Uv lamp blanket for curing uv-resin saturated material

Abstract

A light blanket for installing an in-situ curing pipe liner and a method of installing an in-situ curing pipe liner using a light blanket, the light blanket being made from an ultraviolet light emitting diode (UV LED) sheet embedded in a flexible circuit array, surrounded by a protective translucent material, allowing the sheet, and thus the blanket, to illuminate and illuminate.

Description

Technical Field

[0001] The present invention relates generally to pipe liners for pipelines and, more particularly, to cured-in-place pipe liners. Background Art

[0002] Much of the infrastructure in cities around the world was installed many years ago and is now beginning to age and break down. For example, pipes for sewers, drains, water, gas, oil, etc. age and begin to leak due to cracks / damage in the pipe walls and joints between pipe segments. In the case of pipes that carry sewage or other hazardous materials, it is unacceptable for them to leak into the environment. Therefore, it is an important task for local, state, and national governments around the world to replace damaged pipes with new ones.

[0003] However, since most pipelines are underground, replacing them is extremely expensive and time-consuming. The land around the damaged pipeline must be excavated and the damaged pipeline removed from the land. Then, a new pipe segment must be placed in the excavation site, connected to the adjacent pipe segments and sealed, and then buried again. All of these tasks are very time-consuming and require heavy machinery and many workers, making the replacement process very expensive.

[0004] As an alternative to digging up a damaged pipe, it is possible to replace / repair the pipe from the inside out using a curable fabric liner. The liner is typically fiberglass or felt, which is first impregnated with a curable resin and then inserted or inverted (i.e., turned inside out) into the damaged pipe. The liner is pressed against the interior wall of the existing damaged pipe using a fluid medium (e.g., gas or liquid, including air or water) under pressure. Once the resin cures (due to heat, light, or a chemical catalyst), the liner is rigid and the pressure source can be removed, leaving a new gas-tight / liquid-tight interior wall in the damaged pipe.

[0005] In addition to pipes, there are many other surfaces that require repair using hardened, curable materials. Examples include, but are not limited to, boat hulls, windmill blades, surfboards, building surfaces and floors.

[0006] The prior art is to cure pads or other flat materials by external stimuli (environmental or thermal). The proposed system is an additive light curing technology to the prior art, which eliminates the need for additional expensive curing equipment required for light curing. Summary of the invention

[0007] The present invention provides a light blanket according to the present disclosure, which is made of a thin sheet of ultraviolet light emitting diodes (UV LEDs) embedded with a flexible circuit array, surrounded by a protective translucent material, thereby allowing the sheet and therefore the blanket to illuminate and emit light.

[0008] The blanket is designed specifically for curing light-activated resins and epoxies. The wavelength of light emitted by the diodes (between 365nm and 420nm) activates the resin, causing it to cure into a hardened material in whatever shape the blanket is formed into. In the case of patching a pipe, the blanket can be a) wrapped around an existing spot patch / point patch balloon with the light facing outward; b) the blanket can act as the balloon of the spot patch / spot patch device itself; or c) the blanket can act as a flat curing device that is formed into different shapes depending on the application. The blanket overlaps itself a few inches, allowing the balloon underneath to expand.

[0009] Before the balloon is inserted into the pipe, the balloon is covered with a blanket. The material, saturated with photosensitive resin, is then wrapped around the blanket, overlapping itself on the ends, or in the case of a single tube of material, pulled over the blanket. The resulting device, i.e., a balloon wrapped with overlapping lights and wrapped with material, is then inserted into the pipe, through a "cleaned" section or manhole, and pushed or pulled to the point of repair. Air is introduced into the balloon, causing it to expand along with the overlapping blankets and material to fit tightly to the inside of the pipe. The lights on the blanket are turned on by an external power source attached to the blanket. The UV lights activate the resin, curing the material in situ to form a new pipe segment within the existing pipe, repairing the pipe in minutes without the need for replacement. Once the repair is complete, the balloon is deflated, relieving pressure on the blanket, and both the balloon and blanket are then pulled out of the pipe, leaving the repair in place.

[0010] Alternatively, the blanket can serve as the balloon of the device itself. In this case, the blanket is sandwiched between two layers of expandable material with the lights facing outward. The outer layer of material is translucent and allows UV light to pass through. The two pieces of material that sandwich the blanket (overlapping on themselves) are closed at each end with an end piece that clamps each side to ensure that the light-emitting balloon can maintain air pressure.

