U.S. patent application number 14/132763 was filed with the patent office on 2015-06-18 for methods and systems for jacket joints.
This patent application is currently assigned to ILLINOIS TOOL WORKS INC.. The applicant listed for this patent is ILLINOIS TOOL WORKS INC.. Invention is credited to Johnny Dale Angel, James Martin Roberts.
Application Number | 20150167887 14/132763 |
Document ID | / |
Family ID | 51730565 |
Filed Date | 2015-06-18 |
United States Patent
Application |
20150167887 |
Kind Code |
A1 |
Roberts; James Martin ; et
al. |
June 18, 2015 |
METHODS AND SYSTEMS FOR JACKET JOINTS
Abstract
A system comprising a protective jacket for insulating pipe is
provided. The protective jacket comprises a first metal shell
comprising an interior surface and an exterior surface, wherein the
interior surface comprises a moisture protective coating, and the
exterior surface comprises a film adhered to the exterior surface
by an adhesive, and wherein the adhesive provides for a toolless
removal of the film.
Inventors: |
Roberts; James Martin;
(Houston, TX) ; Angel; Johnny Dale; (Houston,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ILLINOIS TOOL WORKS INC. |
Glenview |
IL |
US |
|
|
Assignee: |
ILLINOIS TOOL WORKS INC.
Glenview
IL
|
Family ID: |
51730565 |
Appl. No.: |
14/132763 |
Filed: |
December 18, 2013 |
Current U.S.
Class: |
138/158 ;
138/177; 29/424; 29/458; 72/46 |
Current CPC
Class: |
Y10T 29/49885 20150115;
B32B 7/10 20130101; B32B 1/08 20130101; B21D 49/005 20130101; B32B
15/08 20130101; B21D 47/04 20130101; F16L 59/103 20130101; B32B
7/06 20130101; F16L 59/106 20130101; F16L 59/22 20130101; F16L
59/168 20130101; Y10T 29/49812 20150115 |
International
Class: |
F16L 59/02 20060101
F16L059/02; B21D 49/00 20060101 B21D049/00; B21D 47/04 20060101
B21D047/04 |
Claims
1. A system comprising: a protective jacket for insulating pipe,
wherein the protective jacket comprises: a first metal shell
comprising an interior surface and an exterior surface, wherein the
interior surface comprises a moisture protective coating, and the
exterior surface comprises a film adhered to the exterior surface
by an adhesive, and wherein the adhesive provides for toolless
removal of the film.
2. The system of claim 1, wherein the first metal shell comprises a
geometric shape having a fillet at a junction of one or more
fingers.
3. The system of claim 1 wherein the first metal shell comprises an
aluminum alloy, a stainless steel, a zinc, an aluzinc, a galvanized
metal, or a combination thereof.
4. The system of claim 1, wherein the moisture protective coating
comprises a polysurlyn.
5. The system of claim 1, wherein the film comprises a
polyethylene, a polypropylene, a plastic, a vinyl, a polymer, or a
combination thereof.
6. The system of claim 1, wherein the adhesive comprises an acrylic
adhesive, a water-based adhesive, a medium-tack adhesive, or a
combination thereof.
7. The system of claim 1, wherein the first metal shell comprises a
first finger formed at least about 0.5 inches from a second finger
to accommodate banding.
8. The system of claim 1, comprising a second metal shell having
substantially similar dimensions as the first metal shell, wherein
the protective jacket comprises the first and the second metal
shells fastened to each other.
9. The system of claim 8, comprising a strap fastening the first
metal shell to the second metal shell.
10. The system of claim 1, wherein the protective jacket comprises
an angled jacket, a tee junction jacket, or a combination
thereof.
11. A method for manufacturing a protective jacket for insulating
pipe, the method comprising: manufacturing a first metal shell,
wherein manufacturing the first metal shell comprises: applying a
moisture protective coating to a first surface of a metal sheet;
applying a film to a second surface of the metal sheet using an
adhesive, wherein the adhesive provides for toolless removal of the
film; and forming the metal sheet into a shape configured to follow
contours of the pipe.
12. The method of claim 11, wherein forming the metal sheet
comprises disposing the metal sheet between a male mold having the
shape and a female mold conforming to the male mold, and applying a
pressure suitable to insert the male mold into the female mold.
