Resin Mortar Pipe Lining Abrasion Resistance
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Solution Overview
Problem
Existing pipe coatings for wastewater transportation are prone to degradation and abrasion due to aggressive water conditions, particularly when exposed to pH levels between 4 and 13, and current solutions like cement mortars are not durable enough.
Innovation Solution
A resin mortar coating is applied to the inside of pipes made of cast iron, comprising a specific blend of mineral fillers with different grain sizes and a polyepoxide or polyurethane organic binder, along with reinforcing fibers, and a specialized installation for precise application, which includes a unique projection head design and separate introduction of binder components to enhance durability and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cement mortar is used as the internal coating, then the pipe can withstand water with pH between 4 and 13, but the coating is susceptible to deterioration and has poor abrasion resistance
Solution Approach 1:
The patent uses a composite material consisting of mineral filler (such as sand or crushed stone) combined with an organic binder (such as epoxy resin, polyurethane, or vinyl ester resin) to create a resin mortar coating. This composite structure combines the abrasion resistance of mineral fillers with the chemical resistance and adhesion properties of organic binders, simultaneously improving both durability and abrasion resistance compared to traditional cement mortar coatings.
2Reliability
If resin mortar is applied to improve durability and abrasion resistance, then the coating becomes more resistant to aggressive water, but the application process becomes more complex requiring specific mixing ratios and controlled conditions
Solution Approach 1:
The patent specifies precise parameter ranges for the resin mortar application, including weight ratios of mineral filler to binder (typically 3:1 to 6:1), particle size distributions of the filler (with specific proportions of fine and coarse fractions), and chemical composition ratios of the organic binder components. These controlled parameters ensure optimal performance while providing clear guidance for consistent application results.
3Strength
If the mineral filler consists of multiple sub-components with different particle sizes, then the coating density and resistance are improved, but the manufacturing process requires separate mixing and proportioning of different filler fractions
Solution Approach 1:
The patent divides the mineral filler into multiple size fractions (typically a first sub-component with particle size 0.063-2mm and a second sub-component with particle size 0.063-0.4mm, with specific weight ratios between them). This segmentation allows each fraction to fill voids between larger particles, increasing coating density and mechanical strength, while the defined ratios simplify the mixing process by providing clear proportioning guidelines.
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 coating significantly improves durability and resistance to abrasion, allowing for effective transportation of wastewater across a wide pH range while minimizing material loss during application, ensuring a robust and long-lasting inner lining.
Implementation Method 1
The organic binder includes and is notably composed of a polyepoxide or polyurethane resin; the polyepoxide resin is composed of an epoxy sub-component and a hardener sub-component
Implementation Method 2
designed to withstand water with a pH between 4 and 13. The coatings typically used are cement mortar. These hydraulic mortars are susceptible to deterioration, particularly when the pipes carry aggressive water
Implementation Method 3
The invention aims to improve the durability and abrasion resistance of the internal coating of piping elements
Data Source
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AI summary
This section of pipe comprises a basic body (10) made of metal, defining a basic body external surface (12) and a basic body internal surface (14), and an internal lining (16) applied to the basic body internal surface (14). The internal lining (16) comprises a resin mortar and in particular consists of a resin mortar, and the resin mortar comprises a mineral filler and an organic binder.