EE01662U1 - Method for manufacturing a pre-cut insulation cover installation kit - Google Patents

Abstract

The invention relates to a method for making a pre-cut insulation cover installation kit. The insulation cover details 2, 3, 4, 5, 6, 7 are cut from the insulation material sheet 1, where the contour lines of the insulation cover details 2, 3, 4, 5, 6, 7 are distributed on the insulation material sheet 1 so that the contour lines of these details do not overlap. Then, the contour lines of the details of the insulation covers are cut at least partially into the thickness of the insulation material sheet 1 so that the said details can be separated from the insulation material sheet for use by tearing. A sheet of insulation material cut with the contour lines of the details of the insulation covers is preferably rolled and packaged.

Description

 Technical field

The invention relates to the manufacture of insulation coatings and a corresponding installation kit for pre-cut insulation coatings, such as a noise reduction mat or thermal insulation mat installation kit. Such an installation kit is intended for insulating pipes and pipe fittings, as well as for covering equipment housings, vehicles and other equipment parts with thermal insulation mats.

State of the art

When installing insulation covers on pipe fittings, such as elbows, T-fittings, etc., one option is to cut out the insulation cover details on site by hand drawing or using a template from a sheet of insulation material. However, this installation method is extremely time-consuming and wastes insulation material, as it depends on the skills of the cutter to optimally place the shapes of the different details on the sheet of insulation material. Since the cutting out is done by hand, the details are not of the same shape and size, which results in a lot of scrap.

According to another common variant, the insulation cover details are cut out of the insulation material sheet by machine (with a die or cutting knife) and the finished cut-out insulation cover details are stacked and packaged. At the installation site, the necessary insulation cover details are taken from the packaging and glued to the pipe elbows. In this solution, it is necessary to deliver the corresponding insulation cover details separately for several pipe connections of different diameters to the installation site. In addition, some insulation cover materials cannot withstand stacking on top of each other, as the lower details deform under the weight of each other and become unusable.

An insulating mat for wrapping around a pipe fitting is known from German patent application DE3517235A1. In this solution, a rectangular insulating mat is cut to size and divided by two parallel straight cuts into an S-shaped insulating piece, which is wrapped around the pipe fitting to be insulated and fixed thereto.

This shape of the insulation detail does not always allow the insulation mat to be installed tightly against the pipe fitting to be insulated in the same way, as the position of the insulation detail on the pipe fitting depends on the installer's skill and choices when installing the insulation detail.

A kit comprising a segmented insulation mat is known from United States patent application US2011020579A1. The kit comprises a segmented insulation mat sheet formed from a segmented, flexible, pre-sewn layer of insulation material that can be easily cut to size at the installation site with scissors, a knife or other suitable cutting device.

The kit also includes a mounting strap equipped with a Velcro fastener, which is attached to the segment with a clip, after which the segments are fixed to the pipe fitting to be insulated with said mounting strap.

Also in this solution, the position of the insulation on the pipe fitting depends on the skill of the installer and the choices made when installing the insulation. It is also always necessary to cut the insulation mat to size, which causes material loss and in which case the quality of the final result depends on the accuracy of the cut to size and the skill of the installer.

Therefore, there is a need for an installation kit for insulation cover parts that would ensure that the insulation cover parts are not damaged during delivery and that they are easy to handle at the installation site.

The essence of the invention

The present invention provides a method for manufacturing a pre-cut insulation cover installation kit and an insulation cover installation kit.

In the method according to the invention, to produce a pre-cut insulation cover installation kit, insulation cover details are cut from a sheet of insulation material.

The method includes steps in which the contour lines of the insulation covering details are placed on the sheet of insulation material so that the contour lines of these details do not overlap.

Then, the contour lines of the insulation covering details are cut at least partially into the thickness of the sheet of insulation material, and the sheet of insulation material cut along the contour lines of the insulation covering details is packaged.

According to the first embodiment of the invention, a sheet of insulation material cut along the contour lines of the insulation cover details is rolled into a roll before packaging.

According to a second embodiment of the invention, at least one other sheet of insulation material cut along the contour lines of the insulation covering details is stacked on the sheet of insulation material cut along the contour lines of the insulation covering details before packaging.

According to a third embodiment of the invention, the contour lines of the insulation covering details are cut into the thickness of the sheet of insulation material so that the contour line includes a section not completely cut through the thickness of the material, which is intended to hold said details in place in the sheet of insulation material.

