Multi-layer Patch System for Plastic Pipe Repair
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for repairing plastic piping, tanks, and vessels are inefficient due to non-uniform seals, long curing times, labor-intensive processes, risks of ignition during welding, and lack of effective adhesive methods for polyolefins, which pose challenges in terms of safety, cost, and material integrity.
Innovation Solution
A multi-layer patch (MLP) system comprising a polymer adhesive layer, a support film, and optional reinforcing materials, which incorporates a solvent delivery system and heating elements for rapid bonding, providing a uniform seal and enhanced strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If adhesive or composite is applied directly to the crack, then the repair can be performed in place, but the seal is non-uniform and curing time is extended (2-3 hours to 1-7 days)
Solution Approach 1:
The repair system is divided into multiple functional layers: a first layer comprising polymer adhesive and a second layer comprising support film. This segmentation allows each layer to perform its specific function optimally - the adhesive provides bonding while the support film ensures uniform distribution and structural integrity, resolving the seal uniformity issue while maintaining in-place repair capability.
2Ease of operation
If adhesive or composite is applied directly to the crack, then the repair can be performed in place, but curing time is extended (2-3 hours to 1-7 days)
Solution Approach 1:
The patent modifies the chemical parameters of the adhesive system by incorporating specific polymers and solvents that enable faster curing. The support film also contributes to accelerating the curing process by providing a controlled environment for adhesive bonding, reducing curing time from days to hours while maintaining in-place repair capability.
3Strength
If welding is performed on plastic piping, then the pipe sections can be joined, but there is risk of ignition of flammable substances and excavation is required
Solution Approach 1:
The patent replaces the thermal/mechanical welding process with a chemical adhesive bonding system. Instead of using heat and pressure to fuse plastic materials, the invention uses polymer-based adhesives that chemically bond to the pipe surfaces, eliminating the ignition risk associated with welding while providing sufficient bond strength for repair applications.
4Reliability
If multipart sleeve is placed over the damaged area, then the damaged area is sealed, but significant labor for excavation is required
Solution Approach 1:
The patent extracts the essential sealing and bonding functions from the complex multipart sleeve system and combines them into a simplified two-layer adhesive system. This eliminates the need for excavation and complex sleeve installation while maintaining seal integrity through the coordinated action of the adhesive and support film layers.
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 MLP system achieves a uniform seal, reduces curing time, and enhances the strength of the bond, making repairs more efficient and safer by eliminating the need for excavation and minimizing the risk of ignition, while being suitable for polyolefin materials.
Implementation Method 1
The first layer is a polymer adhesive; this includes gels formed from dissolved polymers, solvent swollen polymer films, or solvent saturated polymer foams
Implementation Method 2
The second layer is a support film, or backing layer, that becomes intimately incorporated with the first polymer adhesive layer upon application of heat
Data Source
AI summary
A multi-layered patch including a backing layer, an outer layer, polymer adhesive layers that include a polymer foam and a solvent, and a heating layer that includes a polymer substrate, a heating element and a sensor, and methods of making and using the multi-layered patch.