UV light blanket for the curing of UV - resin saturated material

Abstract

A light blanket for use in the installation of cured-in-place pipe liners, made from a sheet of ultraviolet light emitting diodes (UV LEDs) embedded in a flexible array of circuitry, enclosed by a protective, translucent material allowing the sheet, and therefore, the blanket, to illuminate and emit light.

Description

[0001] UV LIGHT BLANKET FOR THE CURING OF UV - RESIN SATURATED MATERIAL by

[0002] Richard Montemarano and Rene Quitter

[0003] FIELD OF THE INVENTION

[0004] The present invention relates generally to tube liners for pipes and more particularly to cured-in-place tube liners.

[0005] BACKGROUND OF THE INVENTION

[0006] Much of the infrastructure in cities around the world was installed many years ago, and is now beginning to age and decay. For example, aging pipes for sewers, storm drains, water, gas, oil, etc. begin to leak due to cracks / damage in the walls of the pipes and in connection between pipe segments. Where the pipe is carrying sewage or other hazardous materials, it is unacceptable to allow leaks into the environment. Thus, a significant task for local, state and national governments around the world is to replace damaged pipelines with new ones.

[0007] However, as most pipes are underground, it is extremely expensive and time consuming to replace pipes. The earth around the damaged pipe must be excavated, and the damaged pipe must be removed from the ground. The new pipe segment must then be placed in the excavation site, joined and sealed to adjacent pipe segments, and then buried again. All of these tasks are very time consuming and require heavy machinery and many workers, thus making the replacement process very expensive.

[0008] As an alternative to excavating damaged pipes, it is possible to replace / repair the pipe from the inside out using a curable fabric liner. The liner, typically fiberglass or felt, is impregnated with a curable resin and then inserted or inverted (i.e. turned inside-out) into the damaged pipe. By using a fluid medium under pressure (e.g. gases or liquids, including air or water), the liner is pressed against the inner walls of the existing damaged pipe. Once the resin cures (due to a catalyst of heat, light, or chemical), the liner is rigid and the pressure source can be removed, leaving a new gas / liquid-tight inner wall of the damaged pipe.

[0009] In addition to pipes, there are a wide array of other surfaces that need repair using a hardened, curable material. Examples include but are not limited to boat hulls, windmill blades, surfboards, building surfaces, and floors.

[0010] Existing technology is a liner or other flat material cured by external stimulation, either ambient or heat. Proposed is a system that is an add-on light curing technology to the existing technology eliminating the need for additional costly curing equipment required for light curing.

[0011] SUMMARY OF THE INVENTION

[0012] The present invention provides for a light blanket in accordance with the disclosure, made from a sheet of ultraviolet light emitting diodes (UV LEDs) embedded in a flexible array of circuitry, enclosed by a protective, translucent material allowing the sheet, and therefore, the blanket, to illuminate and emit light.

[0013] The blanket is made specifically to cure light activated resins and epoxies. The wavelength of light given off by the diodes (between 365 and 420nm) activates the resin to cure to a hardened material in any shape to which the blanket forms. In the case of repairing pipes, the blanket can be a) wrapped around an existing spot repair / point repair bladder with the lights facing outward; b) the blanket can serve as the bladder of the spot repair / point repair device itself; or c) the blanket can serve as a flat curing device that forms to different shapes depending on the application. The blanket overlaps itself by several inches allowing the underlying bladder to expand.

[0014] Prior to the bladder being inserted into a pipe, the bladder is covered with the blanket. A material saturated with light sensitive resin is then wrapped around the blanket overlapping itself on the ends, or pulled over the blanket if it is a single tube of material. The resulting device, i.e., the bladder, wrapped by the overlapped lights, wrapped by the material, is then inserted into a pipe through a “clean out” section or a manhole and pushed or pulled to the point of repair. Air is introduced into the bladder, expanding it along the overlapped blanket, and the material, to fit tightly up against the interior of the pipe. The lights on the blanket are turned on from an external power source attached to the blanket. The UV lights activate the resin, curing the material in place to form a new pipe segment within the existing pipe, repairing the pipe in a matter of minutes without the need for replacement. Once the repair is complete, the bladder is deflated, relieving pressure on the blanket, and both the bladder and the blanket are pulled out of the pipe leaving the repair in place.