13. The method of claim 11, comprising manually removing the film
before shipping the first metal shell, or manually removing the
film after shipping the first metal shell.
14. The method of claim 11, wherein forming the metal sheet
comprises forming the metal sheet into an elbow joint shape having
an angle of between approximately 45.degree. and approximately
150.degree., or forming the metal sheet into a tee junction
shape.
15. The method of claim 11, comprising manufacturing a second metal
shell having a substantially similar geometry as the first metal
shell, and joining the first and second metal shells together.
16. The method of claim 15, wherein the first and second metal
shells overlap at a seam.
17. The method of claim 11, wherein the film comprises a
polyethylene, a polypropylene, a plastic, a vinyl, a polymer, or a
combination thereof, and the adhesive comprises an acrylic
adhesive, a water-based adhesive, a medium-tack adhesive, or a
combination thereof.
18. A method for manufacturing a protective jacket for insulating
pipe, the method comprising: manufacturing a metal shell, wherein
manufacturing the metal shell comprises: applying a moisture
protective coating to a first surface of a metal sheet; applying a
film to a second surface of the metal sheet using an adhesive,
wherein the adhesive provides for toolless removal of the film; and
using a male mold and a female mold to form the metal sheet into a
shape configured to follow contours of the pipe by press or punch
molding.
19. The method of claim 18, comprising manually removing the film
before shipping the metal shell, or manually removing the film
after shipping the metal shell.
20. The method of claim 18, wherein the film comprises a
polyethylene, a polypropylene, a plastic, a vinyl, a polymer, or a
combination thereof, and the adhesive comprises an acrylic
adhesive, a water-based adhesive, a medium-tack adhesive, or a
combination thereof.
Description
BACKGROUND
[0001] The present disclosure relates generally to methods and
systems for improved metal insulation jacket joints.
[0002] A wide range of industrial, commercial, residential and
other applications may provide for conduits (e.g., pipes) insulated
with fiberglass or other materials. The insulated conduits may then
be covered in a protective jacket for preserving and protecting the
insulation material and underlying conduits. In linear conduits,
the protection may entail wrapping the conduit with a protective
material, such as aluminum sheeting. In angled or bent conduits
(e.g., elbow joints), aluminum sheeting may also be used but,
because of the angled geometry, it may be beneficial to use
aluminum sheeting having a geometry that more comformably follows
the angles of the conduit, such as jacket joints. Similar jacket
joints may be used for tee (e.g., "T") junctions.
[0003] The jacket joints may include two symmetrical metal portions
(e.g., "shells") that may follow a desired angled geometry (e.g.,
90.degree. elbow). The two shells may be placed opposite each other
and covering a desired angled conduit. The shells may then be
secured in place, for example, by screws, by securing the shells
with one or more metal bands or strips, and/or by using other
fastening techniques. The installed shells may then provide
protection against external elements (e.g., dust, fluids, and so
forth), inadvertent contact, and so forth, of the conduit and its
overlaying insulation. It may be useful to improve the manufacture
and installation of jacket joints.
BRIEF DESCRIPTION
[0004] Present embodiments are designed to respond to such a need.
In accordance with a first embodiment, a system comprising a
protective jacket for insulating pipe is provided. The protective
jacket comprises a first metal shell comprising an interior surface
and an exterior surface, wherein the interior surface comprises a
moisture protective coating, and the exterior surface comprises a
film adhered to the exterior surface by an adhesive, and wherein
the adhesive provides for a toolless removal of the film.
[0005] In another embodiment, method for manufacturing a protective
jacket for insulating pipe is provided. The method comprises
manufacturing a first metal shell. The manufacturing the first
metal shell includes applying a moisture protecting coating to a
first surface of a metal sheet and applying a film to a second
surface of the metal sheet by using an adhesive, wherein the
adhesive provides for a toolless removal of the film. The
manufacturing the first metal shell additionally includes forming
the metal sheet into a shape configured to follow contours of the
pipe.
