All-in-one design and fabrication of vacuum insulation panels for ultra-efficient pipeline thermal management

Effective thermal insulation is vital for minimizing heat loss in high-temperature pipeline systems. Conventional insulation materials, such as glass wool and polyurethane (PU) foam, are limited by high thermal conductivities (0.023–0.04 W/(m·K)) and bulky structures. Here, we introduce an all-in-one design and fabrication approach for special-shaped vacuum insulation panels (VIPs), achieving an ultra-low thermal conductivity of 0.0017 W/(m·K). The developed process enables the production of cylindrical VIPs for pipeline insulation while effectively mitigating thermal bridging effects. A double-layer VIP structure with staggered gaps further enhances insulation performance, significantly reducing heat loss. Infrared imaging confirms superior thermal efficiency, with outer surface temperatures as low as 9.5 °C, compared to 35 °C for traditional glass wool insulation. This scalable approach offers a promising solution for ultra-efficient pipeline thermal management.