Carbon Fiber Reinforced Polymer Pipe Lining

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Solution Overview

Problem

The existing pipeline infrastructure faces challenges in maintenance due to the need for frequent repairs and replacements, especially for underground pipes, which is time-consuming and costly, particularly when pipes are located under roads or thoroughfares.

Innovation Solution

A composition comprising hydroxyl functional prepolymers and isocyanate prepolymers, combined with carbon fibres, which forms a polymer upon mixing, offering improved rigidity, abrasion resistance, and adherence to pipe surfaces, thereby extending the lifespan of pipes and reducing maintenance costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If pipes are repaired or replaced traditionally, then the pipeline network can be maintained, but significant time and cost are required, especially for underground pipes under roads or thoroughfares

Engineering Contradiction:

Improvepipeline network maintenanceVSAvoidtime for pipe repair or replacement

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent applies a flexible polymer coating composed of hydroxyl functional prepolymers and isocyanate prepolymers that cures to form a protective lining inside the pipe. This thin film reinforcement extends pipe lifespan and maintains reliability without requiring full pipe replacement, thereby reducing downtime and loss of time for maintenance operations.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the chemical and physical parameters of the pipe surface by applying a reactive polymer composition that cures in situ. The composition transforms from liquid state to solid protective coating, altering the surface properties to improve corrosion resistance and structural integrity, enabling maintenance without excavating roads or interrupting service for extended periods.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If pipes are repaired or replaced traditionally, then the pipeline network can be maintained, but significant cost is required, especially for underground pipes under roads or thoroughfares

Engineering Contradiction:

Improvepipeline network maintenanceVSAvoidcost of pipe repair or replacement

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The flexible polymer coating provides a cost-effective solution by reinforcing existing pipes internally rather than replacing entire pipe sections. This thin film approach maintains pipeline reliability at lower cost compared to traditional excavation and pipe replacement, particularly for pipes located under roads or thoroughfares where access is difficult.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The polymer composition is applied and then cures autonomously to form the protective coating. The self-curing mechanism eliminates the need for complex external curing equipment or prolonged maintenance operations, reducing labor costs and making the manufacturing process more economical while maintaining pipeline reliability.

Inventive Principle:

Principle #25Self-service

3Strength

If carbon fibre is added to the composition, then rigidity and abrasion resistance are improved, but the composition complexity increases

Engineering Contradiction:

Improverigidity and abrasion resistanceVSAvoidcomposition complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent creates a composite material by combining organic polymer components (hydroxyl functional prepolymers and isocyanate prepolymers) with inorganic carbon fibre reinforcement. This composite structure synergistically improves rigidity and abrasion resistance beyond what either component could achieve alone, while the two-part formulation keeps the overall system manageable despite the enhanced performance requirements.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The application of the described composition as a lining or coating for pipes enhances their structural integrity, increases their lifespan, and improves their resistance to chemical damage and pressure, thus reducing the frequency of repairs and replacements.

Implementation Method 1

the hydroxyl functional prepolymers are formulated to polymerise with the isocyanate prepolymers to form a polymer containing carbon fibre

Methodology Applied

Scientific EffectPolymerisation:

Implementation Method 2

when the base component is mixed with the activator, the resulting polymer also comprises carbon fibres. It has been found that this results in a cured composition having advantageous properties, for example increased rigidity

Methodology Applied

Scientific EffectReinforcement:

Implementation Method 3

when the composition is applied as a lining or coating of a pipe, additional advantageous properties are obtained. These include improved adherence to the pipe surface

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 4

improved chemical resistance to water and waste water

Methodology Applied

Scientific EffectChemical resistance:

Data Source

PatentUS12304990B2Method and apparatus for lining a pipe

Publication Date: 2025.05.20 AXALTA COATING SYSTEMS IP CO LLC

AI summary

A composition for application to a substrate is provided. The composition comprises a base component and an activator component. The base component comprises hydroxyl functional prepolymers and the activator comprises isocyanate prepolymers. The composition further comprises an amount of carbon fibre. The hydroxyl functional prepolymers are formulated to polymerise with the isocyanate prepolymers to form a polymer containing carbon fibre.