Silane Polymer Pipe Coating via Self-Curing
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Solution Overview
Problem
Existing methods for internally coating pipes are time-consuming, pose health and environmental risks due to hazardous uncured resin components, and fail to provide a durable, high-stress-resistant coating that can withstand frequent use and high temperatures, while also being costly and disruptive to renovate.
Innovation Solution
A method using a silane-based polymer composition that self-cures at ambient temperature, eliminating the need for controlled curing and reducing operation time by almost 50%, with a non-toxic and environmentally friendly coating that is chemically, mechanically, and thermally resistant, applied through a process involving dehumidified compressed air, abrasive cleaning, and controlled air flow with a silane-based polymer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two-component materials are mixed at the place of use for coating, then the coating can be applied, but the uncured resin components are harmful to health and the environment
Solution Approach 1:
The harmful uncured resin components are extracted and removed from the system by using pre-packaged single-component materials that only require adding water, eliminating the harmful two-component mixing process while maintaining coating application capability
Solution Approach 2:
The material formulation is changed from two-component epoxy or polyester resin to single-component silane-modified polymer that cures upon water addition, changing the chemical composition parameters to eliminate harmful substances while preserving coating functionality
2Ease of manufacture
If two-component materials are used for coating, then the coating can be applied, but it is difficult to ensure high and even quality since the material is applied while curing
Solution Approach 1:
The coating material is prepared in advance as a stable single-component formulation that does not begin curing until water is added at the application stage, allowing proper mixing and even distribution before the curing process starts, ensuring uniform coating quality
3Ease of manufacture
If conventional coating methods are used, then the pipe can be coated, but the process takes several days and reduces productivity
Solution Approach 1:
The curing mechanism is changed from slow ambient curing of conventional resins to rapid curing upon water addition for silane-modified polymers, reducing the curing time from several days to a few hours and significantly improving renovation productivity
Solution Approach 2:
The curing process is changed from thermal or chemical curing requiring controlled conditions to simple water addition curing, replacing complex curing systems with a simple water-based activation process that accelerates the overall timeline
4Reliability
If the coating material requires controlled curing conditions, then the coating can cure properly, but additional heating equipment and time are required
Solution Approach 1:
The coating material performs self-curing through a chemical reaction with water that occurs at ambient temperature, eliminating the need for external heating equipment or controlled curing environments, simplifying the overall system while maintaining reliable cure quality
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 method significantly reduces renovation time, enhances coating durability, and meets safety and environmental standards by providing a fast, non-toxic, and high-quality coating that can be applied in multiple layers, improving productivity and safety for workers and the environment.
Implementation Method 1
allowing the polymer to self-cure at ambient temperature
Implementation Method 2
blowing compressed air at a controlled flow and temperature together with a liquid polymer coating material into the pipe
Implementation Method 3
cleaning said pipe by pumping a mixture of compressed air and particles of an abrasive material, such as sand or aluminium oxide, through the pipe
Data Source
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AI summary
The invention relates to a method of internally coating a pipe comprising the steps of; drying the pipe by a flow-through of dehumidified, compressed air followed by; cleaning said pipe by pumping a mixture of compressed air and particles of an abrasive material through the pipe and; possibly blowing compressed air at a controlled flow together with a liquid silane based polymer coating material into the pipe so that a coating layer is applied onto the interior walls of the pipe, and allowing the polymer coating material to self-cure at ambient temperature. The method is useful for internally coating a pipe or a system of pipes such as a gutter pipe, a rain pipe, a sewage pipe, a hot water pipe, a cold water pipe, a drain pipe, a portable water pipe, a natural gas pipe, and a fire sprinkler system pipe. By means of the inventive method non-toxic internal coating of a pipe is achieved according to construction industries requirements as regards use of non-toxic substances.