GROUTING MATERIAL DELIVERY AND APPLICATION SYSTEM

A wetout funnel (82) including opposite walls (88) forming a v-shape with a slot (90) at the bottom of the v-shape and a squeegee (102) disposed at the slot (90) for controlling the coating of grouting material for a uniform covering on a liner (50) as it passes through the wetout funnel (82). A first ejector pipe (104) receives and dispenses grouting material (52) to coat one half of the exterior of the liner (50) and a second ejector pipe (106) receives and dispenses grouting material (52) to coat the opposite half of the exterior of the liner (50). The wetout funnel (82) is mounted on a supporting framework (84) that is positionable over a manhole. The supporting framework (84) has end pieces (92) movable to engage the edges of a liner (50) of different widths.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a mobile grouting delivery and applicator system for evenly applying an adhesive grouting material to an expandable flexible liner during the repair of an underground conduit.

2. Description of the Prior Art

Such grouting material delivery and application systems are well known. One such grouting material delivery system, disclosed in U.S. Pat. No. 5,139,751 to William Mansfield et al., includes a trailer having a base and reel of hose, a power source, a grouting material storage tank, and pump to pump the grouting material through the hose for treating the interior of a conduit.

Another such grouting material delivery and application system is disclosed in U.S. Pat. No. 5,314,100 granted May 24, 1994 to Jim Deaver includes a trailer with a power supply containing a grouting material storage hopper connected to a motor-operated pump and having a flexible hose where the grouting material flow can be adjusted by a discharge nozzle.

Alternatively, a grouting material delivery and application system is disclosed in U.S. Pat. No. 4,740,110 granted Apr. 26, 1988 to Ray Saffrhan and includes a barge for travelling over the water having a power supply, pump and tank for grouting material storage with a winch and/or crane for lifting and lower grouting material hose into and out of the water.

Conventionally, once at the repair site, the liner is pulled through the conduit with a winch. Once the liner is in place, the grouting material is then pumped into the conduit between the damaged conduit interior surface and the exterior surface of the liner. Another common method is to pump the grouting material into the conduit and then pull the liner through the grouting material-filled conduit. One such assembly, disclosed in U.S. Pat. No. 6,167,913 granted Jan. 2, 2001 to Peter Wood et al., discloses a method of repairing a conduit by pulling a flattened tubular liner with grouting material anchor hooks, for collecting grouting material when applied, through the conduit from one manhole to another using a winch. The conduit is precharged with grouting material and once the liner is pressurized and inflated, the grouting material flows between the outer surface of the liner attaching to the anchor hooks and the inner surface of the conduit. This method leaves open the possibility of not having a uniform coating on the liner which could lead to voids in the coverage of the grouting material and weak spots of the conduit after curing. Similarly, both U.S. Pat. Nos. 5,762,450 and 5,791,378, also discuss pulling a liner through the conduit and pumping grouting material in the annular space between the liner and conduit for repair of the conduit.

Alternatively, U.S. Pat. No. 5,993,114 granted Nov. 30, 1999 to Gerald Jones, discloses an apparatus and method of repairing a conduit by providing a tubular liner having a first surface facing inwardly of the liner and a second surface facing outwardly of the liner and where a grouting material is disposed on the first surface, inverting the liner adjacent one end of the liner and moving a portion of the liner along the length of the pipe to progressively cause the first surface to face outwardly of the liner and to come into direct contact with the inner surface of the pipe without contacting any other material so that the coating comprises the only material between the pipe and the liner.

Alternatively, U.S. Patent Application Publication 2010/0212803 published Aug. 26, 2010 to Heath Car et al., discloses a method of reinforcing a conduit with fiber reinforced polymer including coating a raw carbon fiber material with an epoxy resin by directing the fiber material stored on a reel into a dipping tank and through rollers acting as squeegees and finally applied to the walls of a conduit.