[0011] Prior to inserting the glowing balloon into the pipe, the material saturated with photosensitive resin is wrapped around the glowing balloon, overlapping itself on the ends, or if it is a single piece of tubular material, pulled over the balloon. The resulting device, i.e., a glowing balloon wrapped with material, is then inserted into the pipe, through a "cleaned" section or manhole, and pushed or pulled to the point of repair. Air is introduced into the glowing balloon, causing it to expand along the material to fit tightly to the inside of the pipe. The light on the glowing balloon is turned on by an external power source attached to the balloon. The UV light activates the resin, curing the material in situ to form a new pipe segment within the existing pipe, repairing the pipe in minutes without the need for replacement. Once the repair is complete, the glowing balloon is deflated and the glowing balloon is pulled out of the pipe, leaving the repair in place.

[0012] Still, alternatively, the blanket can be used as a flat curing device that can be formed into different shapes depending on the application. For example, repairing damage to the side of a ship hull or a windmill turbine blade can be accomplished by laying or wrapping the blanket over the material to be cured, which has been applied to the area to be repaired. The blanket can be secured with straps, tape or other means to press it firmly against the material. The light is activated and the material is cured. The blanket is then removed for reuse.

[0013] Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter.It should be understood that the detailed description and specific examples, while indicating various embodiments, are intended for purposes of illustration only and are not intended to necessarily limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The invention will now be described by way of non-limiting examples, with reference to the accompanying drawings, in which:

[0015] Figure 1 A preferred embodiment of the invention is presented which comprises an internal light source comprising a UV LED sheet.

[0016] Figure 2 Shows a UV LED sheet enclosed in a protective translucent housing ( Figure 1 ) is a side view of the housing constituting the lamp carpet of the present invention.

[0017] Figure 3 The application of blankets around existing technologies is demonstrated.

[0018] Figure 4 A cured in place liner material is shown that is applied within a pipe during the curing process.

[0019] Figure 5 Another application of the blanket was demonstrated, where the blanket acts as a balloon. Each end of the UV balloon made from the UV blanket is inserted or clammed around two end pieces, forming an enclosure into which air can be introduced, inflating the UV balloon to push the UV curable material onto the pipe. The UV is then irradiated on the curable material separated by the translucent layer.

[0020] Figure 6 Shown Figure 5 A separate UV balloon as discussed in which may be part of the device. In the case where 210 is an expandable translucent material, 310 is the expandable material and 100 is an overlapping light sheet. DETAILED DESCRIPTION

[0021] Figure 1An example of a light source according to the present disclosure is shown in FIG. The light source matrix is ​​a sheet with embedded UV LEDs. The sheet 100 is specifically designed to allow maximum UV light coverage and a minimum amount of UV light diodes 110 to cure the light activated resin. This is achieved by the spacing and pattern of the lights embedded in the flexible substrate and the lumens emitted by the lights. The sheet 100 is made flexible enough to be rolled into a tubular form without affecting the structure of the circuit.

[0022] The UV sheet 100 is constructed of a material having sufficient flexibility to lie substantially flat so as to define an upper side and a lower side. The sheet 100 is in a flat state of 2 to 4 millimeters thickness when manufactured, and when inserted into the pipe to be repaired, it is deployed into a tubular shape. The sheet 100 is in a flat state when manufactured, can have various sizes depending on the inner diameter of the pipe and the outer diameter of the balloon, and in the case of use, will be wrapped around or become part of the light-emitting balloon.

[0023] The spacing between the diodes 110 and the rows of diodes 110 is critical to curing and providing adequate light coverage in the edge overlap area. The design of the sheet 100 is a plastic sheet 210 with UV diodes 110 in the middle of two layers of sheets 210. The preferred voltage of the LED diodes is 12V to 48V. Design examples are contemplated in which the individual diodes 110 and the rows of diodes 110 are equidistant between the diodes and the rows of diodes, approximately between 0.25 and 1 inches, and include but are not limited to: 1) diodes 110 are arranged side by side in a straight line parallel to the edge of the sheet; 2) diodes 110 are staggered in a straight line parallel to the edge of the sheet; 3) diodes 110 are arranged side by side in a straight line diagonal to the edge of the sheet; 4) diodes 110 are staggered in a straight line diagonal to the edge of the sheet. The power circuit 120 is located around the edge of the blanket 100 and is connected to an external power source 130.

