Multi-Layer Patch for Plastic Pipe Repair

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Solution Overview

Problem

Current methods for repairing plastic piping, such as using adhesives, sleeves, or welding, face challenges like non-uniform seals, labor-intensive installation, risk of ignition, and costly excavation, especially when dealing with flammable substances or liquids.

Innovation Solution

A multi-layer patch (MLP) system comprising a polymer adhesive layer and a support film that becomes incorporated upon heat application, optionally with additional layers for reinforcement or barrier functions, allowing for a uniform seal and bonding without free-flowing solvents, enabling repair or connection of plastic piping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If adhesive or composite is applied directly to the crack in the pipe, then repair can be performed, but the seal is not uniform and material may be forced out of the crack during curing

Engineering Contradiction:

Improverepair processVSAvoidseal uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention uses a composite patch assembly consisting of a porous backer layer and a polymer adhesive layer. The porous backer layer provides structural support and allows for uniform distribution of the adhesive, while the polymer adhesive layer forms the sealing bond. This composite structure resolves the contradiction by providing both ease of application and uniform seal quality simultaneously.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a multipart sleeve is placed over the damaged area, then the pipe can be sealed, but significant labor and excavation are required

Engineering Contradiction:

Improvepipe sealVSAvoidinstallation labor

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patch assembly is segmented into two functional layers: a porous backer layer and a polymer adhesive layer. This segmentation allows each layer to perform its specific function optimally - the backer provides structural support and adhesive distribution, while the polymer layer provides the sealing function. The segmented design enables easy application without requiring extensive excavation or labor-intensive installation procedures.

Inventive Principle:

Principle #1Segmentation

3Reliability

If the pipe is cut out and replaced with a new section, then the damaged area can be removed, but excavation and shutdown are required which are costly and time-consuming

Engineering Contradiction:

Improvepipe integrityVSAvoidrepair time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patch assembly is prepared in advance with the porous backer layer and polymer adhesive layer already configured. This preliminary preparation allows for rapid deployment at the repair site without requiring time-consuming excavation, pipe removal, or system shutdown. The pre-configured patch can be applied directly to the damaged area, significantly reducing repair time while maintaining pipe integrity.

Inventive Principle:

Principle #10Preliminary action

4Strength

If welding or spot welding is used to repair the pipe, then the plastic piping can be joined, but the arc or flame could ignite flammable substances

Engineering Contradiction:

Improvepipe connectionVSAvoidignition risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention replaces the thermal/mechanical welding process with a chemical bonding process. Instead of using arcs, flames, or high temperatures that could ignite flammable substances, the patch assembly uses a polymer adhesive that chemically bonds to the pipe surface at lower temperatures. This substitution eliminates the ignition risk while providing sufficient connection strength for pipe repair applications.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 provides a uniform seal that maintains integrity over time, avoids solvent leakage, and allows for low-temperature bonding, reducing the risks associated with traditional repair methods and minimizing costs.

Implementation Method 1

The first layer is a polymer adhesive; this includes gels formed from dissolved polymers or solvent swollen polymer films

Methodology Applied

Scientific EffectAdhesion: Adhesive

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

Methodology Applied

Scientific EffectHeating: Heating