Pipe Liner Spray Apparatus for Uniform Polyurea Lining
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Solution Overview
Problem
Conventional methods for rehabilitating pipes and conduits are inefficient due to issues like leaching of harmful chemicals, uneven lining thickness, static buildup, and mechanical limitations that lead to incomplete coverage and frequent apparatus failure, resulting in environmental damage and economic losses.
Innovation Solution
A pipe liner spray apparatus that uses a mixture of isocyanate and amine resin, applied via a dissipation device with a rotating shaft and reciprocating head, capable of continuous 360-degree coverage, self-cleaning, and adjustable flow, which eliminates static buildup and allows for precise, uniform lining with a cure time of seconds to minutes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thermosetting resin is used for pipe lining, then the pipe can be rehabilitated, but the resin shrinks causing an annulus to form between the pipe wall and the liner which permits infiltration and exfiltration
Solution Approach 1:
The patent changes the material parameter from conventional thermosetting resin to a two-component polyurea system that cures without shrinkage. This parameter change eliminates the annulus formation problem while maintaining pipe rehabilitation effectiveness, as the polyurea liner maintains intimate contact with the pipe wall throughout curing.
Solution Approach 2:
The patent uses a composite material system consisting of isocyanate and amine resin components that react to form polyurea. This composite material approach provides both structural integrity and shrinkage-free curing properties, resolving the contradiction between rehabilitation effectiveness and annulus prevention.
2Productivity
If conventional spray methods are used, then the pipe can be lined, but the lining thickness is uneven and coverage is incomplete
Solution Approach 1:
The patent employs a rotating spray head that dynamically distributes the polyurea material uniformly around the pipe circumference. This dynamic rotation ensures even thickness distribution and complete coverage while maintaining high application speed, resolving the contradiction between productivity and manufacturing precision.
Solution Approach 2:
The spray head is designed to rotate and distribute material in a circular pattern matching the pipe's curvature. This spherical/d rotational approach ensures uniform coverage around the entire pipe circumference, eliminating uneven thickness and incomplete coverage problems.
3Ease of operation
If the apparatus is positioned at the manhole for lining, then the lining can be applied, but the vehicle and equipment tear up soils, grass, remove trees, and cause environmental damage
Solution Approach 1:
The patent extracts the harmful environmental impact by using a remotely operated apparatus that can be positioned outside the manhole. The lining material is delivered through a flexible hose to the pipe interior, eliminating the need for heavy equipment to be positioned in sensitive areas, thus resolving the contradiction between ease of operation and environmental protection.
Solution Approach 2:
The patent introduces a flexible delivery hose as an intermediary between the remote apparatus and the pipe interior. This mediator allows the apparatus to be positioned away from sensitive areas while still delivering lining material effectively, resolving the contradiction between accessibility and environmental protection.
4Reliability
If the pipe capacity is downsized due to liner installation, then the pipe is rehabilitated, but the increased flow velocities cause creek scour and loss of stream banks
Solution Approach 1:
The patent changes the material parameter to shrinkage-free polyurea that maintains the original pipe diameter. By eliminating the annulus that would otherwise reduce pipe capacity, the patent restores pipe integrity while maintaining original flow velocities, thus resolving the contradiction between pipe rehabilitation and prevention of creek scour.
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
Enables remote, efficient lining of pipes with uniform thickness, reducing environmental impact and extending the life of rehabilitated pipes by preventing effluent infiltration and exfiltration, while allowing for multiple layers and precise application in various pipe geometries and diameters.
Implementation Method 1
uses a mixture of isocyanate and amine resin, applied via a dissipation device with a rotating shaft and reciprocating head
Implementation Method 2
dissipation device with a rotating shaft and reciprocating head, capable of continuous 360-degree coverage
Implementation Method 3
eliminates static buildup
Data Source
AI summary
A method and apparatus for remotely installing a monolithic liner in a conduit is disclosed. The apparatus includes a main component body including electromagnetic actuators, pneumatic cylinders, linear actuators relays, solenoids, ion generator, attachment points for tethers, umbilical, cameras and diameter specific guides and a reciprocation head attached thereto. The longitudinally traversing reciprocation head incorporates a fluid driven rotary turbine motor assembly communicating with shaft and self cleaning dissipation device integrating both conical and inverted cone surfaces. Also included on the reciprocating assembly is an impingement block for the efficient mixing of products and a termination mechanism for the precise remote control of product flow. Additionally, the assembly provides the ion generator to direct a stream of negatively charged air flow to the shaft and the diffusion device to effectively prohibit excess material accumulation.