DEVICE FOR CUTTING AND/OR BORING OUT DEBILITATED AND/OR BULGING PIPE LINER, AND METHOD OF MAKING AND USING SAME

A device configured to bore out a section of underground pipe or an interior liner therein without the need to dig out the section of pipe can include a plurality of arms extending radially outwardly from a central shaft. The central shaft can be configured to attach to a tool or a robot. The device can also at least one cutting device extending radially outwardly from the central shaft. The at least one cutting device can be configured to move in unison with the central shaft. rotation of the central shaft can cause the at least one cutting device to contact and cut an interior surface of the underground pipe or the interior liner thereof.

FIELD

The presently disclosed technology relates generally to an apparatus for fixing and/or repairing debilitated pipe and/or bulging newly installed pipe liner, and method of making and using same. Optionally, the apparatus can be coupled to existing or prior art robotic drills or tools.

BACKGROUND

It is known to insert a liner, sleeve, or sock into a debilitated pipe (e.g., wastewater pipes made of cast iron and/or other materials) to line the interior of at least a portion of the pipe to fix or repair the pipe. This process can significantly extend the useful life of the old or existing pipe. One example is INSITUFORM® cured-in-place pipe (CIPP) technology by AEGION of St. Louis, Missouri.

The liner begins as soft, flexible, and/or malleable, and then hardens into a strong, fiberglass-type material once in position. This leaves the inside of the pipe clean and clear for use. The liner allows cities or municipalities to fix run-down pipes without having to dig the pipes out of the ground and replace the debilitated portions, or even entire lengths, with new pipe. The cost and time savings can be tremendous.

Despite the numerous benefits of the above technology, there are drawbacks or challenges associated with it. In some instances, the liner incorrectly or prematurely hardens, cures, or otherwise fails or deteriorates inside the pipe. For example, the liner can undesirably bulge into the interior of the pipe. These bulges are commonly called “lifts”, which do not allow for proper drainage from the pipe. In these scenarios, the liner either needs to be removed so a new or different liner can be installed or that section of the pipe needs to be replaced. In the scenario where the liner is removed, the affected portion of the pipe liner can be etched out, which is a tedious, cumbersome, and time-consuming process. In the scenario where the pipe is replaced, the portion of the pipe is dug out and replaced with new pipe, which is an expensive proposition.

SUMMARY

The presently disclosed technology overcomes the above and other challenges in the prior art.

In one embodiment, the presently disclosed technology is directed to a device, which optionally can be coupled to existing or prior art robotic equipment, that bores out a section of underground pipe and/or interior liner thereof without the need to dig out the section of pipe. This invention thereby saves time and money.

In another embodiment, the presently disclosed technology is directed to a device configured to bore out a section of underground pipe and/or interior liner thereof without the need to dig out the section of pipe, where the device can include a plurality of arms extending radially outwardly from a central shaft. The central shaft can be configured to attach to a tool, such as existing robotic equipment with or without cameras. The device can include a plurality of cutting devices (e.g., blades) extending outwardly from the central shaft at one end of the device. Each cutting device can be configured to move in unison with the central shaft. Rotation of the central shaft can cause each cutting device to contact, cut, and/or remove an interior surface of underground pipe or an interior liner thereof.

Optionally, each arm helps to properly position the device within the pipe. Each arm can be fixed or automatically adjustable to the radius of the pipe and/or imperfections in the pipe.

DETAILED DESCRIPTION

While systems, devices and methods are described herein by way of examples and embodiments, those skilled in the art recognize that the systems, devices and methods of the presently disclosed technology are not limited to the embodiments or drawings described. Rather, the presently disclosed technology covers all modifications, equivalents and alternatives falling within the spirit and scope of the appended claims. Any headings used herein are for organizational purposes only and are not meant to limit the scope of the description or the claims.

Certain terminology is used in the following description for convenience only and is not limiting. The words “bottom.” “top.” “left,” “right,” “lower” and “upper” designate directions in the drawings to which reference is made. Unless specifically set forth herein, the terms “a,” “an” and “the” are not limited to one element but instead should be read as meaning “at least one.” As used herein, the word “may” and “can” is used in a permissive sense (i.e.., meaning having the potential to) rather than the mandatory sense (i.e., meaning must). The terminology includes the words noted above, derivatives thereof and words of similar import.

