# US 11,028,959 B2 · Coated closed-cell foam tube insulations and methods for producing the same

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- Number: US 11,028,959 B2
- Document ID: US11028959B2
- Status: Granted
- Kind: B2
- Application number: 16/014,333
- Filed: 2018-06-21
- Published: 2018-12-27
- Granted: 2021-06-08
- Earliest claimed: 2017-06-22
- Assignees: L'Isolante K-Flex S.p.A.
- Applicants: L'Isolante K-Flex S.p.A.
- Inventors: Biju Valakkadavil Thomas
- Web page: https://patentgrep.com/patent/US11028959B2

## CPC

- F16L 59/14: Arrangements for the insulation of pipes or pipe systems (F16L59/02 - F16L59/12 take precedence)
- B32B 1/08: Tubular products
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 15/046: {of foam}
- B32B 15/18: comprising iron or steel {(B32B15/011, B32B15/012 and B32B15/013 take precedence)}
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 27/065: {of foam}
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/22: using plasticisers
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/40: comprising polyurethanes
- C09D 123/16: {Elastomeric} ethylene-propylene or ethylene-propylene-diene copolymers {, e.g. EPR and EPDM rubbers}
- F16L 59/029: {layered}
- F16L 59/10: Bandages or covers for the protection of the insulation, e.g. against the influence of the environment or against mechanical damage (integral with insulating materials F16L59/02)
- F24F 13/0245: {Manufacturing or assembly of air ducts; Methods therefor}
- F24F 13/0263: {Insulation for air ducts}
- B32B 27/285: {comprising polyethers}
- B32B 37/15: with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
- B32B 2250/03: 3 layers
- B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
- B32B 2255/102: synthetic resin or rubber layer being a foamed layer
- B32B 2255/26: Polymeric coating
- B32B 2266/0207: Materials belonging to B32B25/00
- B32B 2266/0228: Aromatic vinyl resin, e.g. styrenic (co)polymers
- B32B 2266/0235: Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
- B32B 2266/025: Polyolefin
- B32B 2266/0292: Thermoplastic elastomer
- B32B 2266/08: Closed cell foam
- B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers
- B32B 2274/00: Thermoplastic elastomer material
- B32B 2305/022: Foam
- B32B 2307/302: Conductive
- B32B 2307/304: Insulating
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2307/402: Coloured
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/554: Wear resistance
- B32B 2307/558: Impact strength, toughness
- B32B 2307/5825: Tear resistant
- B32B 2307/71: Resistive to light or to UV
- B32B 2307/712: Weather resistant
- B32B 2307/72: Density
- B32B 2307/724: Permeability to gases, adsorption
- B32B 2307/732: Dimensional properties
- B32B 2307/734: Dimensional stability
- B32B 2319/00: Synthetic rubber
- B32B 2323/04: Polyethylene
- B32B 2323/16: EPDM, i.e. ethylene propylene diene monomer
- B32B 2597/00: Tubular articles, e.g. hoses, pipes
- C09D 127/06: Homopolymers or copolymers of vinyl chloride
- C09D 133/20: Homopolymers or copolymers of acrylonitrile (C09D155/02 takes precedence)
- F16L: PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- F24F: AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING (removing dirt or fumes from areas where they are produced B08B15/00; vertical ducts for carrying away waste gases from buildings E04F17/02; tops for chimneys or ventilating shafts, terminals for flues F23L17/02)

## Abstract

Provided is an insulation product, optionally in a tubular form, that includes a coated foam insulation layer, where the foam insulation layer has a closed-cell structure. The coating can comprise a thermoplastic elastomer that seamlessly covers and is bonded to an outer surface of the elastomeric foam layer in the absence of an adhesive bonding material to protect the foam insulation layer, e.g., during outdoor insulation applications. A pipe where the insulation product is installed is also provided, as is a method of installing the insulation product, and a method of producing the insulation product.

