METAL SILICONE HYBRID INSULATING STRUCTURES AND METHODS THEREFOR

Abstract

A thermally insulated structure comprises a conduit and an end cap that is coupled to the conduit. In especially preferred aspects, the conduit is insulated with a first and second insulation material, wherein the end cap is coupled to the conduit and the second insulation material, and wherein the first insulation material is disposed between the conduit and the second insulation material. It is further preferred that the end cap has a thermal dissipation zone that allows use of the second flexible and fluid resistant isolation material isolation without thermal degradation, even where the temperature in the conduit exceeds 500° F., or more.

Description

This application claims priority to our copending provisional application with the Ser. No. 61/174372, which was filed Apr. 30, 2009 and is incorporated by reference in its entirety.

FIELD OF THE INVENTION

The field of the invention is insulating structures, especially as it relates to fluid-resistant and flexible insulating structures that can be produced without the need for configuration specific tooling.

BACKGROUND OF THE INVENTION

High-temperature thermal insulation of conduits that convey hot gases or liquids is often performed by applying pliable insulating materials to the conduit and then encasing the pliable insulating materials with a stainless steel shell to provide protection against mechanical damage and/or intrusion of fluid into the pliable insulating material. Most typically, such process requires use of preformed steel shells (or parts thereof), which in turn necessitates equipment and tooling to produce the shells. Moreover, in most cases the shell portions need to be connected to produce a barrier that is fluid-tight.

For example, in certain known configurations, multi-layer insulation can be applied to conduits that convey material at high temperatures (e.g., above 700° F., and more typically above 900° F.) as shown in U.S. Pat. No. 5,379,804 where a flexible resilient sheet with one or more windows is applied onto insulating material over a pipe and conforms to the insulating material. This and all other extrinsic materials discussed herein are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

As is readily apparent, the number of possible shell configurations will quickly present an economic and logistic challenge where numerous types and/or shapes of shells are needed. To circumvent at least some of these challenges, a predefined set of shell portions may be provided to at least somewhat reduce the number of shell pieces. However, such sets will often not be suitable to a variety of applications, and custom shells are thus often required, which is costly and time consuming. Such disadvantages are even more exacerbated where the number of custom pieces is low or where multiple and different custom pieces are needed. Alternatively, and in certain instances, the shell portion can be replaced with “soft wraps” that are fluid resistant. While such approach will provide adequate insulation for most low-temperature conduits, soft wraps will generally rapidly degrade where used under high-temperature conditions (e.g., above 500° F., and more typically above 700° F.), and particularly at locations where the wrap connects to the conduit.

Insulation end caps are known for various configurations and uses, and exemplary end caps are disclosed in U.S. Pat. No. 6,291,043 where a one-piece device is shown for protecting the cut end of insulation on a pre-insulated tubing. Such end caps often tend to provide ease of installation and thermal insulation. However, due to the pre-formed nature of these end caps, the end caps must be adapted for the exact diameter of the conduit that receives the end cap. Where nested pipes are configured to provide vacuum insulation, suitable end caps have been described, for example, in U.S. Pat. No. 6,257,282. Vacuum insulation is often highly effective where low-temperature fluids such as liquefied natural gas is transported. However, end cap installation will require gas-tight sealing, which is often difficult to achieve under field conditions. Moreover, end pieces often require use of vacuum sleeves, which further complicates installation.

Protective end caps are also known to prevent solid contamination of insulating material from a welding operation where ends of insulated pipes are joined as described in U.S. Pat. App. No. 2002/0163182. Here, prefabricated plastic end caps are used to seal the ends of insulating materials at a pipe terminus to allow formation of a sealable gap between two pipe ends. Once more, such use requires preformed end caps and is therefore not applicable to a variety of pipes. U.S. Pat. No. 3,744,823 describes composite end caps having a disc shaped ring that is welded to a pipe and onto which a thermally non-conductive material is fused to prevent heat loss through the end cap. While such approach advantageously eliminates the need for prefabricated end caps, other disadvantages arise. Most significantly, installation is more complex. Additionally, thermo-mechanical stresses may reduce the useful lifetime of such elements. Thermo-mechanical stresses can be entirely avoided where flexible end caps as shown in U.S. Pat. No. 4,086,736 are used. Here, a pipe is fed through a fire barrier and/or wall by including a pipe shell that includes insulation material and that extends through the barrier or wall. The open ends of the shell are then capped using a flexible material that is connected to the pipe and the shell. Such assembly allows accommodation of various pipe geometries and is typically insensitive to thermal expansion or other moderate movement. However, as the flexible material is directly attached to the pipe, such approach is limited to pipes conveying low-temperature fluids.

