Apparatus and method for installing a liner in a pipe

Abstract

An apparatus and method for installing a liner in a pipe, including a flexible tube assembly (2) with a proximal and a distal end, where the proximal end is attached to a proximal collar fitting (3) and the distal end is attached to a distal collar fitting (4). An inflatable bladder (110) is disposed over the tube (2) and the ends of the bladder (110) are secured to the collar fittings (3,4) forming sealed connections with the collar fittings. The proximal collar fitting (3) has a connection to connect to a guide hose (5), and includes at least one conduit for a fluid to inflate the inflatable and deflate bladder.

Claims

1. An apparatus for installing a liner (120) in a pipe (101) for domestic piping including pipe bends (102a,102b), said apparatus so flexible and slim that it easily passes said bends in said pipe, said apparatus comprising: a tube assembly (1) comprising: a proximal collar fitting (3) and a distal collar fitting (4) interconnected by a small cross-sectional area flexible rubber tube or rod (2) reinforced with a steel or other high strength material mesh, and an inflatable bladder, one end of the inflatable bladder being secured to the proximal collar fitting (3) and the other end of the inflatable bladder being secured to the distal collar fitting (4), with the small diameter flexible tube or rod (2) disposed inside the interior of the inflatable bladder (110), said bladder (100) being made of a suitable elastic and substantially non-permeable elastomeric material and comprising a layer of fiber based fabric; and a push-pull-turn hose (5) with a proximal end and a distal end, said push-pull-turn hose (5) being a reinforced rubber hose with one or more layers of steel or carbon fiber mesh, wherein said distal end of said push-pull-turn hose (5) is connected in a releasable way to the proximal collar fitting (3) and said push-pull-turn hose (5) is in fluid communication with the interior of the inflatable bladder, wherein said push-pull-turn hose (5) is stable enough to transmit a pushing force and a rotational force to the tube assembly (1), and said small cross-sectional area flexible rubber tube or rod (2) is stable enough to allow said inflatable bladder to be pushed and rotated into position.

2. An apparatus according to claim 1, wherein there are no other components than the flexible tube or rod (2) in the interior of the inflatable bladder (110).

3. An apparatus according to claim 1, wherein a liner is disposed over said inflatable bladder (110).

4. An apparatus according to claim 1, wherein said push-pull-turn hose (5) is in fluidic connection with the interior of the inflatable bladder (110) via a conduit (25) in the proximal collar fitting (3).

5. An apparatus according to claim 1, wherein said push-pull-turn hose (5) is flexible enough to go through said pipe bends (102a,102b) and stable enough to transmit a pushing force to the proximal collar fitting (3) at the distal end of the push-pull-turn hose (5) and stable enough to transmit rotational force to the proximal collar fitting (3) at the distal end of the push-pull-turn hose (5).

6. An apparatus according to claim 1, wherein the proximal collar fitting (3) and/or the distal collar fitting (4) comprises at least one through-going bore (23) that is provided with threads at both ends.

7. An apparatus according to claim 6, wherein the through-going bore (23) of said distal collar fitting (4) is closed with a threaded plug.

8. An apparatus according to claim 1, wherein said fluid communication between said push-pull-turn hose (5) and the interior of the bladder (110) is located in the proximal collar fitting (3) and/or in the distal collar fitting (4) and/or in the tube (2).