Referring to the drawings in detail, wherein like numerals indicate like elements throughout,FIGS.1-8show a device, generally designated1, according to an optional embodiment of the presently disclosed technology. The device1can be configured to bore out or clean out a section of pipe110, such as buried underground or in any other difficult-to-access location, and/or an interior liner10thereof without the need to dig out the section of pipe110. This can allow for the removal of sections of an interior liner10and/or portions of an interior surface of the pipe110without causing structural damage to the pipe110and/or damage to an exterior surface of the pipe110. As a result, liner10that incorrectly hardens, for example, can be removed prior to insertion or application of a new liner10.

In one embodiment, the device1can include one, two, or a plurality of radially spaced-apart arms, generally designated12, that extend radially outwardly from a central shaft100. Optionally, a radial length of each arm12is adjustable, for example manually or automatically (e.g., spring loaded or telescoping). In another optional embodiment, a radial length of each arm12is fixed, and each arm12can be attached to the central shaft by one or more fasteners.

One end (e.g., a proximal end) of the central shaft100can be attached or removably attachable to a tool16(seeFIG.1). The tool16can optionally be a pneumatic or rotary tool, such as a drill, that can include a motor, or any other type of spinning tool.

Optionally, each arm12can be rotatably attached to the central shaft100, meaning as the central shaft100rotates along its central axis or the longitudinal axis of the pipe110or the interior liner10thereof (e.g., extending into or out of the page at the center of the circle inFIGS.7A-7C) in a clockwise or counterclockwise direction, each arm12can maintain its original position and or radially length. Thus, each arm12can rotate independent from any rotation of the central shaft100. In one embodiment, at least one bearing50is located between and attaches each arm12to the central shaft100. The bearing50can be press fit or welded onto the central shaft100. The bearing50can allow the central shaft100to spin freely with respect to the arm12.

In one optional embodiment, the device1can include more than one set of plurality of arms12. For example, the device1can optionally include a first set of a plurality of arms12that can include four radially spaced-apart arms12. The device1can also optionally include a second set of a plurality of arms12. The second set can be comprised of optionally four radially spaced-apart arms12. The first set can be spaced-apart from the second set along the central axis of the central shaft110or the longitudinal axis of the pipe110or the interior liner10thereof.

In one embodiment, as shown inFIG.1, the device1can include two or more or a plurality of radially spaced-apart cutting devices, generally designated14, that extend radially outwardly from the central shaft100. The cutting devices14can be positioned between the first and second set of a plurality of arms12.

Optionally, a first end of each cutting device14is configured to move in unison with the central shaft100. An opposing second end of each cutting device14is moveable with respect to the central shaft100. Rotation of the central shaft100can cause the second end of each cutting device14to contact and cut an interior surface of the pipe110or an interior liner10thereof. The liner10can be formed of fiberglass or other material.

In one optional embodiment, at least two or a plurality of spaced-apart fins70can extend radially outwardly from the central shaft100. Each fin70can optionally be fixed with respect (e.g., welded) to the central shaft100, meaning as the central shaft100rotates along the longitudinal axis in a clockwise or counterclockwise direction, so does each fin70. In another embodiment, each fin70is removably fastened to the central shaft100. Optionally, the fins70can be positioned between two sets of arms12along the longitudinal axis. In one embodiment, each fin70can include two or more or a plurality of spaced-apart holes at or near an end opposite the central shaft100.

Each cutting device14can be directly attached, or optionally removably fastened, to one of the fins70. In one optional embodiment, each fin70is attached to four spaced-apart cutting devices14that extend along the longitudinal axis. Each cutting device14can include a holding chain80and a cutting end90. A first or proximal end of each holding chain80can be attached, either removably or permanently, to one of the fins70, optionally through one of the holes. A second or distal end of each holding chain80can be attached to one of the cutting ends90.

Optionally, each holding chain80can be formed by two or more links of a chain depending on length requirements. Each cutting end90can have at least one sharp blade or edge designed to remove or scrape against the interior of the pipe110or a linear10thereof. The cutting ends90are shown as having a U-shaped configuration, but other sizes, shapes, and configurations are possible. For example, adjacent cutting ends90can have different configures, such as pointed and/or flat tips.

