Abstract:
A repair process for a puncture through a plumbing pipe, the process initiates with a step of machining a puncture hole to a uniformly shaped hole having a diameter for receiving a repair rivet. The process continues by inserting and securing a blind rivet through the hole. The rivet can be sealed via any of a variety of methods, including using a solderable rivet and soldering the rivet to the pipe, utilizing a sealed blind rivet, combined with a gasket assembled between a rivet flange and the pipe surface. For two punctures, a section of coupling material can be utilized, sized to cover both punctures. The section is assembled to the pipe by inserting the rivet through both the section and the pipe, securing the rivet, then soldering the coupling to the pipe.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a pipe hole repair apparatus, and more particularly, sizing an inadvertent hole of a copper pipe wall, inserting a solderable blind rivet therethrough, and soldering the rivet, securing and sealing the rivet in position. 
     BACKGROUND OF THE INVENTION 
     The invention pertains to a plumbing pipe repair method of repair and respective apparatus. 
     When completing work around a structure, such as a residence, a commercial building, and the like, comprising plumbing, there is a risk of damaging or puncturing the plumbing. A simple drilling operation or installation of a drywall screw can puncture the wall of a pipe. The hardship is finding a method to repair the damaged pipe while causing a minimal amount of additional damage to the area. 
     One known method of repairing the damaged pipe is by removing a section of wall covering to provide sufficient working space. At times, the piping is embedded into a concrete or other poured material, such as foam and the like. This enhances the difficulties in a repair process. The section of damaged pipe is cut and removed. The cutting process requires sufficient clearance. A pipe coupling is slipped over the two sections of pipe providing a splice between them. The interior of the pipe needs to be sufficiently dried to allow for soldering (sometimes referred to as sweating). The area needs to be prepared to ensure against any fire from heat applied during the soldering process. A flux is applied to the pipe tubing and the pipe coupling member. The joint is formalized by soldering the pipe coupling member to the pipe tubing. 
     Accordingly, there remains a need in the art for a device that provides a method to repair the damaged pipe while causing a minimal amount of additional damage to the area. 
     SUMMARY OF THE INVENTION 
     The present invention overcomes the deficiencies of the known art and the problems that remain unsolved by providing a method and respective apparatus for repairing a puncture through a copper pipe. 
     In accordance with one embodiment of the present invention, the invention consists of a method for repairing a hole inadvertently created through a pipe, the method comprising the steps of: 
     enlarging the hole to a diameter for receiving a solderable rivet; 
     inserting the solderable rivet into the hole; 
     securing the solderable rivet into the hole via a deformation step; and 
     forming a watertight seal between the solderable rivet and the pipe. 
     In one aspect, the watertight seal is formed by soldering the solderable rivet to the pipe. 
     Yet another aspect, the watertight seal is formed by a gasket assembled between the solderable rivet and the pipe. 
     While another aspect, the seal can further seal a plurality of holes, utilizing a section of a coupling member, the coupling section being first riveted to the pipe, covering the plurality of holes, then soldered to the pipe providing a seal. 
     With yet another aspect, the method further comprises a step of drying an interior of the pipe section 
     Yet another aspect, the solderable rivet includes a rivet body being fabricated of copper, brass, and any other solderable material. The copper can be coated with an organic protectant, thus increasing the solderability of the copper surface. 
     Regarding another aspect, the solderable rivet includes a rivet body being coated with a solder material such copper cladding, copper plating, nickel plating, gold plating, gold plating over nickel, and the like. 
     In accordance with a second embodiment of the present invention, the invention consists of a method for repairing a hole inadvertently created through a pipe, the method comprising the steps of: 
     enlarging the hole to a diameter for receiving a sealed rivet; 
     inserting the sealed rivet into the hole; 
     securing the sealed rivet into the hole via a deformation step; and 
     forming a watertight seal between the sealed rivet and the pipe. 
     In yet another aspect, the sealed rivet being in a form factor of a blind rivet, comprising a mandrel for deforming the body and a sealed end about a bulbous end of the mandrel. 