Also, U.S. Patent Application Publication 2010/0215859 published Feb. 20, 2010 to David Lee Alexander, discloses a dip-coating system for applying a liquid coating material onto building materials such as lumber. The system comprises a funnel box containing a dipping slot and dipping sleeve to hold the liquid coating material and end pieces that are adjustable for varying sizes of lumber. Brushes are attached to the funnel box to act as squeegees for wiping off excess coating material.

Finally, U.S. Pat. No. 1,498,738 published Jun. 24, 1924 to Joseph Lahousse discloses an apparatus and method for coating wires. The wire stored on a reel is pulled through a liquefied coating followed by a gauge tube for regulating the thickness of the coating on the wire.

SUMMARY OF THE INVENTION

In view of the foregoing state of the art, the object of the invention is to provide an apparatus of the type for coating the exterior of a collapsed liner with an even distribution of a grouting material. The apparatus includes a wetout funnel for receiving grouting material to evenly coat the entire outside diameter of the liner. The wetout funnel includes opposite walls forming a v-shape with a slot at the bottom of the v-shape and a squeegee disposed at the slot for controlling the coating of grouting material for a uniform covering on the liner as it passes through the wetout funnel. A first ejector pipe having an inflow end and an outflow end for receiving and dispensing grouting material to coat one half of the liner exterior. A second ejector pipe having an inflow end and an outflow end for receiving and dispensing grouting material to coat the opposite half of the liner exterior. The shape of the wetout funnel and the positioning of the ejector pipes provides for even distribution of the grouting material onto the liner so that when the liner is pulled through the conduit, the grouting material fills cracks and holes in the conduit inner walls.

DESCRIPTION OF THE ENABLING EMBODIMENT

Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, an apparatus20, generally shown inFIG. 1, is a mobile grouting system used for repairing a damaged conduit. According to the present invention the apparatus20includes a support22, trailer, extending along an axis between a first end24and a second end26with two or more road wheels spaced from one another transversely of the axis and carrying the support22. The apparatus20can be self-contained on the support22which can be attached to a transport vehicle, such as a truck or tractor, using a hitch to be conveniently towed to and from a conduit repair location. The apparatus20can also be three integrated units with each unit either on the support22or placed on the ground during the repair of the conduit. Alternatively, the support22could be a barge or boat for travelling over the water to repair damaged conduits under the water.

A power supply28and/or an air compressor and/or blower is mounted on the first end24of the support22for supplying electrical power to the equipment of the apparatus20and inflation air for the liner placement. The power supply28and/or air compressor could also be used to supply electrical energy to operate any electrically based or pneumatic power tools and equipment used during the repair of the underground conduit. The power supply28can include, but is not limited to generators, batteries, inverters, etc.

A crane assembly30is mounted adjacent to the power supply28on the support22. The crane assembly30is connected to the power supply28for hoisting movable equipment and tools onto and off of the support22and for lowering the equipment and tools down into a manhole.

The crane assembly30includes a mast32extending vertically from the support22and a boom34mounted and cantilevered to the mast32and extending from a near end36adjacent the mast32to a far end38. The crane assembly30also includes a trolley40movably supported by the boom34for moving back and forth on the boom34. A pulley42is supported by the trolley40along with a cable44extending along the length of the boom34that loops through the pulley42to a hook46on the end of the cable44for lifting and lowering of the equipment and tools.

As shown inFIG. 2, an expandable pipe system48includes a liner50and a grouting material52where the grouting material52is applied to the liner50. The expandable pipe system48is inserted into a damaged conduit, as shown inFIG. 4, and allowed to expand and adhere to the host conduit in a manner that eliminates void spaces, cracks, and holes, and increases the structural integrity of the conduit.