## Claims

### Claim 1

A composite tubing configured for use as an insulation product, wherein said composite tubing consists of two layers:
(a) a foam insulation layer, wherein the foam insulation layer is an elastomeric foam insulation layer having a closed-cell structure comprising a combination of polyvinylchloride and acrylonitrile-butadiene rubber (PVC/NBR) and configured to fit directly over the surface of a round pipe; and
(b) a coating layer bonded to and seamlessly covering an outer surface of the foam insulation layer, wherein the coating layer comprises a thermoplastic elastomer comprising ethylene propylene diene monomer (EPDM) and is bonded to the outer surface of the foam insulation layer in the absence of an adhesive, wherein the composite tubing is configured to fit a round pipe.

### Claim 2 (depends on 1)

The composite tubing of claim 1, wherein the foam insulation layer has a density of between about 3 and about 6 pounds per cubic foot (lb/ft3).

### Claim 3 (depends on 1)

The composite tubing of claim 1, wherein the coating layer further comprises a flame retardant and/or one or more additional additives.

### Claim 4 (depends on 1)

The composite tubing of claim 1, wherein the tubing has a wall thickness of between about 0.5 inches and about 1 inch.

### Claim 5 (depends on 1)

The composite tubing of claim 1, wherein the tubing is a straight tubing having a length of between about three feet and about six feet or a continuous coil tubing having a length of up to about 1,000 feet and/or wherein the tubing has an inner diameter (ID) ranging from about 0.25 inches to about 6.0 inches.

### Claim 6 (depends on 1)

The composite tubing of claim 1, wherein the EPDM is a UV-resistant EPDM.

### Claim 7

A pipe installation, consisting of:
(a) a round pipe; and
(b) a composite tubing encompassing an outer surface of the pipe, wherein said composite tubing consists of two layers: (i) a foam insulation layer, wherein the foam insulation layer is an elastomeric foam insulation layer having a closed-cell structure comprising PVC/NBR and configured to fit directly over the surface of the round pipe, and (ii) a coating layer comprising a thermoplastic elastomer comprising ethylene propylene diene monomer (EPDM) bonded to and seamlessly covering an outer surface of the foam insulation layer, wherein said insulation product is free of an adhesive to bond the coating layer to the outer surface of the foam insulation layer.

### Claim 8 (depends on 7)

The pipe installation of claim 7, wherein the coating layer further comprises a flame retardant and/or one or more additional additives.

### Claim 9 (depends on 7)

The pipe installation of claim 7, wherein the composite tubing has a thickness of between about 0.5 inches and about 1 inch.

### Claim 10 (depends on 7)

The pipe installation of claim 7, wherein the round pipe is a round-shaped metal pipe, further optionally wherein the round-shaped metal pipe has an outer diameter of about 4.125 inches or less.

### Claim 11 (depends on 7)

The pipe installation of claim 7, wherein the installation is at an outdoor location and/or where there is heat exposure, optionally wherein the installation is part of a heat pump or a solar hot water heating unit.

### Claim 12

A method of making an insulation product, the method consisting of:
(a) providing a closed-cell foam tube, wherein the closed-cell foam tube is a closed-cell elastomeric foam tube comprising PVC/NBR and configured to fit directly over the surface of a round pipe; and
(b) extruding a polymeric coating in an encapsulating manner over the closed-cell foam tube to seamlessly cover the outer surface of the foam tube, wherein the extruding is performed at a temperature to provide a bond between the polymeric coating and the foam surface and wherein the polymeric coating comprises a thermoplastic elastomer comprising ethylene propylene diene monomer (EPDM), and wherein the bond is an adhesive-free bond.

### Claim 13 (depends on 12)

The method of claim 12, wherein the closed-cell foam tube is prepared via extrusion and vulcanization.

### Claim 14 (depends on 12)

The method of claim 12, wherein the method comprises an in-line process with manufacture of the closed-cell foam tube.