     These and other aspects, features, and advantages of the present invention will become more readily apparent from the attached drawings and the detailed description of the preferred embodiments, which follow. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The preferred embodiments of the invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, where like designations denote like elements, and in which: 
         FIG. 1  presents an isometric view of a solderable blind rivet assembly; 
         FIG. 2  presents an isometric view of a sealed blind rivet assembly; 
         FIG. 3  presents an isometric view of a screw puncturing a piping assembly; 
         FIG. 4  presents an isometric view of a drill bit sizing the punctured location of the piping assembly; 
         FIG. 5  presents an isometric view of a sized hole through the piping assembly; 
         FIG. 6  presents an isometric view of a blind rivet being inserted into the sized hole of  FIG. 5 ; 
         FIG. 7  presents an isometric view of the blind rivet secured within the sized hole of  FIG. 5 ; 
         FIG. 8  presents an isometric view of the blind rivet soldered to the pipe; 
         FIG. 9  presents a sectional view illustrating the blind rivet as assembled through the sized hole; 
         FIG. 10  presents an isometric view of a sealed rivet and a gasket seal being inserted into the sized hole of  FIG. 5 ; 
         FIG. 11  presents a sectional view illustrating the sealed rivet and the respective gasket seal as assembled through the sized hole; 
         FIG. 12  presents a sectional view illustrating the sealed rivet and a coupling member section for sealing two puncture locations through a pipe; 
         FIG. 13  presents a flow diagram detailing a puncture repair method using a solderable rivet; and 
         FIG. 14  presents a flow diagram detailing a puncture repair method using a sealed rivet. 
     
    
    
     Like reference numerals refer to like parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     Detailed embodiments of the present invention are disclosed herein. It will be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of particular embodiments, features, or elements. Specific structural and functional details, dimensions, or shapes disclosed herein are not limiting but serve as a basis for the claims and for teaching a person of ordinary skill in the art the described and claimed features of embodiments of the present invention. The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. 
     For purposes of description herein, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in  FIG. 1 . Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise. 
     The present invention utilizes two form factors of rivets, with a solderable blind rivet assembly  100  being illustrated in  FIG. 1  and a sealed blind rivet assembly  150  being illustrated in  FIG. 2 . The solderable blind rivet assembly  100  is fabricated having a mandrel  120  inserted through a solderable blind rivet body  110 . The solderable blind rivet body  110  is formed including a rivet shank  112  with a rivet flange  116  extending radially outward and generally perpendicular from a periphery of a sealing edge of the rivet shank  112 . The mandrel  120  is formed having a mandrel shank  122  with a body expander  124  provided at a forming end. The rivet shank  112  is hollow, providing the mandrel passage  118  for the passage of the mandrel shank  122 . The body expander  124  is formed having a diameter that is greater than a diameter of a mandrel passage  118  and resides against a shank end  114  of the rivet shank  112 . When the mandrel shank  122  is pulled forward from the solderable blind rivet body  110 , the body expander  124  deforms the rivet shank  112 , expanding it to generate a clamping force between the deformed portion of the rivet shank  112  and a contacting surface (proximate the shank) of the rivet flange  116 . 
     The piping assembly  200  is fabricated having a mandrel  170  inserted through a solderable blind rivet body  160 . The solderable blind rivet body  160  is formed including a rivet shank  162  with a rivet flange  166  extending radially outward and generally perpendicular from a periphery of a sealing edge of the rivet shank  162 . The mandrel  170  is formed having a mandrel shank  172  with a body expander  174  provided at a forming end. The rivet shank  162  is hollow, providing the mandrel passage  168  for the passage of the mandrel shank  172 . The body expander  174  is formed having a diameter that is greater than a diameter of a shank wall interior diameter reduction  165  and resides against a rear edge of the shank wall interior diameter reduction  165  of the rivet shank  162 . When the mandrel shank  172  is pulled forward from the solderable blind rivet body  160 , the body expander  174  deforms the rivet shank  162 , expanding it to generate a clamping force between the deformed portion of the rivet shank  162  and a contacting surface (proximate the shank) of the rivet flange  166 . 