The liner50is brought to the repair location loaded on to the support22. As shown inFIG. 1, the liner50, flexible and made of a polymer material, such as thermoplastic polyurethane (TPU) or a recycled polypropylene (PP), is coiled, lying flat like a firehose, stored onto a reel54located on the support22. As shown inFIG. 2, the liner50has an exterior surface56surrounding a center opening58and extending between opposite liner ends60. The exterior surface56of the liner50has a liner width W, shown inFIGS. 2 and 3, extending across its center opening58and a liner length L extending along the center opening58. The exterior surface56defines a plurality of grooves62spaced from one another for containing the grouting material52in the grooves62prior to insertion into the conduit. The plurality of grooves62can be formed by cutting or stamping into the exterior surface56of the liner50, or by other methods known in the art. Each of the grooves62extend radially into the exterior surface56to a depth as shown inFIGS. 3 and 3A. The grooves62are typically spaced an equal distance from one another around or along the liner50. As shown in theFIGS. 2-7, the grooves62only extend partially through the liner50so that the inside of the liner50presents a continuous smooth and sealed surface. In other words, the liner50is free of holes.

In one embodiment, each of the grooves62extends longitudinally between the ends along the exterior surface56, as shown inFIG. 2. In another embodiment, each of the grooves62extend circumferentially around the center opening58along the exterior surface56, as shown inFIG. 8. In yet another embodiment, the grooves62extend both circumferentially around the center opening58, and longitudinally between the ends along the exterior surface56, as shown inFIG. 9. The grooves62are typically spaced an equal distance from one another around or along the length of the liner50. Alternatively, the grooves62can be formed in only certain sections of the liner50so that the grouting material52material is only disposed in those sections. The grouting material52is disposed in the grooves62and flush with the exterior surface56of the liner50so that the grouting material52does not escape the grooves62as the liner50brushes against the conduit when the liner50slides into the conduit. The plurality of grooves62also make the liner50more flexible and easier to insert into the underground conduit and navigate dips and bends in the conduit, as well as, wind up and store on the reel54.

The reel54that stores the liner50has a base64that can be located on at the second end26of the support22for allowing the reel54to rotate relative to the base64and dispensing lengths of liner50from the reel54.

As the liner50unravels from the reel54and base64, the liner50and grouting material52are routed through the coating process and becomes the expandable pipe system48. The expandable pipe system48is guided down the manhole into the damaged conduit. The expandable pipe system48is pulled through by a towline and strung through the conduit attached to a winch mounted at the next manhole. The external diameter of the expandable pipe system48is slightly smaller than the internal diameter of the underground conduit and an annular space is formed between the two surfaces of the expandable pipe system48and conduit. The grouting material52of the expandable pipe system48expands and fills in the annular space. Once the full liner length L of the expandable pipe system48has been pulled through the conduit, the ends of the expandable pipe system48are capped, and as shown inFIGS. 5 and 6, the flattened expandable pipe system48is inflated to a specific volume pressure to minimize the annular space. As shown inFIG. 7, the grouting material52goes through a curing process where the expandable pipe system48adheres to the inner diameter surface of the damaged conduit, filling the holes and cracks of the damaged conduit with the expanding grouting material52.

As stated above, the expandable pipe system48is disposed in a conduit having cracks, voids, holes, or other imperfections due to corrosion, erosion, or other circumstances, as well as, to increase the structural integrity of the conduit. The conduit typically includes a cylindrical shape so that the conduit opening has an annular shape, but the conduit can include other distinct shapes. The conduit can be any type of conduit or pipe. The conduit may be located in the ground, such as a sewage pipe, inside a building, such as a drain pipe, water pipe, or electrical pipe, or under water on a seabed, such as an oil line. The conduit is typically formed of metal, such as copper, aluminum, or iron, or of another material such as concrete, vitrified clay, or asbestos cement. However, the conduit can also be formed of plastic or another material.