[0024] Figure 2 An example of a blanket 200 according to the present disclosure is shown in . The blanket 200 is made of an internal light source (sheet 100) encapsulated in a waterproof translucent material 210, which allows UV light to pass through. The outer layer covering the LED diodes 110 must be translucent and allow UV light to pass through. Examples of translucent materials are expandable silicone or polyethylene or any other translucent and expandable material. The layer on the back of the sheet can be a different material as long as it is flexible. A heat absorbing layer like aluminum or copper foil can be coated or laminated on the protective layer on the back of the sheet to absorb heat from the LED diodes 110 during the curing process. Other heat absorbing materials can also be used.

[0025] The light sheet 100 is composed of UV light diodes 110 in a pattern that allows the light to overlap so no part of the surface it covers is without light. The light angle of the LED lens should be between 120 and 180 degrees. This range is from 1 diode per square inch to 10 diodes per square inch. The blanket is powered along the edge of the sheet through one or more connections to an external power source.

[0026] One or more waterproof power connections 130 may be attached to the light blanket 100. The power cable may be combined with the air hose or may be a single power cable. The power cable runs along the air hose or push rod and is used to inflate the balloon or push and pull the balloon into the pipe. The air / power or single cable may be connected to a control box outside the pipe or patch point. The control box is used to turn the LED blanket on and off and to inflate the balloon through an air pressure valve. The control box also includes a volt and amp display. Both displays indicate the function of the LED blanket. The device may have a camera inside or outside to observe the curing process. The image from the one or more cameras will be displayed at a screen mounted inside the control box.

[0027] Use of existing technology

[0028] Convert existing ambient or heat curing equipment to UV curing equipment

[0029] like Figure 3 As shown, when used to patch damaged pipes of various sizes, the blanket 200 can be wrapped around an existing point repair / field repair balloon 300. Figure 3 ) uses an opaque rubber balloon and an ambient or heat activated material wrapped around the opaque balloon. The curing material (not shown) must be statured at the construction site and is time sensitive. The curing time can be several hours until the material hardens in the pipe. In the present invention, the blanket 200 can be overlapped 250 on itself, allowing the balloon 300 below to expand, allowing the light blanket 200 to expand with it, maintaining an uninterrupted pattern of lights facing the outside of the pipe. A light activated resin saturated material is then wrapped or pulled around the blanket 200. The resin saturated material can be multiple layers of fiberglass, felt, polyester, Kevlar, or any other UV curable material.

[0030] Figure 4An example of the resulting device is shown in FIG. 2. Before the balloon 300 is inserted into the pipe 500, the balloon 300 is covered with a blanket 200. Then, a material 400 saturated with a photosensitive resin is wrapped around the blanket 200, overlapping itself 250 at the end. The resulting device, i.e., a balloon wrapped with overlapping lights, wrapped with material, is then inserted into the pipe 500, through a "cleaned" section or manhole, and pushed or pulled to the repair point. Air is introduced into the balloon 300, causing it to expand along with the overlapping blanket 200 and material 400 to fit tightly to the inside of the pipe. The lights on the blanket are turned on by an external power source attached to the blanket. The UV lights activate the resin, curing the material in situ to form a new pipe segment within the existing pipe, repairing the pipe without replacing it. Once the repair is complete, the balloon is deflated, relieving the pressure applied to the blanket, and both the balloon and blanket are pulled out of the pipe, leaving the repair in place. Therefore, the originally flat UV blanket 100 is formed into a cylindrical shape, wrapped with the UV light curable material 400, and then inserted into the pipe to repair various problems in the pipe, such as leaks, cracks, holes, etc.

[0031] Example Use - Use of a UV Cured Packer with a Blanket as Part of the Equipment

[0032] In existing UV curing packers (an expandable tube used to install CIPP liner repairs, i.e., in-situ repairs, spot repairs; also known as balloons), the light-emitting LED or UV bulb is located in the center of the device to provide equal light exposure to the curing material. The UV LED or bulb is surrounded by an inflatable balloon. The construction of this device is cost-effective but has limited flexibility. During inflation using existing UV packers, the flow of water in the pipeline will be blocked because there is no flow during application with existing equipment. The risk of flooding or damage to the UV packer is very high.