[0006] In a further embodiment, a method for manufacturing a
protective jacket for insulating pipe comprises manufacturing a
first metal shell. The manufacturing the first metal shell includes
applying a moisture protecting coating to a first surface of a
metal sheet and applying a film to a second surface of the metal
sheet by using an adhesive, wherein the adhesive provides for a
toolless removal of the film. The manufacturing the first metal
shell additionally includes using a male and a female mold to form
the metal sheet into a shape configured to follow contours of the
pipe by press or punch molding.
DRAWINGS
[0007] These and other features, aspects, and advantages of the
present disclosure will become better understood when the following
detailed description is read with reference to the accompanying
drawings in which like characters represent like parts throughout
the drawings, wherein:
[0008] FIG. 1 is a top view of an embodiment of a metal sheet used
in manufacturing an insulation jacket;
[0009] FIG. 2 is a side view of an embodiment of single layer film
and a moisture protective coating disposed on the metal sheet of
FIG. 1;
[0010] FIG. 3 is a side view of an embodiment of multiple layer
film and a moisture protective coating disposed on the metal sheet
of FIG. 1;
[0011] FIG. 4 is a top view of an embodiment of a metal sheet as
shown in FIGS. 2 and 3 with a separation line superimposed onto the
sheet;
[0012] FIG. 5 is a top view of an embodiment of a metal sheet
separated into two components;
[0013] FIG. 6 is a perspective view of embodiments of angled molds
used in manufacturing angled insulation jackets;
[0014] FIG. 7 is a perspective view of embodiments of angled jacket
shells;
[0015] FIG. 8 is a perspective view of an embodiment of an
insulation jacket;
[0016] FIG. 9 is a perspective view of embodiments of molds used in
manufacturing tee junction insulation jackets;
[0017] FIG. 10 is a perspective view of embodiments of tee junction
jacket shells;
[0018] FIG. 11 is a perspective view of an embodiment of a tee
junction insulation jacket; and
[0019] FIG. 12 is a flow chart of an embodiment of a process
suitable for manufacturing insulation jackets.
DETAILED DESCRIPTION
[0020] The present disclosure provides improvements to the
manufacturing and installation of jacket joints. The techniques
described herein are based upon the use of a single- or
multi-layered protective sheet disposed on an exterior surface of
shell portions suitable for protecting sheet metal during jacket
manufacturing and installation. By disposing the protective sheet
on the exterior surface, the jacket may be manufactured without
applying an external coating (e.g., paint), thus improving
manufacturing time and decreasing cost. Before (or during)
installation of the jacket onto the conduit, the protective sheet
may be removed, for example, by hand, leaving a substantially
scratch-free outer surface. Indeed, toolless removal of the
protective sheet is provided, thereby improving installation times.
In certain embodiments, the use of metal that is galvanically
compatible with linear conduits is also provided. That is, the
angled conduit (e.g., elbow joint) may be coupled to a linear
conduit (e.g., straight pipe) so that the resulting combination
includes a metal composition that minimizes or eliminates galvanic
corrosion. In one embodiment, the jacket may include a polymeric
coating on an interior surface, such as a multilayer polysurlyn
moisture barrier, particularly useful for minimizing or eliminating
corrosion in the interior of the jacket. By providing for an
interior polysurlyn-based coating, and exterior protective film
coating in lieu of painted coatings, the embodiments described
herein may provide for increased operational life with improved
manufacturing and installation efficiencies.
[0021] Turning now to the drawings, and referring first to FIG. 1,
an embodiment of a metal plate or sheet 10 used in manufacturing an
insulation jacket is shown. Insulating and/or covering linear pipe
with metal is relatively simple: a flat metal sheet is wrapped
concentrically around the linear cylindrical portion of pipe and
secured with a banding (e.g., strap) or fasteners. Linear portions
of pipe may be covered with, for example, 1000 or 3000 series
aluminum. Protecting the turns and bends in the pipe, such as at
angled portions, tees, or elbows, can be difficult, however. Corner
or elbow portions of pipes may be covered using softer or more
malleable metal to facilitate wrapping around the "bent" portion.