Therefore, although numerous methods and materials for insulating structures are known in the art, there remains a considerable need for improved insulating structures that will allow for simple and flexible installation while providing fluid and particle resistance in high-temperature conditions.

SUMMARY OF THE INVENTION

The inventive subject matter provides devices and methods of insulating a conduit, and especially a high-temperature conduit, where the conduit is most preferably insulated by first and second insulation materials. In such insulation configurations and methods, an end cap engages with the conduit and the second insulation material (most preferably a flexible and fluid resistant material) that is positioned above the first insulation material. To avoid thermal degradation of the second insulation material, the end cap includes a thermal dissipation zone that is sufficiently large to dissipate heat to a degree that allows coupling and retention of the second insulation material to the end cap without thermal degradation.

In one aspect of the inventive subject matter, a method of thermally insulating a conduit having an outer surface includes a step of coupling to the outer surface of the conduit an end cap that is preferably manufactured from a metal. Most typically, the end cap has (1) a first engagement portion configured to allow coupling of the first engagement portion to the conduit, (2) a second engagement portion, and (3) a thermal dissipation zone located between the first and second engagement portions that is configured to allow radiation of heat received from the first engagement portion in an amount sufficient to allow retention of a second insulation material on the second engagement portion without thermal degradation of the second insulation material. In a further step of contemplated methods, a first insulation material is coupled to the outer surface of the conduit, and in another step, the second insulation material is coupled to the first insulation material and to the second engagement portion, wherein the second insulation material is a flexible and fluid resistant material.

Most preferably, the step of coupling the first engagement portion to the conduit includes a step of resistance welding (e.g., spot or seam welding), and/or a step of positioning a portion of the first insulation material between the outer surface and the first engagement portion. In some embodiments, the end cap comprises two independent portions that may be separately coupled to the conduit, wherein the two independent portions are optionally coupled to each other after coupling to the conduit. Most preferably, first and second engagement portions circumferentially enclose the conduit, and the thermal dissipation zone extends in radial direction from the conduit.

In especially preferred aspects, the first insulation material comprises a mineral material, a ceramic material, a refractory carbon material, and/or an organic polymer material, and the second insulation material comprises a silicon material, a fiberglass material, and/or a Teflon material. Alternatively, or additionally, the second insulation material is a composite material and comprises a metal layer, and/or the second insulation material comprises a silicone (which may be cured to form a continuous structure). Moreover, in at least some embodiments, the second engagement surface and the second insulation material are coupled together via an adhesive. Most typically, the conduit conveys a high-temperature fluid having a temperature of at least 700° F., and/or the thermal dissipation zone comprises a corrugated shape, a curved shape, a straight shape, and/or a plurality of protrusions.

Therefore, viewed from a different perspective, a thermally insulated structure may include a conduit having an outer surface, and an end cap coupled to the conduit. In especially preferred aspects, the end cap has (1) a first engagement portion that is configured to allow coupling of the first engagement portion to the conduit, (2) a second engagement portion, and (3) a thermal dissipation zone that is located between the first and second engagement portions, wherein the thermal dissipation zone is configured to allow radiation of heat received from the first engagement portion in an amount sufficient to allow retention of a second insulation material on the second engagement portion without thermal degradation of the second insulation material. It is further preferred that a first insulation material is coupled to the outer surface of the conduit, and that the second insulation material is coupled to the first insulation material and to the second engagement portion. As before, it is generally preferred that the second insulation material is a flexible and fluid resistant material.

In preferred thermally insulated structures, a spot weld or seam weld is disposed between the outer surface and the first engagement portion, and it is further preferred that the second insulation material is a composite material and comprises a metal layer and/or comprises a silicone. While not limiting to the inventive subject matter, it is also preferred that the thermally insulated structure further comprises an adhesive between the second engagement portion and the second insulation material. Lastly, it is preferred that the thermal dissipation zone comprises a corrugated shape, a curved shape, a straight shape, and/or a plurality of protrusions.

Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWING

FIGS. 1A-1C depict selected views of exemplary configurations of insulating structures according to the inventive subject matter.

FIG. 2 depicts another exemplary configuration of an insulating structure according to the inventive subject matter.

FIG. 3 depicts one exemplary configuration of an independent portion of an end cap according to the inventive subject matter.

FIGS. 4A-4C depict selected views of exemplary configurations of thermal dissipation zones in end caps according to the inventive subject matter.

DETAILED DESCRIPTION

The present inventive subject matter is drawn to insulating structures and methods in which the insulation structure most preferably comprises an inner high-temperature insulation portion, an outer flexible and fluid resistant insulation portion, and an end cap that preferably sealingly engages with a high-temperature conduit, the inner, and the outer insulation portions. In especially preferred aspects, the end cap includes a heat dissipation zone to allow coupling of a temperature sensitive outer insulation portion to so enable use of desirable materials in high-temperature operating conditions that would otherwise be rapidly thermally degraded.

In particularly preferred aspects of the inventive subject matter, the insulating structure is installed onto a high-temperature conduit that conveys a fluid (gas and/or liquid) having a temperature of at least 500° F., and more typically at least 700° F. Onto the outer surface of the conduit, one or more layers of mineral wool are applied to a desired thickness using conventional methods known in the art (e.g., fastened to the conduit using wire, fiber glass tape, etc.) to so confine and/or conform the inner high-temperature insulation portion onto the conduit. An end cap, preferably shaped as collar (typically press-formed from stainless steel foil) is then fastened to the conduit. Most preferably, the end cap is welded (typically spot or seam welded) to the conduit at or near the place where the inner high-temperature insulation portion terminates (optionally, at least a portion of the high temperature insulation may be positioned between the end cap and the conduit). Once in place, it is preferred that a flexible and fluid resistant (e.g., metal silicone hybrid wrap) is installed onto the high-temperature insulation material and outer surface of the end cap. Thus, in this example, the inside of the end cap overlaps with the high temperature insulation while the outside matingly and/or sealingly engages with the flexible and fluid resistant insulation. One exemplary and generic configuration of a insulating structure is provided in FIGS. 1A-1C.

Here, FIG. 1A depicts a cross section through an insulation structure that is built onto a pipe. FIG. 1B illustrates the longitudinal cross section of the pipe, and FIG. 1C shows a detail view of the longitudinal cross section of FIG. 1B. Here, end cap 4 is welded onto pipe 1 and has a configuration such that the end cap has a first engagement surface that is welded (preferably spot welded) to the outer surface of the conduit. Perpendicularly extending from the first engagement surface (in radial direction) is a heat dissipation zone that is continuous with the second engagement surface. The second engagement surface overlaps on one side with the high-temperature insulation material 2 and overlaps on the other side with the flexible and fluid resistant insulation material 3. The term “flexible” as used herein in conjunction with the second insulation material is meant to characterize the second insulation material as being readily deformable using manual force, wherein the manual force is typically between the force needed to deform duct tape and the force needed to deform a 1 mm thick non-corrugated card board. The term “fluid resistant” as used herein in conjunction with the second insulation material is meant to characterize the second insulation material as being able to protect a material underneath the second insulation material from water exposure due to water spray (from a non-pressurized water source) onto the second insulation material.

FIG. 2 schematically illustrates another insulated structure in which high-temperature pipe 210 is surrounded by a hybrid insulation structure 220 that includes a first high-temperature insulation material 222 and a second flexible and fluid resistant hybrid insulation material 224. Hybrid insulation material 224 includes a first layer 224A that is preferably a silicone material, which is coated with a second layer 224B, preferably a metal film. Thus, the first layer provides thermal insulation, while the second layer also provides mechanical stability.

While not limiting to the inventive subject matter, it is preferred that the second layer (or other part) of the insulation material 224 is bonded to the second engagement surface of the end cap 230 via an adhesive 226. End cap 230 is preferably bonded to the outer surface of the pipe 210 by a resistance weld 212. It is also contemplated that a portion of the first insulation material 222 is disposed in at least a portion of the space between the outer surface of the pipe and the first engagement surface of the end cap.

