparent that
the whole
sheet of segmented insulation may be provided in a variety of standard sizes.
[0043] With regard to FIGURE 2B, a partial cross section is illustrated from
the
view taken along line 2B-2B in FIGURE 2A. The composite layering of the
segmented
insulation is visible here such that a middle layer 201 of insulation is
sandwiched between
two outer layers 200 of material that may be selected from heat resistant or
heat and
moisture resistant material. In practice, the two outer layers 200 would be
formed from
heat resistant material and either one or both layers may be coated with a
moisture
resistant coating depending upon the given implementation - e.g., a steam pipe
implementation within a damp environment may require would both layers 200 to
be
moisture and heat resistant whereas a steam pipe implementation within a
generally dry
environment may only require the layer adjacent the steam pipe to include
moisture
resistance. Thus heat and moisture resistance may vary in regard to the given
layer (i.e.,
"inner" or "outer" exposure) and related implementation without straying from
the intended
scope of the present invention.
[0044] The insulation may be any suitable insulative material including, but
not
limited to, fiberglass, aramid, silica, aerogel, or any other flexible
insulation material. In
the instance of fiberglass, suitable fiberglass insulation for the middle
layer 201 can
include a fiberglass manufactured and supplied with a density of between 1 and
2 pounds
per cubic foot and may be needled or bonded so as to partially compress the
insulation
and, in the process, to maximize its insulation value. The outer layers 200 of
moisture
and heat resistant material may be fabricated from any flexible material
suitable for
continuous exposure to temperatures up to and exceeding 500 degrees
Fahrenheit. The
outer layers 200 can include a base fabric capable of continuous use at 500
degrees
Fahrenheit having uncoated weights ranging between six and sixty ounces per
square
yard. Such base fabric may be, but not limited to, fiberglass material. As
well, such base
fabric may be coated with suitable heat resistant materials that may include,
but are not
limited to, high temperature coatings of heat resistant rubbers or silicone
compounds.
[0045] With further regard to FIGURE 2B, there are areas visible that are of
reduced thickness 20a. Such thinner areas 20a are formed by the parallel rows
of sewing
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thread 20b. This creates the aforementioned "quilted" characteristic, and more
importantly creates a cut-line guide for the installer. Such cut-line is the
center point
between the two parallel rows of sewing thread 20b. In another embodiment, a
third
sewn line may be provided at the center point between the two parallel rows of
sewing
thread 20b such that three rows of stitching are actually provided. In this
manner, the
cut-line would be the center stitching line. Preferably, an installer would
cut along such
center point in the field. However, the sewing thread 20b will remain intact
and prevent
loss of the flexible insulation 201 from between the two outer layers 200 so
long as the
installer cuts between the parallel rows of sewing thread 20b. That is to say,
minor
deviation from a cut along the center point is tolerable without straying from
the intended
scope of the present invention. This allows for imperfect field cutting
technique during
installation without any impact on the installed segmented insulative device.
[0046] It should be understood that the sewing thread used should be formed
from moisture and heat resistant material suitable for continuous exposure to
temperatures up to and exceeding 500 degrees Fahrenheit. Such suitable
materials may
include, but are not limited to, high temperature filaments. Possible filament
materials
include, but are not limited to, aromatic polyamides and fiberglass that may
be treated
with a polytetrafluoroethylene coating or any other suitable sewing thread
that will
withstand the temperatures of the given implementation.
[0047] Although FIGURE 2B shows only one layer of fiberglass 201 sandwiched
between two outer layers 200, it should be understood that any suitable
composite of
additional layers may be possible and preferable for different working
environments -
e.g., extreme humidity conditions. As well, multiple sections of segmented
insulation can
be used such that they are installed upon one another to create an increased
insulative
effect. In such instance, the multiple sections of segmented insulation can be
overlapped
in such a manner that staggers the thinner areas 20a compressed by the sewing
thread
20b.
[0048] As mentioned above, the sheet of segmented insulation 20 can be formed
in any standard size suitable for the given application. Likewise, the sewing
threads 20b
may be spaced such that the least-compressed areas in FIGURE 2B are generally
square or generally rectangular and formed in any suitable size - e.g., 4" x
4", 4" x 6", 8" x
8", ...etc. However, for most versatility it is preferable that the least-
compressed areas
are a square dimension of between 4" and 12". The segmented pattern
effectively means
that the segmented insulation 20 can be cut along the small separation 20a
between
sewing threads 20b so that there is minimal exposure of the inner insulation
201 and still
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provide a snug fit upon installation. The small section 20a between the sewing
threads
20b is variable upon initial manufacture. However, a range of between 0.5" to
1" is
preferable because larger values will leave more insulation 201 exposed and
would waste
materials, whereas smaller values would make fabrication more difficult.