However, the use of dissimilar metals may lead to galvanic rusting,
and the wrapping may not comformably fit the bends. The techniques
described herein provide for metal sheets that may be formed into
metal jackets to incorporate desired geometries or bends, and that
may use the same metal type used in protecting linear conduits. In
certain embodiments, an inner surface 12 may be coated with a
thermally protective coating, such as polysurlyn. Accordingly, the
inner surface 12 may be disposed facing pipes carrying hot liquids
or gases and provide for longer life and increased protection. An
outer surface 14 may be protected during manufacturing (and
shipping) by using a protective film, as described in more detail
below with respect to FIG. 2. Accordingly, an improved insulating
jacket joint may be provided.
[0022] FIG. 2 is a side view of the metal sheet 10 of FIG. 1
depicting details of a polysurlyn coating 16 and a film 18 applied,
for example, before forming of the metal sheet 10. Before the
techniques described herein, the outer surface 14 of the metal
sheet 10 may have had a protective coating, such as paint, applied.
The paint may then protect the metal sheet 10, for example, from
scratches and additional abrasions that may occur during the
remainder of the forming process. The techniques described herein
replace the protecting coating with the protective film 18. Indeed,
the film 18 may be applied in lieu of any coating and may suitably
withstand various manufacturing processes, including forming of the
metal sheet 10 by using hydraulic presses. Further, the film 18 may
be removed manually after manufacturing of the jacket shell without
the use of special tools, either before shipping a completed jacket
shell or before installation of the jacket shell onto a pipe.
[0023] In the depicted embodiment, the film 18 is applied by using
an adhesive layer 20. In one embodiment, the film 18 may include a
polyethylene, a polypropylene, a plastic, a vinyl, a polymer, or a
combination thereof. The adhesive layer 20 may include an adhesive
such as acrylic-based adhesives, water-based adhesives, and/or
other adhesives that may provide for medium-tack adhesion. These
types of adhesives may provide a secure attachment of the film 18
to the sheet 10 but additionally enable substantially all of the
adhesive layer 20 to remain with the film 18 when the film 18 is
manually removed from the metal sheet 10, for example, by grasping
a corner of the film 18 between the thumb and forefinger and
pulling outwardly from the metal sheet 10. Accordingly, minimal or
almost no cleaning of the outer surface 14 may be needed once the
film 18 has been removed.
[0024] Also depicted are further details of the polysurlyn coating
16 disposed on the inner surface 12. More specifically, the
polysurlyn coating 16 may include a low density polyethylene (LPDE)
layer 22, a Surlyn.RTM. layer 24, and a high density polyethylene
layer 26. The layers 22, 24, 26 may be coextruded and used to
provide for protection against pitting, crevice, and/or galvanic
corrosion. It is to be understood that the cross sections shown in
FIGS. 2 and 3 are not to scale. By way of example only, each of the
three layers 22, 24, 26 may have a thickness of approximately 0.5
to approximately 2.5 mils, the metal sheet 10 may have a thickness
of between approximately 8 and approximately 30 mils, and the film
and adhesive layers may together have a thickness of between
approximately 0.5 and approximately 2.5 mils. It is also to be
noted that in other embodiments, such as the embodiment shown in
FIG. 3, multiple plys of film may be used. For example, FIG. 3
depicts the use of a multiple ply film 28 having a first ply 30 and
a second ply 32. Adding multiple plys 30, 32 may provide for
improved durability of the film 28 during the manufacturing of the
jackets. Because FIG. 3 includes like elements of FIG. 2, the like
elements are depicted using like numbers.
[0025] FIG. 4 is a perspective view of an embodiment of the metal
sheet 10 having the protective film 18 or 28 disposed onto the
outer surface 14 of the metal sheet 10. As mentioned above, the
metal sheet 10 may include the film 18 or 28 suitable for the
protection of the metal sheet 10 as it undergoes manufacturing
processes. In FIG. 4, a cut line 34 is depicted, useful in cutting
or otherwise partitioning the metal sheet 10 into two components as
shown in more detail with respect to FIG. 5. Indeed, the metal
sheet 10 may be cut into two or more pieces or portions, even when
the metal sheet 10 includes the films 18 and/or 28. The films 18
and/or 28 may protect the outer surface 14 of the metal sheet 10
during the cutting operation, reducing or eliminating scratching
and marring. A number of techniques may be used to cut the metal
sheet 10 into portions 36, 38. For example, rotary cutters, press
cutters, metal shears, and so on, may be used to divide the metal
sheet 10 into the portions 36, 38. Accordingly, the protective
films 18, 28 may provide for protection against scratches,
inadvertent abrasions, and inadvertent contact of the metal sheet
10 against undesired surfaces. The portions 36, 38 may then be
shaped into a desired geometry, for example, angled geometries and
t-shaped geometries as described in more detail below with respect
to FIG. 6.