In particularly preferred aspects, it is contemplated that the end caps are configured to fit a variety of standard diameter conduits to so provide a choice of universal end structures. To facilitate installation, the end caps can be prefabricated (e.g., in two 180 degree halves, as shown in FIG. 3, only one half shown) to allow facile on site assembly (e.g., by welding together before or after installation on the conduit). Once the end caps are in place (e.g., at the respective ends of the first, inner high-temperature insulation portion), the end caps are then coupled to the conduit, most preferably by resistance welding using a seam welder or spot welder. With the end caps so attached to the conduit, the second, outer fluid resistant insulation portion is installed. Most preferably, the outer fluid resistant insulation portion is or comprises a thermally resistant silicone tape, numerous varieties of which are well known in the art. In the areas where the end caps are coupled to the second engagement portion, the end caps are preferably pretreated with an agent (e.g., adhesive) that facilitates bonding of the two materials. For example, starting at one end of the insulated conduit, silicone tape may be wrapped around the insulation in an overlapping spiral fashion. Both ends of the silicone wrap overlap on top of the metal end caps. The entire assembly is then cured to thermally bond the silicone tape to itself and the metal end caps. Therefore, it should be appreciated that after the curing process the silicone tape forms a flexible and fluid resistant encapsulation for the inner high-temperature insulation portion.

With respect to suitable end caps it is contemplated that the size, shape, and material of the end cap may vary significantly and will typically at least in part depend on the nature of the conduit, temperature in the conduit, and material of the outer fluid resistant insulation portion. However, it is generally preferred that the end cap will circumferentially engage with the conduit to so alone, or in combination with a sealing element or material sealingly engage with the conduit. To that end, the end cap may have a sleeve portion that engages with the conduit and a second portion coupled to the sleeve portion, wherein the second portion will have a larger diameter. Most typically the larger diameter will be equal or larger than the outer diameter of the inner insulating portion. Regardless of the particular arrangement, it is preferred that the end cap will provide a structure that sealingly (fluidly and/or thermally) engages with the conduit using a first portion and further provides a structure that allows attachment of the outer insulating portion to the end cap in a (fluidly and/or thermally) sealing manner.

Especially preferred end caps will comprise a thermal dissipation zone that is configured to allow heat that was transferred from the conduit to the first engagement portion of the end cap to be dissipated to a degree such that remaining heat in the area of attachment of the outer fluid resistant insulation portion will not negatively affect the outer fluid resistant insulation portion. Thus, a second insulating material can be employed on high-temperature conduits that would otherwise be subject to thermal degradation. For example, suitable thermal dissipation zones may be shaped to have a corrugated, curved, and/or straight configuration, and may alternatively or additionally include a plurality of protrusions. Thus, inclusion of an appropriately sized and configured thermal dissipation zone will allow for sufficient radiation of heat received from the first engagement portion to enable retention of the second insulation material on the second engagement portion without thermal degradation (i.e., embrittlement, breakage, chemical degradation, and/or melting within several hours, more typically several days, and most typically several weeks).

Exemplary end cap configurations are depicted in FIGS. 4A-4C showing end caps with curved, protruded, and corrugated thermal dissipation zones. Most typically, as illustrated in FIG. 4A, the first engagement surface 410 is continuous with the thermal dissipation zone 430, which in turn is continuous with the second engagement surface 420. Viewed from a different perspective, contemplated end caps are configured to allow heat flow from the conduit to the second engagement portion without inclusion of an insulating material. However, numerous alternative geometries are also contemplated herein, and especially include elongated thermal dissipation zones.

In most preferred aspects of the inventive subject matter, it is contemplated that the end cap is fabricated from metal (e.g., stainless steel), however, it should be noted that numerous alternative materials are also contemplated herein, and especially include refractory inorganic materials. For example, suitable end caps may comprise various ceramic materials, pyrolytic graphite, metal alloys and all reasonable combinations thereof. Furthermore, and where desired, use of various refractory filler materials to seal possible gaps between the end cap and the conduit and/or the outer insulating portion is also contemplated. Similarly, and again where desired, at least part of the end cap may be modified on a surface to include an adhesive or other agent that facilitates bonding and/or sealing of the outer insulating portion with the end cap. Still further, suitable end caps may also be initially configured as flat metal sheets that comprise a plurality of perforated and/or cut lines to allow cutting and/or folding of the sheet into an end cap configuration (or portion thereof).