[0015] Alternatively, the blanket can serve as the bladder of the device itself. In this case the blanket is sandwiched between two layers of expandible material with the lights facing outward. The outer material is translucent and able to allow UV light through. The two pieces of material that sandwich the blanket, which is overlapped on itself, are closed at each of their ends by end pieces that clamp each side to ensure the light emitting bladder can hold air pressure.

[0016] Prior to the light emitting bladder being inserted into a pipe, a material saturated with light sensitive resin is then wrapped around the light emitting bladder overlapping itself on the ends or pulled over the bladder if it is a single piece of tubular material. The resulting device, i.e., the light emitting bladder, wrapped by the material, is then inserted into a pipe through a “clean out” section or a manhole and pushed or pulled to the point of repair. Air is introduced into the light emitting bladder, expanding it along the material, to fit tightly up against the interior of the pipe. The lights on the light emitting bladder are turned on from an external power source attached to the bladder. The UV lights activate the resin, curing the material in place to form a new pipe segment within the existing pipe, repairing the pipe in a matter of minutes without the need for replacement. Once the repair is complete, the light emitting bladder is deflated and pulled out of the pipe leaving the repair in place.

[0017] Alternatively, still, the blanket can serve as a flat curing device capable of forming into different shapes depending on the application. For example, a repair to the side of the hull of a boat or the damage to 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 blanked can be either secured by straps, tape, or other means to press it firmly against the material. The lights are activated, and the material is cured. The blanked is then removed to be used once again.

[0018] 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 disclosure.

[0019] BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The invention is now described, by way of a non-limiting example, with reference to the accompanying drawings, in which:

[0021] FIG. 1 shows a preferred embodiment of the present invention comprising the internal light source comprising a sheet of UV LEDs.

[0022] FIG. 2 shows a side view of the sheet of UV LEDs, (FIG. 1) enclosed within the protective, translucent enclosure, which makes up the light blanket of the present invention.

[0023] FIG. 3 shows the application of the blanket around the existing technology.

[0024] FIG. 4 shows the cured-in-place liner material as applied within a pipe during the curing process.

[0025] FIG. 5 shows another application of the blanket where the blanket acts as the bladder. Each end of the UV bladder, created by the UV blanket, is inserted into or clapped around two end pieces creating an enclosure that air can be introduced, inflating the UV bladder pushing the UV curable material up against the pipe. The UV lights then being up against the curable material separated by a translucent layer. FIG. 6 shows the standalone UV bladder discussed in FIG. 5 that can be part of a device. Where 210 is a expandable translucent material, 310 is an expandable material and 100 is the overlap light sheet.

[0026] DETAILED DESCRIPTION OF THE INVENTION

[0027] An example of the light source in accordance with the disclosure is shown in FIG. 1. The light source matrix is a sheet embedded with UV LEDs. The sheet 100 is specifically designed to allow for maximum coverage of UV light with the minimal amount of UV light diodes 110 to cure light activated resins. This is accomplished by the spacing and patterns of the lights embedded in the flexible substrate as well as the lumens emitted by the lights. The sheet 100 is made to be flexible enough to roll into a tube form without compromising the construction of the circuitry.

[0028] The UV sheet 100 is constructed of material sufficiently flexible to lie substantially flat to define an upper portion and a lower portion. The sheet 100, when manufactured, is in the flat state of between two to four mm thick and, when inserted into a pipe to be repaired, is deployed into a tubular shape. The sheet 100 when manufactured is in a flat state in a variety of sizes depending upon the inner diameter of the pipe and the outer diameter of the bladder and will wrap around or become a part, of in the case of use, as a light emitting bladder.

[0029] The spacing between the diodes 110 and rows of diodes 110 is critical for curing as well as providing sufficient light coverage in the areas of overlap at the edges. The design of the sheet 100 is a plastic sheet 210 with UV light diodes 110 in the middle of the two layered sheets 210. The preferred voltage of the LED diodes is 12V to 48V. Examples of the design where the individual diodes 110 and rows of diodes 110 are equidistant at roughly between 0.25 and 1 inch between diodes and rows of diodes are contemplated and include but are not limited to: 1) diodes 110 side by side in lines running parallel to the edge of the sheet; 2) diodes 110 staggered in lines running parallel to the edge of the sheet; 3) diodes 110 side by side in lines diagonal to the edge of the sheet; and 4) diodes 110 staggered in lines running diagonal to the edge of the sheet. Power source circuitry 120 is positioned around the edge of the blanket 100 and connects to an external power source 130.