9. An apparatus for installing a liner (120) in a pipe (101) for domestic piping including pipe bends (102a,102b), said apparatus so flexible and slim that it easily passes said bends in said pipe, said apparatus comprising: a tube assembly (1) comprising: a proximal collar fitting (3) and a distal collar fitting (4) interconnected by a small cross-sectional area flexible solid tube or rod (2), wherein the proximal collar fitting (3) comprises a proximal threaded coupling member for engaging a distal threaded coupling member of a push-pull-turn hose (5), and a distal threaded coupling member for engaging a proximal threaded coupling member of said flexible solid tube or rod, and wherein the distal collar fitting (4) comprises a proximal threaded coupling member for engaging a distal threaded coupling member of said flexible solid tube or rod and a distal threaded coupling member for engaging a threaded plug (39), and an inflatable bladder, one end of the inflatable bladder being secured to the proximal collar fitting (3) and the other end of the inflatable bladder being secured to the distal collar fitting (4), with the small diameter flexible tube or rod (2) disposed inside the interior of the inflatable bladder (110), wherein said push-pull-turn hose (5) has a proximal end and a distal end, said distal end of said push-pull-turn hose (5) being secured to said distal threaded coupling member of said proximal collar fitting (3) and being connected via threaded engagement to the proximal threaded coupling member of the proximal collar fitting (3), and a lumen in said push-pull-turn hose (5) is in fluidic connection with the interior of the inflatable bladder (110) via a conduit (25) in the proximal collar fitting (3).

10. An apparatus according to claim 9, wherein there are no other components than the flexible solid tube or rod (2) in the interior of the inflatable bladder (110).

11. An apparatus according to claim 9, wherein a liner is disposed over said inflatable bladder (110).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the following detailed portion of the present description, the invention will be explained in more detail with reference to the exemplary embodiments shown in the drawings, in which:

(2) FIG. 1 is a depiction of a tube assembly used in an apparatus for installing a liner according to an exemplary embodiment,

(3) FIG. 2 is a depiction of a proximal collar fitting of the tube assembly shown in FIG. 1,

(4) FIG. 2a is a detailed cross-sectional view of the proximal collar fitting of FIG. 2,

(5) FIG. 3 is a depiction of a distal collar fitting of the tube assembly shown in FIG. 1,

(6) FIG. 3a is a detailed cross-sectional view of the proximal collar fitting of FIG. 3,

(7) FIG. 4 is a depiction of the collar fitting of FIG. 2 in greater detail,

(8) FIG. 5 shows the tube assembly of FIG. 1 and a bladder to be installed to the tube assembly,

(9) FIG. 6 shows the bladder of FIG. 5 installed to the tube assembly of FIG. 1,

(10) FIG. 7 shows a liner disposed over the bladder that is installed to the tube assembly as shown in FIG. 6, and

(11) FIG. 8 is a worked open view of an apparatus according to an exemplary embodiment in a pipe that is to be provided with a liner.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(12) FIG. 1 shows a tube assembly 1 according to an exemplary embodiment of the invention. The device 1 is part of a toolkit for installing a liner in a pipe and the tube assembly includes a flexible tube or rod 2 with a proximal collar fitting 3 connected to its proximal end and a distal collar fitting 4 fitted to the distal end of the flexible tube or rod 2. The proximal collar fitting 3 is also connected with a push-pull-turn rotate guide hose 5.

(13) The flexible tube or rod 2 is a rubber tube reinforced with a steel or other high strength material mesh, which flexible tube or rod 2 can be obtained as a standard product and cut into desired lengths, whereby the length of the tube assembly 1 easily can be adjusted. The flexible tube 2 can be of the same tube material as the push-pull-turn tube, but can also be of different tube material or of a solid rod of suitable flexible material.

(14) The collar fittings 3 and 4 are suitably made from metal, e.g. stainless steel, brass, messing or copper, and preferably the collar fittings are made from aluminum, which is a metal that is easy to adapt to any desired size and shape and also relatively inexpensive.

(15) The push-pull-turn guide hose 5 is a reinforced rubber tube that is flexible enough to go through 90 deg. bends in a 75 mm pipe but at the same time stable enough to provide a solid pushing force and torsional stability to be able to transmit a substantial rotational force to the tube assembly 1 for turning the latter (and a bladder and a liner installed on the tube assembly) in the correct rotational orientation. Preferably the rubber tube is reinforced with one or more layers of steel mesh, although other reinforcement arrangements such as carbon fiber fabric or mesh can also be used. Hydraulic hoses as used in high pressure hydraulic systems have proven to be very suitable as push-pull-turn hose. A particularly suitable type of hose is Dunlop Highflex Super Slimline 2410 WP 350 BAR 5075 PSI 3010 to 725210 hosing which is a compact 2 wire braid hydraulic hose with a minimum bend radius of 100 mm and sold by the Dunlop Hiflex Company.