Each arm12can be self-adjusting or automatic-adjusting to the interior of the pipe110or the interior liner10thereof. For example, as shown inFIGS.7A,7B, and8-10, each arm12can optionally include a fastening coupler {grave over ( )}, a locking nut30, and a roller20. The fastening coupler40of each arm12can be welded to the bearing50. The locking nut30can allow the user or operator to ensure that the roller20does not loosen under stress. The roller20can be adjustable and/or centering, which ensures that the device1is properly centered within the section of the pipe110so that the cutting devices14do not remove more material (e.g., of the pipe110or the liner10) than desired or required.

Optionally, each roller20can include a spacer, a spring, and/or a thumb screw within a hub assembly to allow for self-adjustment or automatic-adjustment.

In one embodiment, each set of a plurality of arms12can include an optional stiffening ring60. The stiffening ring60can contact or be attached to each arm of the set. The stiffening ring can optionally be welded to each fastening coupler40to lock all of the arms12and/or the rollers20from moving with respect to each other.

In operation, the device1can be inserted into an interior of a pipe110that requires attention or is debilitated. The device1can be properly aligned by having the roller20of each arm12contact an interior surface of the pipe110or the liner10. Each arm12can have the same length, or the arms12can be adjusted to have the same length, such that the central shaft100of the device1is co-linear with the longitudinal axis of the section of the pipe110or situated as required for other uses.

Next, the central shaft100of the device1can be rotated with respect to the pipe110or the liner10such that the arms12maintain the central shaft100co-linear with the longitudinal axis of the section of the pipe110. The central shaft100can be rotated by connecting a proximal end thereof to the tool16, for example. The cutting devices14rotate as the central shaft100is rotated, thereby causing each cutting end90to contact the interior surface of the pipe110and/or the liner10. During this time, the arms12can optionally remain stationary with respect to the pipe110.

After a sufficient time and/or number of rotations of the central shaft100, the cutting ends90have cut or scrapped a sufficient or predetermined amount of the interior surface of the pipe110and/or the existing liner10to make room for a new liner to be applied.

FIG.9shows a modified version of the device1. The two versions are substantially similar, and like elements between the two embodiments are identified with like reference numbers, and description of certain similarities between the two embodiments may be omitted herein for brevity purposes only. Items within either version can be interchanged with items in the other version.

Optionally, each arm12is positioned distally with respect to the fins70from the tool.

FIGS.10-12show another modified version of the device1. The three versions are substantially similar, and like elements between the three embodiments are identified with like reference numbers, and description of certain similarities between the three embodiments may be omitted herein for brevity purposes only. Items within one version can be interchanged with items in either or both of the other versions.

FIG.10depicts how a liner10can incorrectly harden or bulge (e.g., identified by raised portion5and commonly referred to as a “lift”) inside of the pipe110. The bulge5must be removed or significantly reduced to allow for a new liner10to be installed properly. To accomplish this, the device1can include one or more blades55extending forward from, and optionally fixedly attached to (e.g., via welding) or removably fastened to a center or blade hub45. In one embodiment, each blade55may include one or more holes or slots to attached to the cutting device(s)14. Optionally, the center or blade hub45can replace the fins70described above. The chain(s)80and cutting end(s)90can extend from and/or be attached to the center or blade hub45. The center or blade hub45can be fixedly attached (e.g., via welding) or removably fixed to the distal end of the central shaft100and/or the bearing50.

Optionally, each blade55can include one or more slots configured to receive a fastener (e.g., a bolt) to attach the blade55to the blade hub45. Each slot can be elongated (e.g., oval) or eccentric in shape so that each blade55can be manually adjustable. Alternatively, in one optional embodiment, each blade55can have rounded stops at back edges to allow the blade55to slide and/or expand outward with centrifugal force so that each blade55is self-adjusting.

In operation, the one or more blades55can be rotated with the central shaft100to cut the majority or entirety of the bulge5of the liner10. The cutting ends90can create finer or more precise cuts, if desired or necessary.

As shown inFIGS.10,11, and13-18, each arm can be attached to a spring hub52instead of or in addition to the fastening hub40of a previous embodiment. Optionally, the spring hub52can include at least one spring therein, or a spring for each of the arms attached thereof. For example, each spring can be a coil spring within a plurality of spaced-apart slots around a periphery of the spring hub. Each spring allows the respective arm12to move radially inward and outward, at least slightly, to accommodate changes in the interior of the pipe110and/or the interior liner10thereof, while still maintaining the blades and/or cutting elements centered within the pipe110and/or the interior liner10thereof.