[0030] An example of the blanket 200 in accordance with the disclosure is shown in FIG. 2. The blanket 200 is made of the internal light source (sheet 100) encapsulated in a waterproof translucent material 210 allowing UV light to pass through. The outer layer which covers the LED diodes 110 must be translucent and allow UV light to pass through. Examples of translucent material are expandable silicone or polyethylene or any other material that is translucent and expandable. The layer on the backside of the sheet may be a different material as long it is flexible. The protective layer on the backside of the sheet can be coated or laminated with a heat absorbent layer like aluminum or copper foil to absorb heat from the LED diode 110 during the curing process. Other heat absorbent material may also be used.

[0031] The light sheet 100 is comprised of UV light diodes 110 in a pattern that allows for light overlap so no portion of a covered surface will be without light. The light angle of the LED lens should be between 120 to 180 degrees. This can range from 1 diode per square inch to 10 diodes per square inch. Power is sent to the blanket along the edge of the sheet by one or more connections to an external power source.

[0032] One or multiple waterproof power connections 130 can be attached to the light blanket 100. The electrical power cable can be combined with an air hose or can stay as a single power cable. The power cable runs along an air hose or push rod that is used to inflate the bladder or pushing and pull the bladder into the pipe. The air / power or single cable may be connected to a control box outside of the pipe or repair point. The control box is used to turn on and off the LED blanket and to inflate the bladder via an air pressure valve. The control box also includes a volt - and amperage display. Both displays indicate the function of the LED blanket. This device can have cameras on the inside or outside to observe the curing process. The picture of one or multiple cameras will be displayed at a screen mounted into the control box.

[0033] - Usage for existing technology -

[0034] Conversion from existing ambient or heat cured devices to UV curing. As shown in FIG. 3, the blanket 200 may be wrapped around an existing point repair / spot repair bladder 300 when used in patching damaged pipes of all sizes. Existing technology (see FIG. 3) uses a non-translucent rubber bladder and an ambient or heat activated material that was wrapped around the non-translucent bladder. The curing material (not shown) must be statured at the jobsite and is time sensitive. The curing time can be several hours until the material is hardened in the pipe. In the present invention, the blanket 200 may overlap 250 upon itself, allowing for the underlying bladder 300 to expand, allowing the light blanket 200 to expand with it, maintaining an unbroken pattern of light facing outward toward the pipe. Material saturated with light activated resin is then wrapped or pulled around the blanket 200. The resin saturated material may be multiple layers of fiberglass, felt, polyesters, Kevlar or any other UV curable material.

[0035] An example of the resulting device is shown in FIG. 4. Prior to the bladder 300 being inserted into a pipe 500, the bladder 300 is covered with the blanket 200. A material 400 saturated with light sensitive resin is then wrapped around the blanket 200 overlapping itself 250 on the end. The resulting device, i.e., the bladder, wrapped by the overlapped lights, wrapped by the material, is then inserted into a pipe 500 through a “clean out” section or a manhole and pushed or pulled to the point of repair. Air is introduced into the bladder 300, expanding it along the overlapped blanket 200, and the material 400, to fit tightly up against the interior of the pipe. The lights on the blanket are turned on from an external power source attached to the blanket. The UV lights activate the resin, curing the material in place to form a new pipe segment within the existing pipe, repairing the pipe without the need for replacement. Once the repair is complete, the bladder is deflated, relieving pressure on the blanket, and both the bladder and the blanket are pulled out of the pipe leaving the repair in place. Therefore, the original, flat, UV blanket 100 has transformed into a cylindrical shape, wrapped with a UV light curable material 400, which is then inserted into a pipe to repair a variety of issues within the pipe, i.e., leaks, cracks, holes, etc.

[0036] Exemplary Usage- Usage for a UV curing packer having Blanket as part of this device In an existing UV curing packer, (an expandible tube used for the installation of CIPP liner repairs, i.e. spot repairs, point repairs; also know as a bladder) the light emitting LEDs or UV light bulbs are centered in the middle of the device to provide an equal light exposure to the curing material. The UV LED’s or light bulbs are surrounded by an inflatable bladder. The construction of such devices is cost effective, but the flexibility is limited. During the inflating process with an existing UV packer, the water flow in the pipe will be blocked because the existing devices have no flow through application. The risk of flooding or damaging the UV packer is very high.

