Composite Pipe Liner Preventing Pinhole Leaks

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Solution Overview

Problem

Existing pipe lining methods using carbon fiber fabrics impregnated with curable resin or epoxy tend to develop pinhole leaks due to separation near gaps between fiber bundles, compromising the watertight barrier and structural integrity, especially under high pressure conditions.

Innovation Solution

A composite liner with a strengthening layer of carbon fibers and a watertight layer of glass fibers, arranged in a multi-layered configuration with a satin or twill weave, is applied to the pipe interior, where the glass layer provides a watertight barrier and the carbon layer offers structural reinforcement, inhibiting force transmission from pressurized fluids.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If carbon fiber fabrics are impregnated with curable resin or epoxy to provide high strength and elastic modulus, then the structural reinforcement capability is improved, but pinhole leaks occur due to separation near gaps between fiber bundles

Engineering Contradiction:

Improvestructural reinforcement capabilityVSAvoidwatertight barrier integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent combines carbon fiber bundles (for strength) with a continuous matrix material (for watertightness) to create a composite liner structure. The carbon fiber bundles provide the necessary structural reinforcement while the continuous matrix material fills the gaps between bundles and prevents pinhole leaks, resolving the contradiction between strength and reliability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different materials to different regions of the liner structure: carbon fiber bundles are concentrated in areas requiring structural reinforcement, while the continuous matrix material is distributed throughout to ensure watertightness. This local differentiation allows each material to perform its optimal function without compromising the other.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If the liner is made thin to minimize manufacturing costs and avoid altering pipe internal dimensions, then cost and dimensional compatibility are improved, but structural strength and leak prevention capability are reduced

Engineering Contradiction:

Improvemanufacturing cost and dimensional compatibilityVSAvoidstructural strength and leak prevention

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent uses a composite structure where carbon fiber bundles provide high strength-to-weight ratio, allowing the liner to be thin yet structurally strong. The continuous matrix material ensures watertightness without requiring additional thickness, thus maintaining dimensional compatibility while preventing leaks.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent employs a thin film structure with embedded carbon fiber bundles and continuous matrix material that provides both structural strength and leak prevention in a thin profile, suitable for lining existing pipes without significantly altering internal dimensions.

Inventive Principle:

Principle #30Flexible shells and thin films

3Strength

If carbon fiber bundles are woven into fabrics to carry curable resin, then structural reinforcement is improved, but gaps between bundles create separation points that lead to pinhole leaks

Engineering Contradiction:

Improvestructural reinforcementVSAvoidpinhole leaks and fluid escape

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent creates a composite structure where carbon fiber bundles are embedded in a continuous matrix material. The matrix material fills the gaps between bundles, preventing separation and pinhole leaks while allowing the carbon fiber bundles to provide structural reinforcement.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The continuous matrix material acts as an intermediary between the carbon fiber bundles, bonding them together and filling the gaps between them. This intermediary material prevents fluid escape through pinholes while maintaining the structural integrity provided by the carbon fiber bundles.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS9993992B2Structural fabric useful for lining pipe

Publication Date: 2018.06.12 HENKEL KGAA

AI summary

A structural fabric suitable for lining pipes and pipes lined with the structural fabric. The fabric includes a strengthening layer laminated to a watertight layer. The strengthening layer may include carbon fiber bundles stitched to a watertight layer of woven glass fibers. In some embodiments, the strengthening layer includes lengthwise oriented carbon fiber bundles and widthwise oriented carbon fiber bundles bound together in a non-woven, non-crimp arrangement. The widthwise oriented bundles can have about three-times greater weight per unit area than the lengthwise oriented bundles. The watertight layer provides a watertight barrier when impregnated with the curable polymer, applied to the interior surface of the pipe, and cured. The watertight layer may include lengthwise and widthwise oriented bundles of glass fiber woven into one of a satin and twill weave.