[0049] The inventive aspects of the segmented insulative device formed by the
kit
elements 10, 11, 11a, 12, and 13 described with regard to FIGURES 1, 2A, and
2B
include the ease by which the segmented insulative device is installed,
uninstalled, and
reinstalled. This contributes to the invention's significant reusability and
related cost-
effectiveness. Installation using the kit elements 10, 11, 11a, 12, and 13
will now be
described with regard to FIGURES 3A through 3E in terms of preliminary sizing
and
FIGURES 4A through 4E in terms of actual installation technique. It should be
understood that these installation figures represent but one installation
example and
relate to a custom installation for an in-line valve 400, 401 of a generally
"T" shaped
configuration. Many other configurations and custom installations are possible
and will
become readily apparent to one of skill in the art upon consideration of the
installation
details herein below.
[0050] Preliminary to any installation, an installer 100 will measure the
portions of
the pipe and/or pipe component (e.g., valve 400, 401) desired to be covered by
the
segmented insulative device. Once measured, the installer 100 will translate
such
measurements to the portion(s) of the whole sheet of segmented insulation.
With regard
to FIGURE 3A, the installer 100 then uses the scissors 12 and proceeds with
cutting the
required portion(s) of the whole sheet 30 of segmented insulation. Once the
required
portion(s) 31 are cut, the installer 100 will then obtain a suitable length of
hook-and-loop
tape 11a as shown in FIGURE 3B from the roll 11 provided in the kit.
[0051] The cut length of hook-and-loop tape 11a is then fastened to the
required
portion(s) 31 of segmented insulation by the installer as shown in FIGURE 3C.
Fastening
of the hook-and-loop tape 11a can be accomplished staples via stapler 13. Such
staples
are preferably capable of use in high humidity/steam environment. To reduce
tangling
and also to provide a firmer hold for the installer 100, the loose end of the
hook-and-loop
tape may be doubled back and stapled to itself as shown in FIGURE 3D as
element 11b.
The resulting assortment of assembled and custom-sized sections 31, 32, 33 of
the
segmented insulative device are shown in FIGURE 3E prior to installation.
[0052] With regard to FIGURE 4A, the smallest section 31 of FIGURE 3E is
shown wrapped and strapped to the uppermost area 400 of the valve. The hook-
and-
loop tape 11a may be strapped either tightly or loosely around the section of
segmented
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insulative device depending on whether the installer intends for the valve to
be usable
without removal of the segmented insulative device. In FIGURE 4B, the
installer is
shown to wrap and strap the next largest section 32 of FIGURE 3E to the
slightly wider
base area of the valve. It should be understood from the figures that the hook-
and-loop
tape 11a is typically not in contact with the areas of highest temperature
which would be
adjacent or contacting the valve or pipe. As such, the hook-and-loop tape 11a
should be
capable of continuous use at temperatures less than 500 degrees Fahrenheit and
more
akin to 325 degrees Fahrenheit surface temperature.
[0053] In FIGURE 4C, the installer 100 is placing the largest section 33 of
FIGURE 3E into place around the in-line section 401 of the valve. In such
situation, it
should be noted that a better fit has been enabled by the installer 100
snipping several
inches into edges of the central seams of the largest section as shown as
element 33a.
This allows the lateral areas 33a of the largest section 33 to be held
securely by the hook-
and-loop tape 11a against the adjacent pipe insulation 402, 403 as seen in
FIGURE 4D.
Likewise, this also allows the valve base area of the largest section 33 to
overlap (at 33a)
the previously installed next smaller section 32 and to also be held securely
thereupon by
the hook-and-loop tape 11a as seen in FIGURE 4E.
[0054] Accordingly, this completed installation (illustrated by the example
seen in
FIGURE 4E) of the segmented insulative device by an installer using the kit in
accordance with present invention results in a cost-effective, removable, and
customizable manner of insulating thermal pipe components that is applicable
to many
different configurations and industrial, institutional, and/or commercial
applications.