The grouting material52applied to the liner50by the apparatus20prior to insertion into the conduit includes urethane, for example, expandable natural urethane grouting material52. The grouting material52can also include other types of urethane grouting material52, as well as, epoxy grouting material52, cement-based grouting material52, and resin-based grouting material52. The grouting material52may include a plurality of fibers such as recycle fiber glass, carbon fiber, coconut fiber, and other recycled or non-recycled fibers for increasing the strength of the grouting material52. The grouting material52can also include a filler material, such as expandable plastic micro-spheres. However, the grouting material52can include a variety of other filler materials. The grouting material52can be pre-mixed from a variety of different materials and obtain a predetermined strength.

A tank66having a top end68and a bottom end70opposite the top end68is installed onto the support22between the first end24of the support22and the reel54of liner50. The grouting material52is pre-mixed and loaded into the top end68through a covered opening of the tank66. The grouting material52is dispensed at the bottom end70of the tank66.

A variable speed pump72is mounted on the support22next to the tank66and between the first end24of the support22and the reel54of liner50and connected to the power supply28. The pump72is a positive displacement pump72that delivers measured volume of fluid as required for a given application and has a suction74and a discharge76. The suction74of the pump72is used for moving the grouting material52from the tank66to the pump72. An inlet pipe78interconnects the tank66and the suction74of the pump72.

The discharge76of the pump72moves the grouting material52into an outlet pipe80. The outlet pipe80directs the flow of the grouting material52from the discharge76of the pump72to a wetout funnel82.

FIG. 1shows the wetout funnel82mounted onto a supporting framework84unloaded from the support22by the crane and set on the ground. Once unloaded, the wetout funnel82and supporting framework84are positioned over top of the manhole. The supporting framework84contains a roller-guide86that hangs above the wetout funnel82for guiding the liner50into the wetout funnel82. Alternatively, the wetout funnel82can be mounted to and extend from the second end26of the support22for positioning over top of the manhole during a conduit repair operation.

As shown inFIG. 10, the wetout funnel82has opposite walls88forming a v-shape angling inwardly from wide at the top and sloping downward narrow at the bottom to form a trough shape with a slot90. The wetout funnel82, having the trough shape with a wide mouth to receive the grouting material52from the outlet pipe80and a narrower stem to channel the grouting material52, is specifically designed for coating the liner50and filling the plurality of grooves62in the liner50as the liner50is pulled through the wetout funnel82. The wetout funnel82has end pieces92positionable to accommodate the liner50having variable width sizes and thicknesses. Mounted to the side of each end piece92is a bracket94. A first roller96and a second roller98being disposed in parallel and spaced relationship from one another extend across the wetout funnel82and mount to the brackets94at each end. The rollers96,98are used for guiding the liner50into the wetout funnel82from the roller-guide86mounted on the supporting framework84of the wetout funnel82.

The interior side of the opposite walls88, angled wide at the top and sloping downward and narrow at the bottom, defining the trough shape, have sheets of organic polymer100fastened to them. Alternatively, the sheets of organic polymer100can be replaced with a plastic-type coating. Each sheet of organic polymer100curls inward to create a seal against the walls88. The sealing action of the sheets100prevent excess grouting material52from leaking out the bottom of the wetout funnel82.FIGS. 10 and 11show a squeegee102attached to each sheet of organic polymer100. The squeegees102are used for controlling the coating of the grouting material52and to give a uniform covering on the liner50and into the grooves62as the liner50passes through the wetout funnel82.

The wetout funnel82includes a limit switch83(not shown) to control the grouting material52level and to ensure complete coverage of the grouting material52by winch speed and pump72where the pump72is programmed to automatically decrease grout delivery on high levels and increase grout delivery at low levels of the grouting material52.

The grouting material52is highly viscous and the size of the inlet pipe78and the outlet pipe80allows for a uniform flow of the grouting material52into the wetout funnel82. Both the inlet pipe78and outlet pipe80is of a specified two-inch schedule standard PVC or equivalent. The size of the inlet pipe78and outlet pipe80must be of sufficient cross-sectional area to deliver a uniform flow of the grouting material52onto the liner50. Working together, the pump72, pipe system, and the wetout funnel82evenly distribute the grouting material52on the exterior surface56of the liner50and smoothing into the grooves62prior to insertion into the conduit.