(16) Another type of hose that is suitable as a push pull turn hose is 730G 06 3/8 DIN 20023 EN Greenline biologically easily degradable hydraulic tube with an inner tube of synthetic oil proof rubber, and outer tube of oil and weather proof rubber and armed with 4 spiraling steel mesh inlays. The outer diameter of this hose is 17.9 mm, the inner diameter is 6.4 mm.

(17) Depending on the size of the pipe to be lined and on other factors other similar hoses with a larger outer diameter can be used.

(18) FIG. 2 shows the proximal collar fitting 3 connected to the flexible tube 2 and to the push-pull-turn guide hose 5. FIG. 3a is a cross-sectional view of the collar fitting as such. The proximal collar fitting 3 is provided with a first flange 13 located close to the flexible tube 2. The proximal collar fitting 3 is also provided with a second flange 14 shaped with a rounded end 15. The flanges 13 and 14 serve to attach an inflatable bladder (shown in FIGS. 5 to 8). A recess for receiving bladder material is provided between the flanges 13 and 14. The extent of the collar fitting 3 between flange 13 and flange 14 is an area 16 formed with ribs 17. This area 16 and the ribs 17 also serve to improve the secure attachment of the bladder. Moreover, the spacing between the flange 13 and the flange 14 forming a sort of recess in the proximal collar fitting that improves the attachment of a bladder (shown in FIGS. 5 to 8) to the proximal collar fitting 3.

(19) The flexible tube 2 is equipped with a band 18 serving to secure the flexible tube 2 to a threaded connector 19. The threaded connector 19 engages a threaded hole in one end of the proximal collar fitting 3 and thereby connects the flexible tube 2 with the proximal collar fitting 3.

(20) Thus, the threaded coupling 19 forms a coupling half, with the threaded hole in the proximal collar fitting forming the other coupling half.

(21) Also the push-pull-turn guide hose 5 is secured with a band 20 to a threaded connector 21. The threaded connector 21 engages a threaded hole in the other end the proximal collar fitting 3 and thereby the connector 21 connects the guide hose 5 with the proximal collar fitting 3.

(22) Thus, the threaded coupling 21 forms a coupling half, with the threaded hole in the proximal collar fitting 3 forming the other coupling half.

(23) The proximal collar fitting 3 is provided with a through going bore 23 that has threaded endings. Three channels 25 (only one can be seen in FIG. 3a) connect the through going bore 23 to openings at the front face of the flange 13 (cf. FIG. 4)

(24) FIG. 3 shows a distal collar fitting 4 connected with a flexible tube or rod 2. FIG. 3a is a cross-sectional view of the distal collar fitting 4 as such. The distal collar fitting 4 is essentially identical to the proximal collar fitting 3 with a first flange 13 located adjacent to the flexible tube or rod 2. The distal collar fitting 34 further comprises a second flange 14 having a rounded end 15 and spaced from the first flange 13. The rounded end 15 makes the distal collar fitting 4 suitable to guide the apparatus through a pipe (not shown). The rounded end 15 facilitates the movement of the apparatus into a pipe as it improves the apparatus ability to pass e.g. bends in the pipe. The threaded hole in the rounded end 34 is closed with a threaded plug 39.

(25) The flanges 13 and 14 provide grip for the bladder 110 and thereby improve the attachment of the bladder 110 to the distal collar fitting 4. Between the flange 13 and the flange 14 there is an area 16 formed with ribs 17. This area 15 and the ribs 17 also serve to improve the attachment of the bladder 110. Moreover, the spacing between the flange 13 and the flange 14 improves the attachment of the bladder 110 to the distal collar fitting 4.