Alternatively, the spring hub52can be devoid of any springs, such that each arm is fixed to the hub.

FIGS.13-17show another modified version of the device1. The four versions are substantially similar, and like elements between the four embodiments are identified with like reference numbers, and description of certain similarities between the four embodiments may be omitted herein for brevity purposes only. Items within one version can be interchanged with items in either or both of the other versions.

A distinguishing feature of the embodiment shown inFIGS.13-17is the omission of the chain-form of cutting devices14from the previous embodiments and reliance upon the at least one cutting element in the form of a blade55that extends outwardly from the distal end of the central shaft. In one embodiment, as shown inFIG.17, the cutting device optionally includes at least two blades55that extend at angles of 90 degrees or 45 degrees to one another. Each blade55, which can be devoid of any holes therein, can move in unison with the central shaft100, and the hub45that connects the central shaft100to each blade55. The hub45is shown to be a three dimensional hexagon inFIG.17, but other sizes, shapes, and configurations are possible.

When viewed along the central axis of the central shaft100, optionally two or four of the blades55can form an X shape. A front end of each blade55can include teeth in an undulating or non-linear pattern. Each blade55can optionally be removably or fixedly mounted to the central shaft100. A radial length of each blade55can optionally be at least slightly less than a radius of the pipe10or the interior liner110thereof. Also, each blade55can optionally be self-adjusting or automatic-adjusting to the interior diameter of the pipe10or the interior liner110thereof, while still maintaining the blades and/or cutting elements centered within the pipe110and/or the interior liner10thereof.

Another distinguishing feature of this embodiment is that one end (e.g., the proximal end) of the central shaft100can be fixedly or removably attachable to a robot92. The robot92can be configured to push and/or pull the device along the longitudinal axis of the underground pipe110or the interior liner10thereof. The robot92can house a motor and can include one or more (e.g., four spaced-apart) wheels that contact an interior of the pipe110or the interior liner10thereof to move the device within the pipe110or the interior liner10thereof. The robot92can be operatable connected or include video equipment (e.g., a camera capable of video feed and/or recording) to allow the user or operator to see the interior of the pipe110or the interior liner10thereof.

FIG.18shows another modified version of the device1. The five versions are substantially similar, and like elements between the five embodiments are identified with like reference numbers, and description of certain similarities between the five embodiments may be omitted herein for brevity purposes only. Items within one version can be interchanged with items in either or both of the other versions.

A distinguishing feature of the embodiment shown inFIG.18is a third set of a plurality of arms12.

FIGS.19-21show one optional aspect of the presently disclosed technology, where each blade55can be manually adjusted. Each blade55can include two, three, or more at least slightly spaced-apart holes, such as first hole75a,second hole75b,and third hole75c,to receive a fastener76(only the head of the fastener76is visible in these figures, as the shaft of the fastener76would extend into the page) therethrough to attach the blade55to the blade hub45. Repositioning of the fasteners76through one of the various holes through the blade55and into the blade hub45modifies or adjusts extend to which the outer edge of the blade55contacts or approaches the interior of the pipe110or the interior liner10thereof.

FIG.19shows two blades55adjusted or positioned for an interior diameter (I.D.) of the pipe110or the interior liner10thereof of7inches.FIG.20shows two blades55adjusted or positioned for an interior diameter of the pipe110or the interior liner10thereof of 7.25 inches.FIG.21shows two blades55adjusted or positioned for an interior diameter of the pipe110or the interior liner10thereof of 7.5 inches. Each of these figures show optional dimensions, as different embodiments are possible for different internal diameters of the pipe110or the interior liner10thereof.

When comparingFIGS.19-21, it is apparent that inFIG.19the blades55are closest to the central shaft100and furthest from the interior of the pipe110or the interior liner thereof10, and inFIG.21the blades55are closest to the interior of the pipe110or the interior liner thereof10. Alternatively or additionally, the configuration shown inFIG.19can be used for a pipe110or liner10with the smallest interior diameter, and the configuration shown inFIG.21can be used for a pipe110or liner10with the largest interior diameter. The presently disclosed technology can be made to accommodate a variety of interior diameter ranges. For example, the blades55can be adjustable to work between 7-7.5 inch interior diameter, 7.5-8 inch interior diameter, 8-8.5 inch interior diameter, and so on.