Therefore, it should be particularly noted that contemplated methods and configurations will advantageously combine the benefits of a universal set of end caps (e.g., stainless steel collars) with the benefits of a flexible and fluid resistant (preferably silicone) wrap. In cases where the operating temperature of a conduit is higher that that which the silicone (or other thermally degradable material) would otherwise permit, the use of the end caps will provide a thermal buffer between the hot surface of the conduit and the silicone of the outer portion. Viewed from a different perspective, it should be noted that the silicone material is thermally isolated from the hot conduit due to the thermal dissipation zone in the (preferably metal) end caps, which eliminates problems associated with silicone wraps that would otherwise be bonded directly to the hot surface of the conduit.

Viewed from yet another perspective, it should be noted that contemplated configurations and methods advantageously allow installation of the insulating structure off-site as well as on-site. Off-site installation may be especially suitable where the end caps are fabricated from a metal and need to be resistance welded onto the conduit, which requires specialized welding equipment. Similarly, where the outer portion requires curing at relatively high temperatures in an oven, off-site installation may be more preferable. However, where end caps can be sealingly formed on-site and where the end caps prevent or significantly reduce (at least 30%, more typically at least 50%) heat transfer from the conduit to the outer portion on-site installation may be advantageous. Regardless of the manner of installation, it should be appreciated that the end caps will significantly reduce heat transfer from the conduit to the second engagement portion and will so allow use of materials that would otherwise be thermally damaged or degraded. Consequently, it should be appreciated that the end caps and configurations contemplated herein allow for heat loss from the conduit. Moreover, it should be noted that contemplated end caps and insulation structures are not limited to placement of the end cap near a weld seam of two pipe sections. Indeed, the end caps can be used in any portion of a conduit. While not limiting to the inventive subject matter, vacuum insulated structures are less preferred, and in some aspects even excluded from the configurations and methods presented herein.

With respect to contemplated conduits it should be noted that all conduits are deemed suitable for use herein that convey a heated fluid, and most typically a high-temperature fluid (e.g., gas, liquid, and/or vapor). For example, especially preferred conduits include exhaust pipes from combustion engines, turbines, gasifiers, industrial pipelines in (petro)chemical plants, heating conduits, etc. Therefore, suitable conduits may typically have a round or a rectangular cross section, and the diameter may vary between ½ inch and several feet. Similarly, suitable conduits will be straight, curved, branched, and/or may comprise manifolds and/or other flow splitting or combining devices. Thus, irregularly shaped conduits will especially benefit from contemplated devices and methods.

Contemplated temperatures of the fluid in the conduit (which will be in most cases the same as the temperature on the outside surface of the conduit) may vary considerably, and the particular temperature will predominantly depend on the specific use of the conduit. However, it is particularly preferred that the temperature will at least 150° F., typically at least 300° F., more typically at least 500° F., even more typically at least 700° F., and most typically at least 900° F. Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints, and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary. On the other hand, it should also be noted that contemplated insulating structures may also be suitable for cryogenic conduits (e.g., liquefied natural gas conduits, liquefied nitrogen or oxygen conduits, or conduits in air separation plants) where the temperature in the conduit may be well below −100° F., and even well below −200° F.

It is still further generally contemplated that numerous materials are suitable for the inner (high-temperature) insulation portion, and that especially preferred materials will be those that are commercially available. For example, particularly suitable materials include inorganic (most commonly mineral) materials, including mineral fiber, mineral wool, asbestos, etc., and various organic materials, including expanded graphite, Teflon fibers, Kevlar fibers, Nomex fibers, etc., and all reasonable combinations thereof. Preferably, such materials will be provided in a form suitable for fast installation, and particularly preferred forms will include bulk packing, stripes and/or blankets, flocks, and compositions suitable for spraying and/or foaming. Installation will therefore be preferably manual by manually applying the materials (e.g., by wrapping, spraying, foaming, stuffing, etc.). As noted above, the so installed inner insulating portion may be further secured in manners well known in the art as appropriate and/or desired.