According to a fourth embodiment of the invention, the contour lines of the insulation covering details on the sheet of insulation material are cut into the thickness of the sheet of insulation material so that the contour line alternately includes sections partially cut into the thickness of the sheet of insulation material and sections completely cut through the thickness.

According to the fifth embodiment of the invention, the contours of the insulation covering details on the sheet of insulation material are cut into the thickness of the sheet of insulation material so that said contour lines are cut into the thickness of the sheet of insulation material to at least 95% of the thickness of the sheet of insulation material.

According to the sixth embodiment of the invention, contour lines of insulation coating details of different shapes are placed on a sheet of insulation material.

In the insulation cover installation kit according to the invention, the insulation cover details are cut from a sheet of insulation material so that the sheet of insulation material contains the contour lines of the insulation cover details so that these contour lines do not overlap.

In this case, the contour lines of the insulation covering details are cut at least partially into the thickness of the sheet of insulation material, and the sheet of insulation material with the cut contour lines of the insulation covering details is packaged.

According to the seventh embodiment of the invention, the installation kit for insulation coating details is an installation kit for insulation coatings for pipelines and pipe fittings.

According to the eighth embodiment of the invention, the installation kit for insulation covering details is an installation kit for noise reduction mats or thermal insulation mats.

According to a ninth embodiment of the invention, the insulation material is a closed-cell rubber insulation material.

According to a tenth embodiment of the invention, the sheet of insulation material is made of a material that is flexible elastomeric foam (FEF), nitrile rubber (NBR), ethylene-propylene-non-conjugated diene rubber (EPDM), polyethylene furanoate (PEF), polyurethane foam (PUF), neoprene rubber (CR), silicone rubber mat, ethylene vinyl acetate (EVA), natural rubber (NR), styrene butadiene rubber (SBR) or mineral wool mat.

Since the pieces of pre-cut insulation coverings are held together by the sheet of insulation material from which they are cut, this sheet of insulation material can be easily rolled, packaged and transported.

At the installation site for the insulation covering piping and pipe fitting parts, this sheet of insulation material must be unrolled and the necessary insulation covering parts for installation must be separated from it one by one. The remaining unused parts remain in the said sheet of insulation material and will not get mixed up or lost.

Since the insulation cover details are placed on the insulation material sheet, i.e. the cutting lines corresponding to their contours are optimally arranged, the existing insulation material sheet is used to the maximum. Also, since the cutting is done by machine, the dimensional accuracy and shape compatibility of the insulation cover details with the pipes and pipe fittings (for example, pipe elbows, tees) to which the corresponding insulation cover details are intended to be installed are ensured.

The partially cut cutting method can be used to produce various types of insulation cover kits from FEF materials (NBR / EPDM rubber mixtures), such as insulation cover kits for pipelines; kits used for noise reduction, insulation and protection against condensation in mechanical engineering (such as external equipment cabinets/shields, ventilation units, food processing equipment, etc.), thermal and sound insulation for camper vans.

For example, if it is necessary to insulate the ventilation ductwork during the construction of a private house, the sheet of insulation material can be optimally prepared in advance by placing the cross-sectional drawings of all the necessary piping parts (e.g. elbows, tees, transitions, straight pipes) on the sheet of insulation material. These can be placed with a program-based algorithm on the width of the sheet of insulation material with the least possible loss of material and the sheet of insulation material can be partially cut through in such a way that after processing the sheet of insulation material can be repacked into a roll and the same cardboard box in which the sheet of insulation material is delivered from the factory can be used for further transport.

When processing insulation material in this way, approximately 4-5 times less material waste is generated compared to manual cutting. Roll packaging prevents deformation of the cut parts, because the cutting residues between the parts act as additional protection and packaging material.

For example, rubber insulation material deforms under constant weight. If you cut out pieces and stack them on top of each other, the pieces in the lower layers of the stack will sink into the skim and the material will lose its intended thickness and the insulation properties will deteriorate.

In addition, roll packaging helps to package multiple parts of different shapes, which is difficult to do correctly by stacking cut-out parts, requires using multiple different packages, and is more expensive, time-consuming, and inefficient.