[0037] The current invention solves the above stated problems because the LED blanket 200 (Fig. 6) is part of the bladder, and the center of the UV packer is hollow. Therefore, a flexible and pressure resistant hose can be mounted in the center of the UV packer and allow the water to flow through during the curing process.

[0038] The LED blanket can be an independent layer under the inflatable bladder 300. Therefore, the UV LED blanket is located close to the inflatable bladder and functions as a light emitting source of the device. In this application the UV LED blanket is not inflatable. The UV LED blanket will be mounted to the end pieces of the UV packer and stays circular and close to the inflatable bladder. The LED UV blanket can be mounted as a solid layer under the inflatable layer or in segments to increase the flexibility of the packer.

[0039] A second exemplary use of the current invention is disclosed in FIG. 5 wherein the light sheet 100 is sandwiched between two layers of translucent material 210, 300 that are inserted / connected to two separate end pieces. The resulting configuration can then be inflated with air 600 and used in patching damaged pipes of all sizes in accordance with the disclosure. The blanket may overlap upon itself 250, allowing for the bladder (not shown) to expand, allowing the light blanket to expand with it, maintaining an unbroken pattern of light facing outward. Material saturated with light activated resin 400 is then wrapped around the bladder (not shown).

[0040] Exemplary Usage - Usage as a standalone UV curing blanket. Existing technologies using UV light curing lamps are limited in size, bulky and heavy. To cure repair patches takes long time because the curing process must be repeated multiple times to cure the entire repair patch. The existing UV curing lamps are equipped with cooling fans and many electrical components to ensure a proper function, witch increase weight and handling. Existing UV curing lamps are not flexible, therefore the curing lamp must be held or mounted away from the repair patch to increase the curing surface. This requires safety protection gear for the operator. The existing UV curing lamps are equipped with high power LED’s and must be operated with 110V or 220V, which requires generators and electrical cables.

[0041] The current invention can be used to cure repair patches in a variety of industrial applications. The usage of repair patches is also common in other industry sectors, like wind turbine, cars, roofing repairs or military application. The advantage of the LED blanket invention is the flexibility and shaping. The LED blanket can be used for very tight bends (angles?) like the rounded edge of a windmill blade or other shapes. The flexibility and unlimited size of the UV LED blanket in the current invention solves the problems discussed above.

[0042] The LED UV blanket can be mounted directly to the repair patch and cover the entire size of the patch. Therefore, no radiation from the UV light will be released and the entire repair patch will be cured in one application. By using low power LED diodes (12V - 48V), the UV LED blanket can be powered by batteries and no external power sources are necessary. This makes this invention unique and increases the availability of the device for different applications.

[0043] In one example, the repair of windmill blades is very risky and difficult because of the high working environment. The operator carries the repair patches, UV curing lamp, electrical cables, and safety gear. With the current invention the UV curing blanket is already included in the repair device and just a small battery is required to power the LEDs. Heavy equipment and risky work operation will be eliminated with the current invention. Due to the unique design of the UV curing blanket and his flexibility the work application will be faster and safer.

[0044] An example of the resulting device, wrapped with material and inserted into a pipe, positioned at the point of repair, and inflated, expanding the bladder containing the light blanket as well as the material wrapped around the bladder, pressing it against the inner surface of the pipe. The blanket of UV lights within the bladder is activated, which then cures the material to form a hard pipe or tube in accordance with the disclosure. Each end of the UV bladder is inserted into two end pieces creating an enclosure that air can be introduced, (not shown) inflating the UV bladder pushing the UV curable material up against the pipe. The UV lights then being up against the curable material separated by a translucent layer.

[0045] One embodiment of the present invention provides a UV blanket for the installation of integrated cured-in-place liner for repair of any and all pipe systems. In a preferred embodiment, the diameter of repaired pipes is 2” and above and exemplary pipe systems include potable water pipes, sewer pipes, lateral sewer pipes, oil pipes, gas pipes, etc. It is further contemplated the system be applied to larger diameter pipes and lateral seals which join pipes together.