FIG. 1shows the outlet pipe80conveying the grouting material52from the pump72to the wetout funnel82through a first ejector pipe104and a second ejector pipe106. As shown inFIG. 1, the ejector pipes104,106suspend over the wetout funnel82in a parallel and spaced relationship with one another and work together to evenly fill the wetout funnel82on each side of the liner50. The first ejector pipe104is of a constant diameter having an inflow end108and an outflow end110for dispensing grouting material52into the wetout funnel82on one side of the liner50, and the second ejector pipe106is of a constant diameter having an inflow end108and an outflow end110for dispensing grouting material52into the wetout funnel82on the opposite side of the liner50.

The outlet pipe80splits into two branches, shown inFIG. 12, by connecting to a feeder112that is defined by an entry leg114, a first leg116, and a second leg118, where the first leg116and the second leg118are disposed at ninety degrees relative to one another and diverge from the entry leg114. A first conduit120interconnecting the first leg116of the feeder112to the inflow end108of the first ejector pipe104conveys grouting material52from the feeder112to the first ejector pipe104. A second conduit122, interconnecting the second leg118of the feeder112to the inflow end108of the second ejector pipe106, conveys grouting material52from the feeder112to the second ejector pipe106. The first conduit120and the second conduit122suspend over the wetout funnel82and work together to evenly coat the liner50as it passes between them.

The outlet pipe80connects the discharge76of the pump72to a first union124. Pipe unions, in general, connect two pipes together in a way that requires only one pipe to be turned when removing the union, facilitating repairs. The first union124is defined by having a nut threaded and joining a female section and a male section where both comprise an inner diameter and an outer diameter forming a tubular body portion of uniform diameter. Threads on the outer diameters of the female section and male section receive the nut and allow for disassembly during maintenance and replacement.

A first coupling126, of the standard type, short length of pipe, is utilized as an adapter to join two pipes. In general, a coupling fitting is used to extend the run of a pipe, or change pipe sizes. The first coupling126comprises an inner diameter and an outer diameter forming a tubular body portion of a uniform diameter provided with ends of reduced diameter adapted to telescope into receiving pipe ends. The first coupling126receives the end of the first union124at one end and the entry leg114of the feeder112at its opposite end.

Beginning the formation of the first conduit120, a second coupling128, utilized as an adapter to join two pipes, comprising an inner diameter and an outer diameter forming a tubular body portion of uniform diameter provided with ends of reduced diameter adapted to telescope into receiving pipe ends, inserts into the first leg116at its end.

A first bend130is received by the other end of the second coupling128. The bend comprises an inner diameter and an outer diameter forming a tubular body portion of uniform diameter. Straight sections at each of the ends and a curved section with a radius of forty-five degrees at the middle of the body portion allows for installation between two lengths of pipe and a change of direction in the flow of grouting material52.

A third coupling132, utilized as an adapter to join two pipes, comprising an inner diameter and an outer diameter forming a tubular body portion of uniform diameter provided with ends of reduced diameter adapted to telescope into receiving pipe ends, is received by the other end of the first bend130.

A second union134is defined by having a nut threaded and joining a female section and a male section where both comprise an inner diameter and an outer diameter forming a tubular body portion of uniform diameter. Threads on the outer diameters of the female section and male section receive the nut and allow for disassembly during maintenance and replacement. The second union134connects to the other end of the third coupling132.

A fourth coupling136, of the standard type utilized as an adapter to join two pipes, comprises an inner diameter and an outer diameter forming a tubular body portion of uniform diameter. The fourth coupling136has ends of a reduced diameter adapted to telescope into receiving pipe ends and inserts into the end of the second union134nearest the first leg116of the feeder112.

A first elbow138, of the standard type, comprising an inner diameter and an outer diameter. A tubular body portion of uniform diameter is formed having straight sections at each of the ends and a curved section of a radius of ninety degrees at the middle of the body portion. The curved section allows for a change of direction in the flow of grouting material52. The first elbow138receives the other end of the fourth coupling136.

