Thermoplastic Pipe Repair Patch Using Epoxy-Fiberglass Composite
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Solution Overview
Problem
Current methods for repairing thermoplastic pipes and fittings are expensive, time-consuming, unsafe, and often result in environmental damage, as they fail to provide a permanent and effective solution for leaks and structural weaknesses, especially under pressure, leading to concerns in fluid transportation and safety.
Innovation Solution
A method involving surface preparation through abrasion and perforation, followed by application of a semi-rigid adhesive and fibrous materials to create a flexible and durable repair patch that can withstand pressure variations and movement, allowing for quick, safe, and environmentally friendly repairs without losing system pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional repair methods (adhesives, welding patches) are used on thermoplastic pipes, then repair can be performed, but the repair fails to adhere sufficiently or creates heat stressed regions prone to failure
Solution Approach 1:
The patent applies composite materials by combining fiberglass reinforcement with epoxy adhesive to create a patch that adheres to thermoplastic pipe surfaces. The composite structure provides both strong adhesion through the epoxy-fiberglass bond and structural strength through the fiberglass reinforcement, resolving the contradiction between adhesion reliability and structural strength maintenance.
Solution Approach 2:
The patent changes the physical and chemical parameters of the repair system by using a two-part epoxy adhesive that cures to form a strong bond, and selecting fiberglass with appropriate weave and thickness. These parameter changes enable the repair to achieve both sufficient adhesion to the thermoplastic surface and structural strength to withstand operating conditions without creating weak heat-stressed regions.
2Reliability
If pipe section removal or bypass is performed for repairs, then leaks are stopped, but the process becomes expensive and time-consuming
Solution Approach 1:
The patent applies segmentation by creating a localized repair patch that addresses only the compromised section of the pipe rather than removing the entire pipe section. The patch is applied in layers (adhesive, fiberglass, adhesive) that are confined to the repair area, stopping the leak while minimizing disruption to the overall system and reducing repair time.
Solution Approach 2:
The patent uses an intermediary repair patch composed of epoxy adhesive and fiberglass material that mediates between the compromised pipe section and the surrounding healthy pipe. This intermediary structure stops the leak without requiring removal of the original pipe section or installation of a complex bypass system, thereby reducing both time and cost.
3Strength
If metal pipe welding is used for repairs, then structural strength is restored, but heat stressed regions are created that are prone to failure
Solution Approach 1:
The patent replaces the mechanical welding process with a chemical bonding system using two-part epoxy adhesive. This substitution eliminates the heat input that creates heat-stressed regions in metal pipe welding, while still providing structural strength through the adhesive-fiberglass composite. The chemical bonding process cures at ambient or elevated temperatures without creating the localized heat zones that lead to future failure.
Solution Approach 2:
The patent uses composite materials (epoxy adhesive combined with fiberglass reinforcement) to restore structural strength without the harmful effects of welding. The composite patch provides both adhesion to the pipe surface and structural reinforcement, achieving durability without creating heat-stressed regions that would compromise long-term reliability.
4Ease of manufacture
If compression fittings are used to couple pipe ends, then connection is achieved, but flexing and movement cause disassociation and leakage
Solution Approach 1:
The patent merges the fitting and pipe into a single integrated structure by applying the epoxy-fiberglass patch to the exterior surface where the fitting meets the pipe. This combined repair approach creates a unified bond that prevents disassociation between the fitting and pipe during flexing and movement, eliminating the leakage problem while maintaining the ease of initial fitting installation.
Solution Approach 2:
The patent uses composite materials (epoxy adhesive with fiberglass reinforcement) to create a reinforced connection between the compression fitting and pipe. This composite patch provides both adhesion and structural strength, preventing the disassociation that occurs with standard compression fittings under flexing and movement conditions, thereby improving connection reliability while maintaining installation simplicity.
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 enables rapid, cost-effective, and permanent repairs of thermoplastic pipes and fittings, maintaining structural integrity and preventing leaks, even under operating pressure, thus addressing the limitations of existing repair techniques.
Implementation Method 1
disposing at least one layer of adhesive upon the abraded surface, wherein the adhesive is comprised of a compound, which cures to a semi-rigid state
Implementation Method 2
abrade at least a portion of the surface of the compromised section and the immediate area of the pipe there around
Data Source
AI summary
Disclosed herein is a repair apparatus and method for pipe and fittings. In one form, the method relates to utilizing fabric-like material which is intermixed with an adhesive. In one form, the adhesive is a two-part adhesive which hardens to a semi-rigid state to avoid stress fractures through repeated expansion and contraction due to physical movement or temperature variation in the pipe and/or fittings. In one form the method and apparatus are particularly useful in thermoplastic pipes. In other forms, the method is particularly useful in metal pipes and fittings, or in non-pipe structures.