Composite Pipe Sleeve With Heat-Cured Solid Resin for Faster Repair
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Solution Overview
Problem
Traditional cured-in-place pipe repair methods require handling liquid epoxy resins, involve two-part epoxy compositions that cure over time, necessitate specialized equipment, and result in a reduced pipe diameter, which limits flow capacity and increases repair time and costs.
Innovation Solution
A composite sleeve comprising a curable one-part resin composition with reinforcing fibers, which is shelf-stable and cures upon heating, allowing for decoupled preparation and installation, reducing the need for in-field equipment and time, and achieving faster curing and improved pipe integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two-part epoxy resin composition is used for cured in place pipe repair, then the resin can be impregnated into the carrier and cured, but the handling of liquid epoxy resins creates environmental issues and requires special equipment
Solution Approach 1:
The patent changes the physical state parameter of the resin composition from liquid (two-part epoxy) to solid (one-part thermoplastic resin). This parameter change eliminates the environmental hazards and equipment requirements associated with liquid epoxy handling, while maintaining the structural integrity and repair effectiveness of the cured pipe.
Solution Approach 2:
The patent utilizes phase transition by employing a thermoplastic resin that transitions from solid state during storage and installation to a moldable state during heating and forming. This phase transition enables the resin to be handled as a solid (eliminating environmental issues) while still being formable into the desired pipe structure when heated.
2Reliability
If two-part epoxy resin composition is used, then the resin cures over time, but the mixing and curing are coupled and cannot be independently controlled, leading to premature curing
Solution Approach 1:
The patent segments the resin system into a single-component thermoplastic resin, separating the mixing and curing functions. The resin requires no mixing (eliminating premature curing risks) and cures only when heated, allowing independent control of the forming and curing processes. This segmentation simplifies the operation and eliminates the timing constraints of two-part epoxy systems.
3Reliability
If the cured in place pipe is located inside the failed pipe, then the repair is minimally invasive, but the inner diameter of the cured pipe is smaller than the failed pipe, reducing flow capacity
Solution Approach 1:
The patent changes the mechanical properties parameter of the resin by using a thermoplastic resin with lower viscosity when heated. This allows the resin to flow and conform to the pipe interior more effectively, potentially achieving a thinner wall thickness and larger inner diameter compared to rigid two-part epoxy systems, thus improving flow capacity while maintaining repair integrity.
4Reliability
If traditional two-part epoxy resin is used, then the pipe can be repaired, but the process requires mixing, filling, rolling, inverting, and inserting a bladder, increasing equipment needs and repair time
Solution Approach 1:
The patent extracts and eliminates the need for a bladder and the complex multi-step process (mixing, filling, rolling, inverting, inserting) by using a single-component thermoplastic resin that can be directly formed and cured in place. This extraction of unnecessary components and steps significantly reduces equipment requirements and accelerates the repair process while maintaining repair effectiveness.
Solution Approach 2:
The thermoplastic resin is prepared in advance in a stable solid form, eliminating the need for on-site mixing and preparation steps. The resin is already in its final form and only requires heating to activate the curing process, performing the preparation action beforehand and simplifying the on-site repair operation.
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 composite sleeve enables efficient, equipment-free repair with reduced wall thickness and increased pipe diameter, enhancing flow capacity and reducing repair time while maintaining pipe integrity.
Implementation Method 1
Curing of the one-part resin composition preferably is activated by heating to a temperature of about 50° C. or more
Data Source
AI summary
The invention relates to composite sleeves for producing a cured in place pipe, to materials and methods for producing the composite sleeve, to methods for repairing a native pipe with the composite sleeve, and to improved cured in place pipes. The composite sleeve has multiple layers including a core layer of a curable one-part resin composition. The curable one-part resin composition is a solid material at 25° C. Preferably the resin composition is pliable at 25° C. so that it can be flexed during manufacturing and/or during installation in a native pipe.