[0033] The present invention solves the above problems because the LED blanket 200 ( Figure 6 ) is a part of the balloon, and the center of the UV packer is hollow. Therefore, a flexible and pressure-resistant hose can be installed in the center of the UV packer, allowing water to flow through during the curing process.

[0034] The LED blanket can be a separate layer below the inflatable balloon 300. Thus, the UV LED blanket is located near the inflatable balloon and acts as a light source for the device. In this application, the UV LED blanket is not inflatable. The UV LED blanket will be mounted to the end piece of the UV packer and kept round and close to the inflatable balloon. The LED UV blanket can be installed as a solid layer below the inflatable layer or in sections to increase the flexibility of the packer.

[0035] Figure 5A second exemplary use of the present invention is disclosed in , wherein the light sheet 100 is sandwiched between two layers of translucent material 210, 300, which are inserted / connected to two separate end pieces. The resulting configuration can then be inflated with air 600 and used to patch damaged pipes of all sizes in accordance with the present disclosure. The blanket can be overlapped 250 upon itself, allowing the balloon (not shown) to expand, allowing the light blanket to expand with it, maintaining an uninterrupted pattern of lights facing outward. The material 400 saturated with a light activated resin is then wrapped around the balloon (not shown).

[0036] Exemplary Uses - Use as a Standalone UV Curing Blanket

[0037] Existing technology using UV light curing lamps is limited in size, volume and weight. Curing the repair patch takes a long time because the curing process must be repeated multiple times to cure the entire repair patch. Existing UV curing lamps are equipped with cooling fans and many electrical components to ensure proper function, but add weight and handling.

[0038] Existing UV curing lamps are not flexible, so the curing lamp must be held or mounted away from the repair patch to increase the curing surface. This requires safety protection for operators. Existing UV curing lamps are equipped with high-power LEDs and must be operated at 110V or 220V, which requires a generator and cables.

[0039] The invention can be used to cure repair patches in various industrial applications. The use of repair patches is also common in other industrial fields, such as wind turbines, automobiles, roof repair or military applications. The advantages of the LED blanket of the present invention are flexibility and formability. The LED blanket can be used for very tight bends (angles?), such as the rounded edges of windmill blades or other shapes. The flexibility and unlimited size of the UVLED blanket of the present invention solves the above problems.

[0040] The LED UV blanket can be mounted directly over the repair patch and covers the entire size of the patch. Therefore, no UV light radiation will be released and the entire repair patch will be cured in one application. By using low power LED diodes (12V-48V), the UVLED blanket can be powered by batteries and does not require an external power source. This makes the present invention unique and increases the usability of the device in different applications.

[0041] In one example, the repair of windmill blades is very dangerous and difficult due to the high working environment. The operator carries the repair patch, UV curing lamp, cables and safety equipment. In the present invention, the UV curing blanket is already included in the repair equipment, and only a small battery is needed to power the LED. Utilizing the present invention will eliminate heavy equipment and dangerous work operations. Due to the unique design of the UV curing blanket and its flexibility, the work application will be faster and safer.

[0042] An example of the resulting device, wrapped with material and inserted into a pipe, is positioned at the repair point and inflated, expanding a balloon containing a light blanket and the material wrapped around the balloon, pressing it against the inner surface of the pipe. The UV light blanket inside the balloon is activated, which then cures the material to form a hard pipe or tube according to the present disclosure. Each end of the UV balloon is inserted into two end pieces, forming an outer shell into which air can be introduced, (not shown) expanding the UV balloon, pushing the UV curable material up against the pipe. UV is then irradiated on the curable material separated by a translucent layer.

[0043] One embodiment of the present invention provides an integrated cured-in-place liner UV blanket for installation repair of any and all piping systems. In a preferred embodiment, the diameter of the repaired pipe is 2 inches and above, and exemplary pipe systems include potable water pipes, sewer pipes, side sewer pipes, oil pipelines, gas pipelines, etc. It is further contemplated that the system will be applied to larger diameter pipes and side seals that connect pipes together.

[0044] In another embodiment, the present invention provides LED carpets for use with repair patches in select industrial applications such as wind turbines, automotive, roof repair, military applications, boat hulls, car body repair, surfboards, etc. The advantages of the LED carpet invention are its flexibility and formability. The LED carpet can be used for very tight bends, such as the rounded edge of a windmill blade or other shapes.