     An exemplary embodiment of the present invention is represented as a piping assembly  200  providing descriptive illustrations shown in  FIGS. 3 through 9 . The piping assembly  200  illustrates an exemplary plumbing configuration consisting of a series of pipes  202 ,  210  coupled via a pipe coupling  220 . It is understood the plumbing can be provided in any configuration. The plumbing is normally provided within a wall, floor, ceiling, ground, and the like. The plumbing can be damaged via any of a variety of methods. In the exemplary illustration, a screw  230  is driven through a copper pipe  202  (as understood) creating a puncture  212  in the copper pipe  202 , referenced collectively as a damaged pipe section  210 . Once the copper pipe  202  is punctured, the water should be turned off to the respective juncture of pipes. The repair process consists of removing the screw  230  to determine the extent of the damage, demolish a small area of the building about the damaged pipe section  210  to provide a reasonable working area, and repair the damaged pipe section  210 . 
     The puncture  212  is prepared for insertion of the solderable blind rivet assembly  100  via a using a drill bit  240  through the puncture  212  to create a sized hole  214 . The drill bit  240  is sized to provide a sized hole  214  for accepting the rivet shank  112 . The rivet shank  112  can be provided in a variety of outer diameters for use for repairing a variety of diameter of holes with minimal intrusion. The rivet shank  112  is inserted though the sized hole  214 , seating the rivet flange  116  against the exterior surface of the damaged pipe section  210 . A rivet gun (not shown, but well understood) is used to install and secure the solderable blind rivet assembly  100  to the damaged pipe section  210 . The gun can apply an insertion force to the rivet flange  116 , ensuring the rivet flange  116  remains in contact with the surface of the damaged pipe section  210 . The gun then draws the mandrel shank  122  away from the copper pipe  202  while continuing to apply a seating pressure to the rivet flange  116 . The drawing force pulls the body expander  124  outward, deforming the rivet shank  112 , illustrated as deformed shank  113  shown in  FIG. 9 . The deformation of the rivet shank  112  creates a clamping force with the rivet flange  116 . The mandrel  120  snaps upon a predetermined tensile force, leaving a snapped mandrel  126  (the body expander  124  and a short portion of the mandrel shank  122 ) in position. The plumber then applies a flux (not shown) to the inserted solderable blind rivet assembly  100  and the adjacent area of the damaged pipe section  210 . The solderable blind rivet assembly  100  and adjacent region of the damaged pipe section  210  is heated and solder is applied. The solder flows, wetting to both the rivet flange  116  and the damaged pipe section  210 , creating a watertight solder seal  216 . The plumber then turns the water on, checking the repair for leaks. 
     An alternate repair process is presented in  FIGS. 10 and 11 . The damage is prepared as described above, reshaping the puncture  212  into a sized hole  214 . A gasket seal  218  is placed over the rivet shank  162  of the sealed blind rivet assembly  150 . The gasket seal  218  can be a stamped piece of gasket material, an o-ring, a shaped piece of rubber, a nylon ring, and the like. The rivet shank  162  is then inserted into the sized hole  214 . The contacting surface of the rivet flange  166  is adequately seated against the damaged pipe section  210 , sandwiching the gasket seal  218  therebetween. The mandrel shank  172  is drawn from the rivet shank  162 , while a seating force remains applied to the rivet flange  166 . The motion of the mandrel shank  172  pulls the body expander  174  outward, deforming the rivet shank  162  (illustrated as deformed rivet shank  163  shown in  FIG. 11 ), creating a clamping force between the deformed portion of the rivet shank  162  and the rivet flange  166 . The clamping force compresses the gasket seal  218 , creating a watertight joint. An optional gasket containment rim  167  can be provide about a perimeter of the rivet flange  166 , ensuring the gasket seal  218  remains in place. The shank end  164  provides a seal for the sealed blind rivet assembly  150 , where the sealed blind rivet assembly  150  would normally include a passageway, such as the mandrel passage  118  ( FIG. 1 ). 