Likewise, it should be noted that the choice of the outer fluid resistant insulation portion should not be limited to silicon tape. Indeed, it should be appreciated that all known alternative (preferably heat resistant) materials are also deemed suitable. Most preferably, such materials will provide a fluid resistant (i.e., will repel water or prevent water from penetrating to the inner portion where water is sprayed into the outer portion) layer to cover the inner portion. However, it is generally preferred that the outer fluid resistant insulation portion is flexible, provides a fluid resistant cover, and can be applied from a prefabricated form (e.g., from a roll of tape, a stack of sheets, etc. Furthermore, it is generally preferred that the outer fluid resistant insulation portion will be curable to form a continuous structure, wherein curing may be chemical curing, or at least in part mechanical (e.g., via shrinkage). Additionally, it is preferred that the outer fluid resistant insulation portion will be configured such that the outer fluid resistant insulation portion will sealingly engage with at least part of the end cap to so allow formation of a continuously fluid resistant structure.

It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

Claims

1. A method of thermally insulating a conduit having an outer surface, comprising:

coupling to the outer surface of the conduit an end cap;

wherein the end cap has a first engagement portion that is configured to allow coupling of the first engagement portion to the conduit, and wherein the end cap has a second engagement portion;

wherein the end cap further comprises a thermal dissipation zone that is located between the first and second engagement portions;

wherein the thermal dissipation zone is configured to allow radiation of heat received from the first engagement portion in an amount sufficient to allow retention of a second insulation material on the second engagement portion without thermal degradation of the second insulation material;

coupling a first insulation material to the outer surface of the conduit; and

coupling the second insulation material to the first insulation material and to the second engagement portion, wherein the second insulation material is a flexible and fluid resistant material.

2. The method of claim 1, wherein the step of coupling the first engagement portion to the conduit comprises resistance welding.

3. The method of claim 1, wherein the end cap comprises two independent portions that are separately coupled to the conduit, and wherein the two independent portions are optionally coupled to each other after coupling to the conduit.

4. The method of claim 1, wherein the step of coupling the first engagement portion to the conduit comprises a step of positioning a portion of the first insulation material between the outer surface and the first engagement portion.

5. The method of claim 1, wherein first and second engagement portions circumferentially enclose the conduit, and wherein the thermal dissipation zone extends in radial direction from the conduit.

6. The method of claim 1, wherein the end cap is manufactured from a metal.

7. The method of claim 1, wherein the first insulation material comprises a material selected from the group consisting of a mineral material, a ceramic material, a refractory carbon material, and an organic polymer material, and wherein the second insulation material comprises a material selected from the group consisting of a silicon material, a fiberglass material, and a Teflon material.

8. The method of claim 1, wherein the second insulation material is a composite material and comprises a metal layer.

9. The method of claim 1, wherein the second insulation material comprises a silicone, and further comprising a step of curing the silicone to form a continuous structure.

10. The method of claim 1, further comprising a step of curing the second insulation material to form a continuous structure.

11. The method of claim 1, wherein the second engagement surface and the second insulation material are coupled together via an adhesive.

12. The method of claim 1, wherein the conduit conveys a high-temperature fluid having a temperature of at least 700° F.

13. The method of claim 1, wherein the thermal dissipation zone comprises at least one of a corrugated shape, a curved shape, a straight shape, and a plurality of protrusions.

14. A thermally insulated conduit made by the method of claim 1.

15. A thermally insulated structure, comprising:

a conduit having an outer surface, and an end cap coupled to the conduit;

wherein the end cap has a first engagement portion that is configured to allow coupling of the first engagement portion to the conduit, and wherein the end cap has a second engagement portion;

wherein the end cap further comprises a thermal dissipation zone that is located between the first and second engagement portions;

wherein the thermal dissipation zone is configured to allow radiation of heat received from the first engagement portion in an amount sufficient to allow retention of a second insulation material on the second engagement portion without thermal degradation of the second insulation material;

a first insulation material coupled to the outer surface of the conduit;

wherein the second insulation material is coupled to the first insulation material and to the second engagement portion; and

wherein the second insulation material is a flexible and fluid resistant material.

16. The thermally insulated structure of claim 15, further comprising a spot weld or seam weld between the outer surface and the first engagement portion.

17. The thermally insulated structure of claim 15, wherein the second insulation material is a composite material and comprises a metal layer.

18. The thermally insulated structure of claim 15, wherein the second insulation material comprises silicone.

19. The thermally insulated structure of claim 15, further comprising an adhesive between the second engagement portion and the second insulation material.

20. The thermally insulated structure of claim 15, wherein the thermal dissipation zone comprises at least one of a corrugated shape, a curved shape, a straight shape, and a plurality of protrusions.