Moreover, the installer by way of the present inventive kit has the ability to
measure, cut,
and install the segmented insulative device on-site without any need to return
to a
workshop for fabrication such as sewing or molding. In addition to the kit
components
described above, the kit may further include an installation manual and/or a
material
quantity estimating software program or manual worksheet.
[0055] As previously mentioned, high temperature systems and low temperature
systems may benefit from the implementation of the present invention. However,
in low
temperature systems such as a chilled water application or any similar coolant
piping
arrangement, there are unique associated problems. In particular, the
associated problem
of condensation of water vapor in low temperature systems can be a significant
concern
whereby insulation can become saturated with condensed water vapor from the
warmer
and often humid surrounding environment. In such situations, an alternative
sealed, low
permeance embodiment of the present invention is provided.
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[0056] FIGURE 5 shows an illustration including the low permeance embodiment
of the kit components in accordance with the present invention useful for a
chilled fluid
application. Here, there are illustrated the alternative kit elements 50, 51,
51a, and 52 in
accordance with a low permeance segmented insulative device. It should be
understood
that the low permeance characteristics of the inventive segmented insulative
device are
such that a contiguous barrier is formed on an outer surface of the segmented
insulative
device to preclude water vapor penetration. As in the earlier embodiment, the
kit shown
in FIGURE 5 is also used by an installer to fabricate this alternative
insulative device on
site and typically within an industrial, institutional, and/or commercial
setting. The
inventive kit includes a standard sized sheet of segmented insulation 50, a
supply (e.g.,
roll 51) of pressure-sensitive adhesive fastening tape 51a, and a cutting
mechanism 52.
More particular to this embodiment, the supply of this adhesive fastening tape
is a roll 51
of suitably dimensioned (e.g., 1" to 6" wide and 10' to 30' long) adhesive
fastening tape
51a which may include a peel-and-stick type of backing, with release paper,
for ease of
use
[0057] As before, the cutting mechanism 52 may be a pair of scissors,
retractable
razor cutter, utility knife, or any similarly durable cutting device suitable
for cutting both
the supply of adhesive fastening tape 51a and the sheet of segmented
insulation 50.
Because the tape 51a is self-adhesive, no further fastening device is required
in this
embodiment.
[0058] The alternative low permeance embodiment is segmented and generally
fabricated in the same manner shown in the previous embodiment (see FIGURES 2A
and
2B). However, FIGURE 6A reveals that layers 600 and 601 are made from
materials
which differ from one another. Specifically, layer 600 is formed from the same
water-
resistant, rubber-coated woven fiberglass fabric (as shown by layer 200 in
FIGURE 2B).
However, in this alternative embodiment layer 601 is formed from a low
permeance,
laminate sheet material. The laminate sheet material may be multi-ply having a
fabric
base and a low permeance overlay. For purposes of this alternative embodiment,
layer
600 is considered the "inner" layer which contacts the given chilled water
system device
being insulated and layer 601 is considered the "outer" layer which is exposed
to the
surrounding environment.
[0059] Although a single layer of insulation 602 is shown, it should also be
understood that more than one layer of internal insulation may be used in the
alternative
embodiment. Such multiple insulation layers would serve to assist in guarding
against
condensation.
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[0060] A further difference from the previous embodiment is that within this
alternative embodiment the adhesive fastening tape 51a is either a pressure
sensitive
tape fabricated from the same low permeance overlay material as found in layer
601 or
some other vapor retarder sheet material with a low permeance. The adhesive
fastening
tape 51a serves both to hold together the cut seams of segments cut from the
sheet of
segmented insulation 50 and also to seal the lap and butt joints at the cut
seams and any
other portions requiring tight sealing against one another. This assures an
outer surface
that is tightly sealed from water vapor intrusion. In this manner, the
majority of water
vapor in the surrounding environment is precluded from permeating the
insulation 602
sandwiched between layers 600 and 601. Moreover, this arrangement prevents
such
water vapor from reaching any chilled surface where condensation would occur.
If,
however, some condensation does nevertheless occur on the pipe, the inside
face of the
segmented insulation 50 is formed by water repellent layer 600 such that
absorption of
condensed water by the thermal insulation 602 is prevented.
