Pipe Restoration Apparatus Using Airflow Control and Pre-Sealing
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Solution Overview
Problem
Existing methods for restoring small diameter pipes, such as the Air-Sand lining process, face challenges in clearing dry sandblasting media, plugging pipe intersections, and inability to effectively seal leaks, leading to restricted flow and inferior coating thickness.
Innovation Solution
An apparatus utilizing airflow measurements and control to optimize leak sealing and coating application within pipes, including an air compressor, control box, media injection device, and coating injection system, which measures and controls airflow, pre-seals leaks with dry media, applies internal protective coatings, and pressure tests the pipe to ensure thorough restoration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compressed air is used to apply liquid epoxy coating to seal leaks, then the coating is forced out the leak opening, but the leak is not sealed
Solution Approach 1:
The patent applies preliminary action by first pre-sealing leaks with dry leak sealing media (cellulose fibers and metal particles) before applying the liquid epoxy coating. This preliminary sealing step prevents the coating material from being forced out through active leaks during the coating application process, allowing the coating to properly adhere and seal the pipe interior.
2Reliability
If filler is added to liquid coating material to seal leaks, then hole sealing capability is improved, but filler is separated by airflow and moved to the front of the lining stream
Solution Approach 1:
The patent separates the leak sealing function from the coating application function by performing preliminary leak sealing with dry media before applying the liquid coating. This prevents filler separation issues during coating application, as the leaks are already sealed and will not force coating material forward. The coating can then be applied uniformly without being disrupted by active leaks.
Solution Approach 2:
The patent uses dry leak sealing media (cellulose fibers and metal particles) as an intermediary substance to seal leaks before the liquid epoxy coating is applied. This intermediary sealing layer prevents the coating material from being forced through leak openings, allowing uniform coating thickness to be achieved without filler separation.
3Manufacturing precision
If multiple shots of coating material are introduced into pipe system, then individual pipe portions are coated, but filler remains within system causing reduced internal pipe diameter
Solution Approach 1:
The patent performs preliminary leak sealing with dry media before introducing multiple shots of coating material. This preliminary action ensures that no filler from subsequent coating shots will be forced out through leaks and remain in the system, preventing reduction in internal pipe diameter while still achieving complete coating coverage.
4Manufacturing precision
If dry sandblasting media is used for cleaning pipe interior, then cleaning effectiveness is improved, but media is difficult to clear from pipe system
Solution Approach 1:
The patent uses compressed air (pneumatics) to both apply the liquid epoxy coating and to clear the dry sandblasting media from the pipe system. The same compressed air source that propels the coating material forward is used to blow remaining media particles out through the outlet end of the pipe, making media removal efficient and integrated into the overall process.
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 method provides a cost-effective alternative to pipe replacement or exterior repairs by ensuring precise airflow control and leak sealing, resulting in a restored pipe with improved flow and durability, reducing the need for frequent maintenance and enhancing the integrity of the pipe system.
Implementation Method 1
compressed air application of an internal liquid epoxy coating
Implementation Method 2
drying an interior surface of a leaking pipe
Data Source
AI summary
A method of internally restoring a pipe preferably includes the steps of isolating a leaking pipe from a system of pipes; drying an interior of a leaking pipe; measuring the airflow through the leak; cleaning the interior of the leaking pipe; presealing a leak with a leak sealing media, measuring the leak flow rate after the pre-sealing; applying an internal protective coating process; and pressure testing the leaking pipe for leaks. The pipe restoration method preferably uses a control box, a media injection system, an air compressor and a coating dispensing system at an inlet of the leaking pipe. The pipe restoration method preferably uses a coating overflow receiver, a muffler and a dust collector at an exit of the leaking pipe. After the treatments, the leaking pipe becomes a restored pipe. The restored pipe is pressure tested for leaks at a working pressure rating of the pipe.