Polyester Pipe Liner Resin With Ambient Cure and Lower Exotherm

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Solution Overview

Problem

Existing pipeline repair methods face challenges with leakage due to improper installation, aging, and environmental factors, leading to fluid waste and potential structural failures, and current resin systems require cold storage initiators that are hazardous and costly.

Innovation Solution

A curable unsaturated polyester resin system using a Cumene-quat curing system with a single-component, non-cold storage initiator, which is safer, more cost-effective, and easier to handle, comprising cumene hydroperoxide, quaternary ammonium salts, and 2,4-pentanedione, allowing for a longer pot-life and reduced cure exotherm.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional cold storage initiators are used in resin systems, then the resin can be cured, but the system becomes hazardous and costly requiring cold storage facilities

Engineering Contradiction:

Improvecure reliabilityVSAvoidhazard and cost

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the chemical parameters of the initiator system by replacing cold storage peroxide initiators with a cumene hydroperoxide and quaternary ammonium salt combination that operates at ambient temperatures. This parameter change eliminates the need for cold storage facilities while maintaining cure reliability, directly resolving the contradiction between cure effectiveness and hazard/cost reduction.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses a single-component resin system where the initiator is integrated into the resin formulation itself, eliminating the need for separate, expensive cold storage initiator components. This approach reduces both material costs and infrastructure costs for cold storage while maintaining effective curing capability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If traditional resin systems are used for pipeline repair, then the pipeline can be rehabilitated, but the process requires cold storage and complex handling procedures

Engineering Contradiction:

Improvepipeline repair effectivenessVSAvoidhandling complexity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent merges the initiator components (cumene hydroperoxide and quaternary ammonium salt) directly into the resin system as a single-component formulation. This consolidation eliminates the need for separate storage and handling of multiple components, simplifying the overall process while maintaining pipeline repair effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single-component resin system is self-sufficient, containing all necessary curing agents and initiators within the resin itself. This self-service capability eliminates the need for complex external handling procedures and cold storage infrastructure, making the pipeline repair process easier to operate while maintaining reliability.

Inventive Principle:

Principle #25Self-service

3Productivity

If the resin cures quickly, then the repair process is faster, but the risk of hot spots and improper curing increases

Engineering Contradiction:

Improvecuring speedVSAvoidhot spots

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent employs a two-stage curing mechanism where cumene hydroperoxide initiates the reaction and quaternary ammonium salts provide sustained catalytic activity. This periodic action pattern allows the resin to cure at a controlled rate, maintaining productivity while distributing heat generation over time to prevent hot spots and ensure proper curing.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The invention changes the kinetic parameters of the curing reaction by using a catalyst system that provides controlled reaction rates. The quaternary ammonium salts modify the reaction profile to reduce peak exothermic events, thereby preventing hot spots while maintaining overall curing speed and productivity.

Inventive Principle:

Principle #35Parameter changes

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 system provides a safer, cost-effective, and efficient pipeline repair method with extended pot-life, reduced risk of hot spots, and comparable mechanical and corrosion-resistant properties to traditional systems, while eliminating the need for cold storage and complex handling procedures.

Implementation Method 1

a peroxide initiator, a quaternary ammonium salt component, a 2,4-pentanedione component

Methodology Applied

Scientific EffectFree radical polymerization: Photopolymerisation

Implementation Method 2

a peroxide initiator, a quaternary ammonium salt component

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

a 2,4-pentanedione component

Methodology Applied

Scientific EffectChelation:

Data Source

PatentUS11180632B2Unsaturated polyester resin system for cured in-place piping

Publication Date: 2021.11.23 INTERPLASTIC

AI summary

A process to use an unsaturated polyester resin system comprising preparing a curable cumene-quat curing system. The cumene-quat curing system can comprise an unsaturated polyester resin, a peroxide initiator, a quaternary ammonium salt component, a 2,4-pentanedione component, and an inhibitor component. The peroxide initiator can comprise a cumene hydroperoxide component. The process can further comprise applying the curable cumene-quat curing system in a cured-in-place pipe rehabilitation process.