[0061] As mentioned above, the low permeance characteristics of the inventive
segmented insulative device are such that a contiguous barrier is formed on an
outer
surface of the segmented insulative device to preclude water vapor
penetration. The
area indicated as 650 on FIGURE 6A is detailed in close-up view shown in
FIGURE 6B.
From the close-up illustration shown in FIGURE 6B, it should be readily
apparent that the
low permeance overlay 601a of layer 601 is adhered to fabric base 601b . after
the
stitching 700 is added, so that the stitching 700 does not penetrate the low
permeance
overlay 601a. In this embodiment, overlay 601a can have a pressure-sensitive
adhesive
that adheres it to the fabric base 601b, though it should be readily
understood that other
adhesion methods are possible without straying from the intended scope of the
present
invention. This arrangement assures that the low permeance characteristics of
the
barrier against water vapor intrusion are not compromised. In other words,
this
alternative embodiment requires that layer 601 is a multi-ply laminate sheet
that includes
an interior fabric base 601b and an exterior low permeance layer that is
adhered or
otherwise affixed to the interior fabric base 601b. The interior fabric base
601b may be
formed from any suitable material including, but not limited to, a fiberglass
mesh.
[0062] It should further be understood that the stitching 700 is only provided
through the layer 600, the inner layer of insulation 602, and the interior
fabric base 601b.
Thereafter, the low permeance overlay 601a of the laminate that forms the
layer 601 is
thus adhered or otherwise affixed atop the stitching exposed upon the interior
fabric base
601b. In this manner, no water vapor is allowed as no holes are created by
stitching as
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CA 02735115 2011-03-29
no stitching perforates the low permeance overlay 601a. Accordingly, once the
adhesive
tape 51a is provided upon the low permeance overlay 601a along any abutting or
overlapping seams, then a contiguous outside low permeance barrier is provided
against
ingress of water vapor. Further, should any punctures of the low permeance
overlay
601a accidentally occur during or after installation, they may be easily
repaired with a
small piece of the pressure-sensitive adhesive tape. This construction assures
that the
low permeance of the barrier is not compromised by penetratration during the
segmenting
(i.e., quilting) process which is beneficial with regard to low permeance
integrity of the
insulative system and the economics of the inventive system. It should further
be readily
apparent that both the low permeance overlay 601a of layer 601 and the
adhesive
fastening tape 51a are formable from the same pressure-sensitive adhesive tape
with a
peelable release paper to render both "peel-and-stick."
[0063] As is readily apparent from the figures, the particular segmentation
arrangement shown in FIGURE 2A and cutting capability shown in FIGURE 3A with
regard to the previous embodiment are equally applicable to the alternative
low
permeance embodiment without straying from the intended scope of the present
invention
and similar cutting and segmenting techniques as detailed hereinabove are
applicable to
this alternative embodiment. However, the steps for fastening cut segment
portions of
the segmented insulation are simplified such that only the adhesive fastening
tape 51a is
required to secure the cut segment portions in any desired configuration. Once
a portion
of adhesive fastening tape 51a is measured out and cut to the desired length
as is shown
in FIGURE 7, then the installing individual can proceed directly to applying
the cut
segment 70 to a chilled element (e.g., coupling as shown in FIGURE 8) and
securely
sealing such cut segment with the adhesive fastening tape 51a. As mentioned,
this forms
a contiguous vapor resistant outer barrier whereby the low permeance material
of the
tape 51a is a contiguous surface with the outer layer 601.
[0064] It should be understood that the adhesive tape may be easily removed by
a user so as to remove the installed low permeance segmented insulation for
access to
the underlying device (e.g., chilled water valve). Thereafter, either the same
piece of
adhesive tape may be reused or a new piece of adhesive tape may be cut to
length so as
to reinstall the same section of low permeance segmented insulation. This is
facilitated
by the adhesive tape being able to adhere to a preceding layer of adhesive
tape. In this
manner, the overall invention is generally considered to be reusable while
specifically the
adhesive tape may or may not be reusable, depending on its physical condition
after
removal. Indeed, should a user decide to use a new piece of adhesive tape,
then
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CA 02735115 2011-03-29
removal may be limited to cutting the existing adhesive tape along the covered
seam or
abutment.
[0065] The above-described embodiments of the present invention are intended
to be examples only. Alterations, modifications and variations may be effected
to the
particular embodiments by those of skill in the art without departing from the
scope of the
invention, which is defined solely by the claims appended hereto.
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