(26) The flexible tube 2 is equipped with a band 18 serving to fasten the connector 19 to the flexible tube 2. The connector 19 connects the flexible tube 2 with the proximal collar fitting 3.

(27) The distal collar fitting 4 is essentially identical to the proximal collar fitting 3. A difference is that the through going bore 23 of the distal collar fitting 4 is closed at one end with a threaded plug 39.

(28) FIG. 4 is a depiction of the proximal collar fitting 43 showing the main bore 23 and the channels or conduits 25. A collar fitting may serve as both a proximal collar fitting and a distal collar fitting. The bore 23 is threaded at both ends for being able to receive threaded connectors 19,21 or a threaded plug 29. The main bore 23 serves also to transport fluids and the main bore 23 connects to three channels or conduits 25 that have an opening at a front face of flange 13.

(29) The channels 23 are placed symmetrical around the bore 23 collar fitting. The conduits 25 are connected to the through-going bore 23. In this configuration, the channels 25 are in fluid communication with the interior of the bladder 110 (FIG. 6) so that fluid can be transported to and removed from the bladder 110 by applying pressure or vacuum, respectively.

(30) When the tool is in its assembled state, the flexible tube 2 will be connected to the free end of the proximal collar fitting 3 as shown in FIG. 4, with a distal collar fitting 4 at the other end of the flexible tube.

(31) A bladder 110 needs to be installed on the tube assembly 1. FIG. 5 shows the tube assembly 1 connected to the push-pull-rotate hose 5. A bladder 110 to be installed on the tube assembly 1 is shown next to the tube assembly 1.

(32) The inflatable bladder 110 is made of a suitable elastic and substantially non-permeable material, such as elastomeric material, such as e.g. rubber or silicone rubber. A preferred material for the bladder is a sheet material with an inner layer of silicon rubber, an intermediate layer of a fiber based fabric and an outer layer of silicone rubber. The fabric is composed of a suitable fiber material, such as for example polymer based fiber, glass fiber, carbon fiber or natural fiber. The fabric limits the maximum expansion of the bladder and gives it high strength whilst the silicon rubber makes the bladder elastic, impermeable, repelling and non-stick.

(33) Another preferred material for the inflatable bladder is has a specific weight of 405 g/m.sup.2 and is composed 52/48% PA6,6/Silicone.

(34) In the exemplary embodiment the bladder 110 comprises a main body that is made from two parts of bladder sheet material 114a and 114b that are connected at a weld line 115. The bladder in this embodiment also includes a branch 112 at a 45 deg. angle with the main bladder body. The branch 112 is formed by a third piece of bladder sheet material and connected to the main body of the bladder body at a weld line 113.

(35) The bladder main body has open ends so that the tube assembly 1 can be easily inserted therein whilst the branch 112 has a closed end.

(36) FIG. 6 shows the tube assembly 1 connected to the push-pull-rotate hose 5 and with the bladder 110 installed on the tube assembly.

(37) The visible parts of the tube assembly 1 are the proximal collar fitting 3 and the distal collar fitting 4. The rounded end on the distal collar fitting 4 serves to guide the apparatus with the bladder 110 through a pipe that is to be provided with a liner 120 (FIG. 7) in a smooth and efficient way. The proximal collar fitting 3 is connected to the push-pull-turn guide hose 5 that serves to push the apparatus through a pipe, and to rotate the bladder and a sleeve thereon into the right position. The push-pull-turn guide hose 5 also supplies the fluids to inflate, deflate and heat the bladder 110.

