Curable Pipe Liner Resin Ratio for Curing Efficiency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional curable compositions for cured-in-place pipe repair lack adequate latency period, structural integrity, and efficient curing at temperatures compatible with hot water bladders or steam, often requiring high levels of curing agents or diluents, which increase costs and production challenges.
Innovation Solution
A curable composition comprising a 4,4′-isopropylidenediphenol-epichlorohydrin copolymer resin with a specific ratio of resin to curing agents (12:1 to 15:1) that provides a suitable latency period, structural integrity, and efficient curing at compatible temperatures, reducing the need for additional components and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional curable compositions use high levels of curing agent or accelerator to efficiently cure at temperatures compatible with hot water bladder or steam, then curing efficiency is improved, but material costs and production costs increase
Solution Approach 1:
The patent changes the chemical structure parameters of the resin from conventional epoxy resins to a specific phenolic resin with hydroxyl groups, and adjusts the resin-to-curing-agent ratio parameter to 10:1 to 15:1 by weight. This parameter change allows efficient curing at lower curing agent levels while maintaining compatibility with hot water bladder or steam temperatures
Solution Approach 2:
The patent uses a composite curing system combining a carboxylic acid salt of a tertiary amine with specific structural features (Formula I or II) with the phenolic resin. This composite material approach enables efficient curing at reduced curing agent quantities while maintaining cure efficiency at temperatures compatible with hot water bladder or steam applications
2Ease of operation
If conventional curable compositions add diluent to reduce viscosity and increase latency period, then ease of insertion is improved, but material costs and structural integrity decrease
Solution Approach 1:
The patent changes the resin structure parameter to use a phenolic resin with specific molecular weight and hydroxyl group content, and adjusts the resin-to-curing-agent ratio to 10:1 to 15:1 by weight. This parameter change achieves adequate latency period and suitable viscosity without requiring diluents, maintaining both ease of insertion and structural integrity
3Speed
If conventional curable compositions require high levels of curing agent to efficiently cure at compatible temperatures, then curing speed is improved, but overall cost increases
Solution Approach 1:
The patent changes the chemical parameters of both the resin (phenolic structure with specific hydroxyl content) and the curing agent (carboxylic acid salt of tertiary amine with specific Formula I or II structure), and optimizes the ratio parameter to 10:1 to 15:1 by weight. This enables fast curing speed at reduced curing agent quantities while maintaining temperature compatibility with hot water bladder or steam
Solution Approach 2:
The patent employs a composite material system where the specific phenolic resin combines with the structured carboxylic acid salt of tertiary amine. This composite approach achieves rapid curing at lower curing agent levels through synergistic chemical interaction, reducing overall material costs while maintaining curing speed
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 composition offers an extended pot life, maintaining structural integrity and efficient curing, allowing for effective insertion and curing within damaged pipes without excessive viscosity or flowability, thereby enhancing the cost-effectiveness and practicality of the repair process.
Implementation Method 1
Curable compositions comprising an epoxy resin and a curing agent are well known in the art
Implementation Method 2
the curable composition is cured with a hot water bladder or steam to form a tight-fitting replacement pipe
Data Source
AI summary
Disclosed is a curable composition with enhanced curing time at ambient temperatures, the curable composition including (a) a resin, e.g., 4,4′-isopropylidenediphenol-epichlorohydrin copolymer and (b) one or more curing agents, wherein a ratio of a weight percentage of the resin to a weight percentage of the curing agent or curing agents is from about 12:1 to about 15:1. Also disclosed is a method of curing a cured-in-place liner, wherein the cured-in-place liner contains the above curable composition.