[0026] FIG. 6 is a perspective view of an embodiment of a mold 40
suitable for manufacturing improved insulation jackets having
angled geometries. In the depicted embodiment, the mold 40 includes
a female mold 42 and a male mold 44. The male mold 44 has a
generally semi-circular cross-section 46 and two or more fingers
48a, 48b. In one embodiment, the fingers 48a and 48b may be formed
at least 0.5 inches from each other, or between 0.1 and 1.5 inches
from each other, for example, to more comformably provide for
angles .alpha.. Each of the fingers 48a, 48b may defines
fillet-forming areas 50, 52 at a junction of the fingers 48a, 48b
and a base 54 of the mold 40. The female mold 42 corresponds to the
male mold 44 and may be used to form the improved insulation
jacket. For example, the female mold 42 includes receptacles 56a,
56b that may accept the fingers 48a, 48b, respectively, when the
male mold 44 is inserted into the female mold 42, for example, in a
direction 60.
[0027] In one embodiment, each of the portions 36, 38 may be press
or punch molded by using the mold 40. The press or punch operation
may apply forces of between approximately 0.25 and approximately 1
ton per square foot, or more. For example, each portion 36, 38 may
be placed onto the bottom end 62 of the female mold 42 and the male
mold 44 may then be pressed in the direction 60 to transform the
portions 36, 38 into shells 64, 66, shown in FIG. 7, and excess
sections 68, 70, 72 of the portions 36, 38 may be cut off or
otherwise removed. The films 18, 28 may protect the outer surface
14 of the metal sheet 10 from marring, scratching, or more
generally, undesired surface defacement that may have otherwise
occurred during the pressing operation. Indeed, the films 18, 28
may provide for surface defacement protection during the remainder
of manufacture of the insulation jackets.
[0028] As shown in FIG. 7, the films 18, 28 may cover the shells
64, 66, including assorted geometric features, including raised
ridges 80a, 80b conforming to the fingers 48a, 48b of the mold 40,
and an angle .alpha. conforming to a desired angle of a bent
conduit or pipe (e.g., between approximately 45.degree. and
approximately 150.degree.). In one embodiment, the shells 64, 66
may have the films 18 or 28 removed before shipping. For example, a
corner 82 of the films 18 and/or 28 may be grasped between the
thumb and forefinger and pulled outwardly from the shells 64 and/or
66. Once the films 18 and/or 28 have been removed, the shells 64,
66 may include outer surfaces 14 substantially free of scratches,
marring and defacements.
[0029] It is to be noted that the shells 64, 66 may be shipped with
the films 18 and/or 28 still attached. The films 18 and/or 28 may
then protect the shells 64, 66 from marring or scratching that may
occur during shipment. Once the shells 64, 66 arrive at a desired
assembly site, the shells 64, 66 may be used to insulate or
otherwise cover an angled conduit, as shown in FIG. 8. More
specifically, FIG. 8 depicts a perspective view of an assembled
insulation jacket 84 having raised ridges 80a, 80b after assembly
of the shells 64, 66.
[0030] In the depicted embodiment of FIG. 8, the shells 64, 66 are
shown secured to each other using fasteners 86 and a strap 88. More
specifically, the shell 66 is shown as overlapping the shell 64,
thus resulting in a generally gapless seam 90. It is to be
understood that, in other embodiments, the shell 64 may overlap the
shell 66. The strap 88 may be manufactured to be compatible with
the jacket 84 material so as to minimize or eliminate galvanic
corrosion. Accordingly, the strap 88 may be manufactured from
plastics, fiber-reinforced material (e.g., carbon fiber), and/or
the same metal composition used in manufacturing the shells 64, 66.
The techniques described herein may be used to manufacture other
jacket types, such as tee junction jackets described in more detail
below with respect to FIG. 9.