[0045] In another embodiment, the present invention provides a UV blanket for installing an integrated in-situ curing liner, wherein the blanket is constructed of a material flexible enough to lay substantially flat to define an upper side and a lower side. The blanket is manufactured in a flat state of 2 to 4 millimeters in thickness, and when inserted into the pipe to be repaired, it is deployed into a tubular shape. The blanket is manufactured in a flat state, can have a variety of sizes depending on the inner diameter of the pipe and the outer diameter of the balloon, and, in use, will be wrapped around or become part of the light-emitting balloon.

[0046] In another embodiment, the present invention provides a UV blanket for mounting an integrated in-situ curing pad, wherein the blanket is composed of at least two plastic sheets with UV light diodes in the middle of the two sheets. In a preferred embodiment, the spacing between the diodes and the rows of diodes is critical for curing and providing adequate light coverage in the overlapping area at the edge. Design examples are considered in which individual diodes and rows of diodes are equidistant between diodes and rows of diodes with approximately 0.25 to 1 inch between diodes and rows of diodes, and include but are not limited to: 1) diodes are arranged side by side on a straight line parallel to the edge of the sheet; 2) diodes are staggered on a straight line parallel to the edge of the sheet; 3) diodes are arranged side by side on a straight line diagonal to the edge of the sheet; and 4) diodes are staggered on a straight line diagonal to the edge of the sheet. The power circuit is located around the edge of the blanket and is connected to an external power source.

[0047] In a further embodiment, the blanket is made of an internal light source (sheet) encapsulated in a waterproof translucent material that allows UV light to pass through. The outer layer covering the LED diodes must be translucent and allow UV light to pass through. The layer on the back of the sheet can be a different material as long as it is flexible. A heat absorbing layer like aluminum or copper foil can be coated or laminated on the protective layer on the back of the sheet to absorb heat from the LED diodes during the curing process. Other heat absorbing materials can also be used.

[0048] Although the principles of the present disclosure have been described above in conjunction with specific apparatus and methods, it is to be clearly understood that such description is made by way of example only and not as a limitation on the scope of the present disclosure.

Claims

1. A light source for installing an in-situ cured pipe liner, wherein the light source comprises: a) a sheet of ultraviolet (UV) light emitting diodes (LEDs); b) flexible circuit arrays; and c) at least one translucent material, Wherein the light source is substantially flat in an initial configuration to define an upper side and a lower side.

2. The light source of claim 1, wherein the LED emits UV light having a wavelength between 365 and 420 nanometers.

3. The light source of claim 1, wherein the light source further comprises a power cable. The light source of claim 1 , wherein the light source is powered by a battery.

5. The light source of claim 1, wherein the at least one translucent material is flexible, expandable, and waterproof.

6. The light source of claim 1 wherein the sheet of UV LEDs is sandwiched between two layers of expandable material forming an upper layer and a lower layer, wherein the at least one translucent material is the upper layer of the light source to allow UV light from the diodes to pass through the material.

7. The light source of claim 6, wherein the lower layer on the lower side of the light source is an opaque flexible protective layer.

8. The light source of claim 3, wherein the power cable further comprises an air hose.

9. The light source of claim 1, wherein the voltage of the UV LED diode is between 12 volts and 48 volts.

10. The light source of claim 1, wherein the UV LED diodes are equally spaced at intervals between 0.25 and 1 inch.

11. A method for curing a UV resin saturated material in a piping system, the method comprising the following steps: a) obtaining a light source capable of activating the UV resin; b) forming the light source into a substantially tubular shape; c) wrapping the tubular light source with a material saturated with UV photosensitive resin; d) inserting the tubular light source of step c) into the pipe to be repaired; e) clamping the ends of the tubular light source to seal it; f) introducing air into the center of the tubular light source of step e); g) activating the light source for about 5 to 15 minutes to cure the resin in situ to form a new pipe segment; h) turning off the light source of step g); and i) Deflation of the tubular light source and removal from the duct system.

12. The method of claim 11, wherein the light source capable of activating the UV resin consists of: a) a sheet of ultraviolet (UV) light emitting diodes (LEDs); b) flexible circuit arrays; and c) at least one translucent material, Wherein the light source is substantially flat in an initial configuration to define an upper side and a lower side.

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