     A third exemplary embodiment is presented in  FIG. 12 , providing a means for repairing a damaged pipe section  210  comprising two holes, a puncture  212  (illustrated as a sized hole  214 ) and a concealed puncture  213 . This normally occurs when a screw initially penetrates the copper pipe  202  and continues through to a second penetration on a portion of the pipe generally opposite the first hole. It is generally easier to access the portion of the pipe having the sized hole  214 , compared to the ability to access the portion of the pipe having the concealed puncture  213 . The illustrated repair process provides a simple means for repairing a damaged pipe section  210  comprising two punctured sections. The damage is prepared as described above, reshaping the puncture  212  into a sized hole  214 . A sectioned coupling member  250  is provided, wherein the sectioned coupling member  250  is a section of a pipe coupling member sized for the respective damaged pipe section  210 . The section is preferably between 180 and 270 degrees of the overall circumference of the coupling member. A hole (similar to the sized hole  214 ) is provided through the sectioned coupling member  250 . The sectioned coupling member  250  is placed over the damaged pipe section  210  covering both the sized hole  214  and the concealed puncture  213 , aligning the hole of the sectioned coupling member  250  with the sized hole  214 . A solderable blind rivet assembly  100  is then inserted through the aligned holes and secured as previously described. The solderable blind rivet assembly  100  is secured as previously described. The sectioned coupling member  250  is then soldered to the damaged pipe section  210  by applying a flux, applying heat, then having solder contact the heated assembly. The solder flows about the perimeter of the sectioned coupling member  250  forming a soldered interface  252 . Additionally, solder is applied over the rivet flange  116  creating a solder seal  216 . It is understood that the sealed blind rivet assembly  150 , including a respective gasket seal  218 , can be used replacing the solderable blind rivet assembly  100 , thus eliminating the step of applying solder over the solderable blind rivet assembly  100 . It is understood the repair process can be alternately accomplished applying a watertight adhesive to a contacting side of the sectioned coupling member  250  and securing the sectioned coupling member  250  to the damaged pipe section  210  using the sealed blind rivet assembly  150 . 
     A blind rivet repair process  300  is described in a flow diagram presented in  FIG. 13 . The blind rivet repair process  300  initiates with an unfortunate step of the copper pipe  202  inadvertently becoming punctured  302 . The repair process begins by turning the water pressure flowing to the damaged pipe section  210  off  304 . The repair process  300  continues with a step of removing the puncturing object  306 . The area surrounding the damaged pipe section  210  is cleared, providing access  308  for the repair process. The damaged is assessed and the diameter of the repair rivet is determined  310 . A drill bit  240  matching the diameter of the repair rivet is selected and the puncture is machined  312  to receive the rivet. Flux may be applied  314  to the rivet shank  112  as well as the section of pipe being repaired. The solderable blind rivet assembly  100  is then inserted  316  into the sized hole  214 . The solderable blind rivet assembly  100  is secured  318  via a standard blind rivet installed process, preferably using a blind rivet installation tool (commonly known as a rivet gun). The damaged pipe section  210  is heated and solder is applied to seal the rivet and pipe interface in accordance with a soldering or brazing process  320 . The water pressure is carefully increased; checking the repair for leaks  322 . 
     A sealed rivet repair process  350  is described in a flow diagram presented in  FIG. 14 . The sealed rivet repair process  350  adheres to the initial preparation steps of the blind rivet repair process  300 . The process deviates after the hole to match the rivet body diameter is drilled  312 . The gasket seal  218  is placed over the rivet shank  162  in accordance with a gasket installation step  352 . The sealed blind rivet assembly  150  is inserted  316  into the sized hole  214 . The sealed blind rivet assembly  150  is secured  318  via a standard blind rivet installed process, preferably using a blind rivet installation tool (commonly known as a rivet gun). The installation of the sealed blind rivet assembly  150  tightens about the gasket seal  218 , creating a watertight seal. The water pressure is carefully increased; checking the repair for leaks  322 . 
     The above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Many variations, combinations, modifications or equivalents may be substituted for elements thereof without departing from the scope of the invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all the embodiments falling within the scope of the appended claims.