[0031] FIG. 9 is a perspective view of a mold 92 having a female
mold 94 and a male mold 96 suitable for manufacturing tee junction
jackets. As mentioned above with respect to the mold 40 described
in FIG. 6, the films 18, 28 may protect the outer surface 14 of the
metal sheet 10 from marring, scratching, or more generally,
undesired surface defacement that may have otherwise occurred
during mold pressing or punch molding operations. For example, a
portion 36 or 38 may be disposed so that the male mold 96 is
pressed or punched onto the female mold 94 in a direction 98. The
press or punch operation may apply forces of between approximately
0.25 and approximately 1 ton per square foot or more, and the films
18, 28 may suitably protect the portions 36, 38 from undesired
marring and scratching. Once molded, the portions 36, 38 may more
suitably conform to tee junction shapes, as depicted in FIG.
10.
[0032] FIG. 10 depicts tee junction shells 100, 102 that may have
been manufactured from portions 36, 38 respectively. In the
depicted embodiment, the shells 100, 102 may still include the
protective films 18 and/or 28. As mentioned above, the protective
films 18, 28 may be left disposed onto the shells 100, 102 during
the manufacturing process, and may additionally be used to protect
the shells 100, 102 during shipment. By using the films 18, 28
during manufacturing of the shells 100, 102, a substantially
scratch-free outer surface 14 may be provided. The shells 100, 102
may then be fastened our otherwise joined to each other, as shown
in FIG. 11, to manufacture a tee junction jacket 104. In the
depicted embodiment, fasteners 86 (e.g., screws) are used to join
the shells 100, 102 together. Also depicted is a gapless seam 106
that may result from the shell 100 slightly overlapping the shell
102, or vice versa. In other embodiments, adhesives, bonding
agents, and the like, may be used to secure the shells 100, 102 to
each other.
[0033] FIG. 12 is a flow chart of an embodiment of a process 108
suitable for manufacturing the various jacket systems and
components described above. The process 108 may be implemented by
using computer instructions stored in a computer readable medium,
such as a memory of a controller, and executable by the controller.
In the depicted embodiment, the process 108 may first apply (block
110) a moisture protective barrier, such as a surlyn barrier (e.g.,
multilayer polysurlyn moisture barrier) to the interior surface 12
of the metal sheet 10 portions 36 and/or 38. The process 108 may
then apply (block 112) the protective film 18 or 28 onto the outer
surface 14 of the portions 36 and/or 38. The film 18 or 28 with the
adhesive layer 20 may be press rolled or otherwise disposed onto
the outer surface 14. As mentioned earlier, the protective films 18
and 28 may suitably protect the portions 36 and/or 38 from further
marring during manufacturing. Accordingly, the portions 36 and/or
38 may be formed (block 114) into the shells 64, 66, 100, 102 by
using, for example, the molds 40, 92.
[0034] The forming (block 114) into shells 64, 66, 100, 102 may
include press or punch molding, for example, at forces of between
approximately 0.25 and approximately 1 ton per square foot, or
more. The films 18 and 28 may deform plastically during the forming
operation (block 114), but may suitably protect the outer surface
14 from scratching or marring. Any excess material may then be
removed (block 116), for example, by cutting. In one embodiment,
the films 18 and 28 from the completed shells 64, 66, 100, 102 may
then be removed. For example, by grasping a corner of the film 18
or 28 between the thumb and forefinger and pulling outwardly away
from the outer surface 14. In another embodiment, the completed
shells 64, 66, 100, 102 may be shipped with the films 18 and 28
included for further protection during shipping. The films 18 or 28
may then be removed (block 118) prior to installation of the shells
64, 66, 100, 102.
[0035] The process 108 may then join or assemble (block 120) the
shells 64, 66, 100, 102 into corresponding angled jackets 84 and/or
tee junctions 104. As mentioned above with respect to FIGS. 8 and
11, fasteners 86 and/or straps 88 may be used to join the shells
64, 66, 100, 102 to assemble the jackets 84, 104. The jackets 84,
104 may then insulate and protect underlying conduit joints, such
as angled joints and tee-junction joints.
[0036] While only certain features of the invention have been
illustrated and described herein, many modifications and changes
will occur to those skilled in the art. It is, therefore, to be
understood that the appended claims are intended to cover all such
modifications and changes as fall within the true spirit of the
invention.
* * * * *