(38) One of the open ends of the bladder 110 is hermetically attached to the proximal collar fitting 3 by wrapping adhesive tape 116 around the end of the bladder at the location of the proximal collar, thereby forcing the end of the bladder 110 into the recess between the flanges 13,14 of the proximal collar fitting 3 to obtain a strong and hermetic connection between the bladder end and the proximal collar fitting 4. Tape 116 is also used to attach the other open end of the bladder 110 to the distal collar fitting 4, thereby urging the bladder material between the flanges 13,14 of the distal collar fitting 4. Instead of adhesive tape other suitable items can be used to tighten the open end of the bladder 110 around the collar fitting, such as e.g. string or wire, a hose clamp or cable tie.

(39) The branch 112 of the bladder 110 is closed at the top 118.

(40) The use of tape 116 to secure the bladder 110 to the flexible tube assembly 2 enables the quick and easy installation of a bladder 110 to the flexible tube assembly and an easy removal from the flexible tube assembly 2 for example in connection with the replacing a damaged bladder 110 with a new bladder 110 or replacing a bladder 110 with another model bladder 110.

(41) FIG. 7 shows the tool with the tube assembly 1 connected to the push-pull-turn hose 5 and with the bladder 110 installed. A liner 120 with a branch 122 is disposed over the bladder 110. The branch 112 of the bladder 110 is withdrawn into the main body section of the bladder so that the assembly can be transported easier through the pipe system of the pipe to be lined.

(42) The liner 110 and the branch 112 are preferably made from woven fabric or unwoven fabric (felt), which is impregnated with a suitable curable resin. Preferred materials for the liner are glass fiber, Kevlar and/or carbon fiber. The liners can be preformed or made in situ by wrapping the bladder 110 with fabric.

(43) Since the pipes to be lined can have various diameters and can be branched at 45 deg. angles or 90 deg. angles bladders 110 and liners 120 with different diameters and with branches at either 45 deg. or 90 deg. angles are part of the toolkit that is brought to the site of the pipe or pipe system that is to be provided with lining. Also bladders with two oppositely arranged branches (at 90 deg. angle) and corresponding liners 120 are also part of the toolkit.

(44) FIG. 8 shows the assembly of FIG. 7 in a pipe 101 that is to be provided with a liner. The pipe 101 has bends 102a, 102b and a branch 103.

(45) The installation of a liner 120 is in an exemplary embodiment as follows. A flexible tube 2 with appropriate length is chosen. The flexible tube 2 is provided with a proximal collar fitting 3 and with a distal collar fitting 4 to tube assembly 1. The tube assembly 1 is connected to the push-pull-turn hose 5.

(46) A suitable bladder 110 is chosen and secured to be the tube assembly 1 as described above. A suitable preformed sleeve 120 is chosen and drenched in curable resin. Optionally, the bladder 110 is lubricated. In this example the bladder 110 and the preformed sleeve 120 branch at a 45 angle with the main body of the bladder and sleeve, respectively. The apparatus 100 is then ready to enter the pipe 101.

(47) Vacuum is applied to the interior of the bladder by applying a vacuum to the push-pull-turn hose 5, thereby shrinking the bladder 110 to a minimum volume. The shrunken bladder 110 is inserted into the preformed sleeve 110. Vacuum and also pressure can be applied to the push-pull-turn hose 5 with a conventional compressor (not shown).

(48) The tube assembly 1 with the bladder 110 and the sleeve 120 installed thereon is denoted as the lining apparatus 100.

(49) The lining apparatus 100 is now introduced into the pipe 101 to be lined and pushed through the bends 102a and 102b to the correct position. The push-pull-turn hose 5 is stable enough to be able to push the lining apparatus 100 through the bends, but at the same time the push-pull-turn hose 5 is flexible enough to pass through the bends.

(50) Due to the flexibility of the flexible tube 2, and the small cross-sectional area of the combination of the flexible tube 2 and due to the rounded shape of the front of the distal collar fitting 4 the apparatus 100 is so flexible and slim that it easily passes bends 102a and 102b in the pipe 101 and reaches the branch 103 to be lined with the liner 110.