[0046] In another embodiment, the present invention provides an LED blanket for usage with repair patches in alternative industry sectors, like wind turbine, cars, roofing repairs, military application, boat hulls, autobody repair, surfboards and more. The advantage of the LED blanket invention is his flexibility and shaping. The LED blanket can be used for very tight bends like the rounded edge of a windmill blade or other shapes.

[0047] In yet another embodiment, the present invention provides a UV blanket for the installation of integrated cured-in-place liners wherein the blanket is constructed of material sufficiently flexible to lie substantially flat to define an upper portion and a lower portion. The blanket, when manufactured, is in the flat state of between two to four mm thick and, when inserted into a pipe to be repaired, is deployed into a tubular shape. The blanket when manufactured in a flat state in a may be a variety of sizes depending upon the inner diameter of the pipe and the outer diameter of the bladder it will wrap around or become a part of in the case of use as a light emitting bladder.

[0048] In still another embodiment, the present invention provides a UV blanket for installation of integrated cured-in-place liners wherein the blanket is comprised of at least two plastic sheets with UV light diodes in the middle of the two layered sheets. In a preferred embodiment, spacing between the diodes and rows of diodes is critical for curing as well as providing sufficient light coverage in the areas of overlap at the edges. Examples of the design where the individual diodes and rows of diodes are equidistant at roughly 0.25 and 1 inch between diodes and rows of diodes are contemplated and include but are not limited by: 1) diodes side by side in lines running parallel to the edge of the sheet; 2) diodes staggered in lines running parallel to the edge of the sheet; 3) diodes side by side in lines diagonal to the edge of the sheet; and 4) diodes staggered in lines running diagonal to the edge of the sheet. Power source circuitry is positioned around the edge of the blanket and connects to an external power source.

[0049] In a further embodiment, the blanket is made of the internal light source (sheet) encapsulated in a waterproof translucent material allowing UV light to pass through. The outer layer which covers the LED diodes must be translucent and allow UV light to pass through. The layer on the backside of the sheet may be a different material as long it is flexible. The protective layer on the backside of the sheet can be coated or laminated with a heat absorbent layer like aluminum or copper foil to absorb heat from the LED diode during the curing process. Other heat absorbent material may also be used.

[0050] While the principles of the disclosure have been described above in connection with specific apparatuses and methods, it is to be clearly understood that this description is made only by way of example and not as limitation on the scope of the disclosure.

Claims

Claims:What is claimed is:

1. A light source for installation of cured-in-place pipe liners, wherein the light source is comprised of: a) a sheet of ultraviolet (UV) light emitting diodes (LEDs); b) a flexible array of circuitry; 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’s emit UV light of the wavelength between 365 and 420 nm.

3. The light source of claim 1, wherein the light source is further comprised of an electrical cable.

4. The light source of claim 1, wherein the light source is powered by batteries.

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 creating an upper layer and a lower layer wherein the at least one translucent material is the upper layer of the light source so as to allow UV light from the diodes to pass through the material.

7. The light source of claim 6, wherein the lower layer positioned on the lower side of the light source is a non-translucent, flexible protective layer.

8. The light source of claim 3, wherein the electrical cable is further comprised of an air hose.

9. The light source of claim 1, wherein the UV LED diodes are a voltage of between 12 volts and 48 volts.

10. The light source of claim 1, wherein the UV LED diodes are positioned equidistant at between 0.25 and 1 inch apart.

11. A method for curing a UV resin saturated material within a pipe system, the method comprising the following steps: a) obtaining a light source capable of activating a UV resin; b) forming the light source into a substantially tubular shape c) wrapping the tubular shaped light source with a material saturated with UV light sensitive resin; d) inserting the tubular light source of step c) into a pipe requiring repair; e) clamping the ends of the tubular light source closed; f) introducing air into the center of the tubular light source of step e); g) activating the light source for approximately 5-15 minutes to cure the resin in place to form a new pipe segment; h) deactivating the light source of step g); andi) deflating the tubular light source and removing it from the pipe system.

12. The method of claim 11, wherein the light source capable of activating a UV resin is comprised of: a) a sheet of ultraviolet (UV) light emitting diodes (LEDs); b) a flexible array of circuitry; 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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