Epoxy Liner Sealing for Pipe Corrosion and Leak Repair
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Solution Overview
Problem
Current methods for repairing leaks in small diameter metal and plastic pressurized pipes are labor-intensive, costly, and often require extensive demolition, with existing solutions failing to provide a single operation for both leak sealing and barrier coating, leading to temporary fixes and increased maintenance needs.
Innovation Solution
A method and system for repairing interior walls and sealing leaks in small diameter pipes by applying a durable epoxy barrier coating and sealant in a single operation, using a process that includes air drying, profiling with abrasive agents, and applying the coating without dismantling the piping system, suitable for pipes from 3/8 to 6 inches in diameter, including bends, and applicable to various materials like galvanized steel, copper, and PVC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional pipe replacement methods are used, then leak repair reliability is improved, but construction cost and labor time increase significantly
Solution Approach 1:
The invention extracts the pipe section containing the leak and replaces it with a flexible liner that is inserted into the existing pipe. The liner is then inflated to take the shape of the host pipe, creating a new functional pipe within the old one. This removes the need for extensive demolition and reconstruction while maintaining repair reliability.
Solution Approach 2:
The invention implements nesting by placing a flexible liner inside the existing damaged pipe. The liner contains the leak repair functionality within the host pipe structure, allowing the new repair element to be contained within and supported by the original pipe infrastructure, thereby reducing construction complexity.
2Ease of operation
If pipe access demolition is performed to reach hidden pipes, then leak repair accessibility is improved, but building structure damage and repair time increase
Solution Approach 1:
The invention extracts the need for extensive demolition by inserting the repair liner through existing accessible points in the piping system. The liner is fed through the pipe network using water or air pressure, eliminating the need to tear into walls and floors to access hidden pipes, thereby reducing building repair time significantly.
Solution Approach 2:
The invention uses water or air pressure as an intermediary force to propel the flexible liner through the pipe network. This mediator enables the repair element to reach hidden pipes without physical demolition, maintaining accessibility while avoiding building structure damage.
3Manufacturing precision
If chemical cleaning solutions are used to prepare pipes for coating, then coating adhesion is improved, but environmental harm and safety risks increase
Solution Approach 1:
The invention converts the potentially harmful chemical cleaning process into a mechanical/physical cleaning process using water or air pressure. This eliminates environmental harm and safety risks while maintaining coating adhesion through proper surface preparation that removes contaminants without requiring toxic chemicals.
Solution Approach 2:
The invention replaces the chemical cleaning system with a mechanical/physical cleaning system using water or air pressure to prepare the pipe surface for coating. This substitution eliminates the need for harmful chemical solutions while achieving the same coating adhesion results through physical removal of contaminants.
4Reliability
If multiple separate repair applications are used, then specific repair effectiveness is improved, but process complexity and cost increase
Solution Approach 1:
The invention merges multiple separate repair applications into a single integrated process. The flexible liner is inserted, inflated, and cured in one continuous operation, combining leak sealing, structural reinforcement, and coating application into a single repair element that addresses all repair needs simultaneously, thereby reducing process complexity and cost.
Solution Approach 2:
The flexible liner serves multiple functions simultaneously: it seals leaks, reinforces the pipe structure, and provides a protective coating. This multi-functional design eliminates the need for multiple separate repair applications, reducing process complexity while maintaining comprehensive repair effectiveness.
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
This approach minimizes disruption, reduces labor and material costs, extends pipe life by preventing corrosion, enhances hydraulic flow, and allows for quick restoration of piping systems, maintaining operational integrity while reducing waste and environmental impact.
Implementation Method 1
applying a barrier coating leak sealant to interior walls of the pipes... wherein the barrier coating leak sealant provides an interior barrier for protecting the interior walls of the pipes and sealing leaks
Implementation Method 2
profiling the piping system using an abrasive cleaning agent
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
Methods and systems for cleaning, coating and sealing leaks in existing pipes, in a single operation. A piping system can be cleaned in one pass by dry particulates forced and pulled by air throughout the piping system by a generator and a vacuum. Pipes can be protected from water corrosion, erosion and electrolysis, extending the life of pipes such as copper, steel, lead, brass, cast iron piping and composite materials. Coatings can be applied to pipes having diameters up to approximately 6". Leak sealants of at least approximately 4 mils thick can cover insides of pipes, and can include novel mixtures of fillers and epoxy materials, and viscosity levels. A positive pressure can be maintained within the pipes during applications. Piping systems can be returned to service within approximately 96 hours.