(51) The torsional stability of the push-cool-turn hose 5 is also sufficient to be able to rotate the lining apparatus 100 to a desired rotational orientation (with the branch of the bladder 110 and the liner directing in the same direction as the pipe branch 103. A camera 130 provides an operator manipulating the push-pull-turn hose 5 with the required feedback to position the lining apparatus 100. Hereto, the output signal of the camera is in an embodiment shown on a display screen (not shown) that is in the view area of the operator.

(52) When the lining apparatus 100 is in the correct position pressure is applied to the bladder 110 by applying pressurized air to the proximal end of the push-pull-turn hose 5. The pressurized air inside the interior of the bladder causes the bladder to expand and thereby push the liner 122 to the interior walls of the pipe to be lined. The branch 112 of the bladder 110 will extend and press the branch of the liner to the inner walls of the pipe branch 103. Next, the resin of the liner 120 is allowed to cure.

(53) If fast curing of the resin in the liner 120 is desired, heat can be applied. One way of applying heat is by pumping hot steam into the bladder 110 via the push-pull-turn hose 5. Before pumping steam into the bladder 110 vacuum can be applied so that the latter is NT and can be easily filled with hot steam. Alternatively, the lining tool can be provided with a pressure relief valve (not shown, but could be placed inside the plug 39) and steam could be forced into the interior of the bladder by using a pressure higher than the pressure at which the relief valve opens, thus enabling the air in the bladder 110 to be evacuated through the distal collar fitting 4.

(54) When the resin has cured, vacuum is applied again so that the bladder 110 retracts and shrinks and the flexible tube assembly 1 and the bladder 110 can be retracted by pulling the push-pull-turn hose 5.

(55) Normally, the lining apparatus 100 can be pushed upwards in a pipe system towards the ceiling of a room or roof of a building and it can be pushed downward in a pipe system towards the cellar of a building.

(56) The lining apparatus 100 is easy to use, inexpensive and very simple to construct. The apparatus 100 can be used in pipes with very small diameters, i.e. with inner diameters down to approximately 35 mm, but it can also be used in larger pipes with a diameter of up to approximately 300 mm. The lining apparatus 100 is also capable of passing bends in a pipe with acute angles exceeding 90 degrees.

(57) Thus, a very simple and cost effective lining 100 apparatus and toolkit for providing a liner 120 in a branched or non-branched pipe system is provided. The toolkit includes the push-push-turn hose 5, a selection of flexible tubes 2, collar fittings 3,4, a selection of inflatable bladders, and a selection of preformed sleeves. The toolkit may include several push-cool-turn hoses 5 with different diameters and different bending radius and flexibility.

(58) It is noted that the flexible tube 2 can be replaced by a flexible rod (not shown) of suitable material such as for example an elastomeric material, optionally fiber reinforced.

(59) The teaching of this invention has numerous advantages. Different embodiments or implementations may yield one or more of the following advantages. It should be noted that this is not an exhaustive list and there may be other advantages which are not described herein. One advantage of the teaching of this application is that it provides for a very flexible and cost effective apparatus and toolkit for installing a liner in a pipe. The apparatuses according to the invention are easy to manufacture in different sizes and lengths depending on the actual need. The apparatuses are very flexible and do not require man-holes or other complicated accesses to the pipe system.

(60) Moreover, the invention provides a method for installing a liner in a pipe by use of the apparatus according to the invention.

(61) Although the teaching of this application has been described in detail for purpose of illustration, it is understood that such detail is solely for that purpose, and variations can be made therein by those skilled in the art without departing from the scope of the teaching of this application.

(62) It should also be noted that there are many alternative ways of implementing the apparatuses of the teaching of this invention.

(63) The term comprising as used in the claims does not exclude other elements or steps. The term a or an as used in the claims does not exclude a plurality. The single processor or other unit may fulfill the functions of several means recited in the claims.