In addition, if the cut out part is packed in a stack and the package is turned 90 degrees, the part will sink with the cut edge against the wall of the cardboard box and deform when standing. Products packaged in this way are difficult to transport and use in a high-quality manner later. Pre-processing the material and packaging it in a roll saves time, raw material, and part transportation and storage costs.

For example, if it is necessary to insulate equipment cabinets for condensation and thermal insulation purposes, where machine builders install computers, controllers, and other electronic devices necessary for the operation of the machine, then typically there are openings of various shapes and sizes in the walls of such cabinets for the passage of cables/hoses, etc. Some of the openings are small, e.g. -10 to 20 mm in size, and they are difficult to cut out correctly with a knife by hand. The cut edge remains jagged, irregular, and imprecise. This reduces the quality of mechanical engineering. The use of machine-cut parts helps to counteract this. Since the parts are of various shapes and sizes, the previously described cutting and packaging method solves the problem of cutting quality and packaging. The customer is supplied with precise parts that have not been deformed during transportation and storage.

In the case of PEF material, the advantage of similar material processing and packaging is that this raw material in a roll tends to curl back into a roll after cutting and partially cut pieces are easy to pack. In the case of cutting a fully cut material, the pieces curl themselves and are difficult to pack in a stacked form. Since PEF is plastic-based, its internal tension and roll twisting forces are greater than those of FEF materials.

List of illustrations

The invention is described below with reference to the accompanying schematic drawings, in which:

Figure 1 shows a sheet of insulation material, on which the contour lines of the cut insulation covering details shown coincide with the cut lines;

Figure 2 shows individual details of the insulation coating separated from the sheet of insulation material in Figure 1;

Figure 3 shows the installation of a pair of insulation cover pieces on a 45-degree pipe elbow; and

Figure 4 shows the installation of a pair of insulation cover pieces on a 90-degree pipe elbow.

Implementation example

For the sake of clarity, the same details and elements in different drawings are designated by the same reference numbers.

Figure 1 shows a sheet of insulation material 1 of typical size, which in the illustrated embodiment is 3 m x 1 m.

In the method according to the invention, insulation cover details 2, 3, 4, 5, 6, 7 are cut from a sheet of insulation material, in which case the contour lines of the insulation cover details 2, 3, 4, 5, 6, 7 are placed on the sheet of insulation material 1 so that the contour lines of these details do not overlap.

Then, the contour lines of the insulation cover details 2, 3, 4, 5, 6, 7 are cut at least partially into the thickness of the insulation material sheet 1, and the insulation material sheet 1 cut with the contour lines of the insulation cover details 2, 3, 4, 5, 6, 7 is packaged.

Before packaging, the insulating material sheet 1 cut along the contour lines of the insulation cover details 2, 3, 4, 5, 6, 7 is rolled into a roll.

The contour lines of the insulation cover details 2, 3, 4, 5, 6, 7 are cut into the thickness of the insulation material sheet 1 so that the contour line includes a section that does not completely cut through the thickness of the material so that the contour lines are cut into the insulation material sheet 1 pack.

at least 95% of the thickness of the sheet 1 of the insulation material.

In another embodiment, the contour lines of the insulation cover details 2, 3, 4, 5, 6, 7 are cut into the thickness of the insulation material sheet 1 so that the contour line alternately includes sections partially cut into the thickness of the insulation material sheet 1 and sections cut through the thickness.

Six different insulation coating details 2 to 7 are arranged on the sheet of insulation material 1, which are separately shown in Figure 2. Each detail 2 to 7 is in pairs on the sheet of insulation material 1.

In the illustrated embodiment, parts 2, 3 and 4 are intended for installation on a 45-degree pipe elbow 8, an example of which is shown in Figure 3, and parts 5, 6 and 7 are intended for installation on a 90-degree pipe elbow 9, an example of which is shown in Figure 4.

In the illustrated embodiment, part 2 is intended for a 45-degree elbow with a diameter of 125 mm, part 3 is intended for a 45-degree elbow with a diameter of 160 mm, part 4 is intended for a 45-degree elbow with a diameter of 200 mm, part 5 is intended for a 90-degree elbow with a diameter of 125 mm, part 6 is intended for a 90-degree elbow with a diameter of 160 mm, and part 7 is intended for a 90-degree elbow with a diameter of 200 mm.