FIGS.22-25show one optional aspect of the presently disclosed technology, where each blade55is self or automatically adjusted. For example, each blade55can be pivotally attached, such as by a fastener85, to a self-adjusting blade arm86. Each blade arm86can be movably attached to the blade hub45, which is rotatably or fixedly attached (e.g., welded) to the central shaft100, by at least one or two spaced-apart biasing members or retracting springs87. The retracting springs87can allow the blade arms86to move toward and away from the central shaft100and/or the blade hub45. As described above, the central shaft100can be fastened or attached to a robot or a rotary tool.

FIG.22shows the arrangement in a resting or not spinning configuration (i.e., not in use), with a cover plate88attached to the blade hub45by a plurality of spaced-apart fasteners89. The cover plate88is configured to cover and/or protect certain parts (e.g., the blade hub45), and/or seal and keep clean the inside of the blade hub45.FIG.23omits the cover plate88for clarity and also shows the arrangement in the resting or not spinning configuration. When at rest, each blades55can swing downward due to gravity, which makes the assembly smaller to facilitate the insertion into the pipe110and/or the interior liner10thereof before usage.

FIG.24shows an arrangement with three spaced-apart blades55while spinning (i.e.., when in use). The cover plate88is shown inFIG.24.FIG.25also shows the spinning arrangement, but with the cover plate88omitted for clarity.

Optionally, each blade arm86is pushed toward the central shaft100with springs or magnets, thus increasing the distance between an end of each blade55and the interior of the pipe110or the liner10thereof. The springs or magnets are sufficiently strong to keep the weight of each blade55and the arms86tucked toward the center. The springs or the magnets need very little pull to allow the blades55to protrude outwardly to allow the blades55to cut the interior of the pipe110and/or the liner10thereof.

In one optional operation, the robot or tool is pushed into the pipe110and/or the liner10without the robot or tool rotating to a point in the pipe110and/or the liner10that needs to be addressed. Once in place, the robot or tool begins to spin, which in turn rotates the center shaft100. Once the center shaft100spins, the blade arms86begin to spin, and each blade55is forced and/or rotated outwardly by centrifugal force. The expansion or rotation of the blades55outward is dependent upon revolutions supplied by the robot or tool. Once the cutting has finished, the robot or tool stops the rotation of the central shaft100, allowing all springs and gravity to retract blades55back toward the central shaft100, allowing the entire tool to be pulled back out of the pipe110and/or the liner10thereof without obstructions.

Even if it is interpreted that multiple embodiments are shown and/or described herein, it is understood that any one or more features of any particular embodiment can be omitted or included in (e.g., added to) another embodiment. For example, portions of the device may be interchangeable with one or more fasteners.

The following exemplary embodiments further describe optional aspects of the presently disclosed technology and are part of this Detailed Description. These exemplary embodiments are set forth in a format substantially akin to claims, although they are not technically claims of the present application. The following exemplary embodiments refer to each other in dependent relationships as “embodiments” instead of “claims.”1A. A device comprising a plurality of arms extending radially outwardly from a central shaft and a plurality of cutting devices extending radially outwardly from the central shaft, wherein the arms rotate independent of the central shaft and the cutting devices rotate with the central shaft.1B. The device embodiment 1A, wherein a length of each arm is fixed or adjustable.1C. The device of embodiment 1A or 1B, wherein a length of each cutting device is adjustable.1D. The device of any one of embodiment 1A-1C, wherein the plurality of arms includes a first set of a plurality of arms and a second set of a plurality of arms, wherein the plurality of cutting devices is positioned between the first and second set.2A. A combination tool and device configured to removably attach to the tool and configured to be insertable into an existing underground pipe to remove incorrectly hardened portion of pipe liners or bore out an interior surface of the underground pipe or an interior liner thereof.2B. The combination of embodiment 2A, wherein inertial or centrifugal force causes cutting devices to scrape or cut the interior surface of the underground pipe or the interior liner thereof.3A. A method of removing or replacing an interior liner of a debilitated underground pipe, the method comprising inserting into the underground pipe a device that cuts an interior surface of the liner while the device is maintained along a central longitudinal axis of the device.