The cutting lines of the parts 2 to 7 are arranged on the sheet of insulating material 1 in such a way that the contour lines of these parts do not overlap. The part of the sheet of insulating material 1 between the contour lines holds the parts 2 to 7 in place in the sheet of insulating material 1, since the cutting lines include cuts in which the contour line includes a cut that does not completely cut through the thickness of the sheet of insulating material 1. Such a cut line can be made similar to a dashed line that alternately includes cuts that are completely cut through the thickness of the material and cuts that are not completely cut through.

As an alternative, most of the contour lines of the parts may be cut through the thickness of the material, leaving only a few sections not completely cut through the thickness to hold the parts in place in the sheet 1.

For installation, the necessary insulation cover parts 3 or 6 are torn out of sheet 1 and glued, for example, with contact adhesive to the corresponding pipe elbow 8 or 9, as shown in Figures 3 and 4.

List of reference numbers

1 sheet of insulation material

2 insulation cover detail for 45-degree pipe elbow

3 insulation cover detail for 45 degree pipe elbow

4 insulation cover detail for 45 degree pipe elbow

5 insulation cover detail for 90 degree pipe elbow

6 insulation cover detail for 90 degree pipe elbow

7 insulation cover detail for 90 degree pipe elbow

8 45-degree pipe elbow

9 90-degree pipe elbow

Claims (12)

 1. A method for producing a pre-cut insulation cover installation kit, in which insulation cover details (2, 3, 4, 5, 6, 7) are cut from a sheet of insulation material (1), characterized in that the method includes the steps of placing the contour lines of the insulation cover details (2, 3, 4, 5, 6, 7) on the sheet of insulation material (1) so that the contour lines of these details are non-overlapping, the contour lines of the insulation cover details (2, 3, 4, 5, 6, 7) are cut at least partially into the thickness of the sheet of insulation material (1), and the sheet of insulation material (1) cut with the contour lines of the insulation cover details (2, 3, 4, 5, 6, 7) is packaged. 2. Method according to claim 1, characterized in that before packaging, the insulating material sheet (1) cut along the contour lines of the insulation cover details (2, 3, 4, 5, 6, 7) is rolled into a roll. 3. Method according to claim 1, characterized in that the contours of the insulation cover details (2, 3, 4, 5, 6, 7) are cut into the thickness of the sheet of insulation material (1) so that the contour line includes a section not completely cut through the thickness of the material. 4. The method according to claim 1, characterized in that the contour lines of the insulation covering details (2, 3, 4, 5, 6, 7) on the sheet of insulation material (1) are cut into the thickness of the sheet of insulation material (1) so that the contour line alternately includes sections partially cut into the thickness of the sheet of insulation material (1) and sections cut through the thickness. 5. The method according to claim 1, characterized in that the contour lines of the insulation covering details (2, 3, 4, 5, 6, 7) on the insulation material sheet (1) are cut into the thickness of the insulation material sheet (1) so that said contour lines are cut into the thickness of the insulation material sheet (1) to at least 95% of the thickness of the insulation material sheet (1). 6. A method according to any preceding claim, characterized in that the contour lines of insulation cover details (2, 3, 4, 5, 6, 7) of different shapes are placed on the sheet of insulation material (1). 7. The method according to any preceding claim, characterized in that the installation kit for the insulation coating details (2, 3, 4, 5, 6, 7) is an installation kit for insulation coatings for pipelines and pipe fittings. 8. The method according to any one of the preceding claims 1 to 6, characterized in that the installation kit for the insulation covering details (2, 3, 4, 5, 6, 7) is an installation kit for noise reduction mats or heat insulation mats. 9. A method according to any one of claims 1 to 8, characterized in that the sheet of insulating material is made of a material which is a closed-cell rubber insulating material. 10. A method according to any one of claims 1 to 8, characterized in that the sheet of insulating material is made of a material which is a flexible elastomeric foam (FEF). 11. A method according to any one of claims 1 to 8, characterized in that the sheet of insulating material is made of a material which is polyethylene furanoate (PEF). 12. The method according to any one of claims 1 to 8, characterized in that the sheet of insulating material is made of a material selected from the group consisting of nitrile rubber (NBR), ethylene-propylene-non-conjugated-diene rubber (EPDM), polyurethane foam (PUF), neoprene rubber (CR), silicone mat, ethylene-vinyl acetate (EVA), natural rubber (NR), styrene-butadiene rubber (SBR) or mineral wool mat.