A fifth coupling140, of the standard type and utilized as an adapter to join two pipes, comprising an inner diameter and an outer diameter forming a tubular body portion. The tubular body portion is of uniform diameter provided with ends of reduced diameter adapted to telescope into receiving pipe ends. The fifth coupling140connects to the first elbow138nearest the first leg116of the feeder112.

A third union142having a nut threaded joining a female section and a male section where both comprise an inner diameter and an outer diameter forming a tubular body portion of uniform diameter and having threads on said outer diameters of said female section and male section to receive the nut for disassembly. The other end of the fifth coupling140connects to the end of a third union142.

The other end of the third union142connects to the inflow end108of said first ejector pipe104. The first ejector pipe104is cylindrical in shape and disposed about an Axis A. Grouting material52flows out of the outflow end110of the first ejector pipe104.

Beginning the formation of the second conduit122, a sixth coupling144, of standard type, comprising an inner diameter and an outer diameter forming a tubular body portion of uniform diameter. The body portion is provided with ends of reduced diameter adapted to telescope into receiving pipe ends. The sixth coupling144connects into the second leg118at its end.

A second bend146, comprising an inner diameter and an outer diameter forming a tubular body portion of uniform diameter. The second bend146has straight sections at each of its ends and a curved section of a radius of forty-five degrees at the middle of its body portion to allow a change of direction in the flow of grouting material52. The second bend146receives the other end of the sixth coupling144.

A seventh coupling148, of standard type, comprising an inner diameter and an outer diameter forming a tubular body portion of uniform diameter. The body portion is provided with ends of reduced diameter adapted to telescope into receiving pipe ends and inserts into the end of the second bend146.

A fourth union150, of standard type, is defined by having a nut threaded and joining a female section and a male section where both comprise an inner diameter and an outer diameter forming a tubular body portion of uniform diameter. Threads on the outer diameters of the female section and male section receive the nut and allow for disassembly during maintenance and replacement. The fourth union150connects to the other end of the seventh coupling148.

A eighth coupling152, of standard type, comprising an inner diameter and an outer diameter forming a tubular body portion of uniform diameter. The eighth coupling152is also provided with ends of reduced diameter adapted to telescope into receiving pipe ends of another source and connects to the other end of the fourth union150.

A second elbow154, of the standard type, comprising an inner diameter and an outer diameter. A tubular body portion of uniform diameter is formed having straight sections at each of the ends and a curved section of a radius of ninety degrees at the middle of the body portion. The curved section allows for a change of direction in the flow of grouting material52. The end of the third elbow receives the other end of the eighth coupling152,

A ninth coupling156, of standard type, comprising an inner diameter and an outer diameter forming a tubular body portion of uniform diameter provided with ends of reduced diameter adapted to telescope into receiving pipe ends, connects to the other end of the third elbow.

A fifth union158, of standard type, is defined by having a nut threaded and joining a female section and a male section where both comprise an inner diameter and an outer diameter forming a tubular body portion of uniform diameter. Threads on the outer diameters of the female section and male section receive the nut and allow for disassembly during maintenance and replacement. The end nearest the second leg118of the feeder112of the fifth union158connects to the other end of the ninth coupling156.

A fifth union158having a nut threaded joining a female section and a male section where both comprise an inner diameter and an outer diameter forming a tubular body portion of uniform diameter and having threads on said outer diameters of said female section and male section to receive the nut for disassembly. The other end of said ninth coupling156connecting to the end of said fifth union158.

The other end of said fifth union158connecting to the inflow end108of the second ejector pipe106. The second ejector pipe106, cylindrical in shape, disposed about an Axis B, directs the flow of the grouting material through its outflow end110.

Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the appended claims. In addition, the reference numerals in the claims are merely for convenience and are not to be read in any way as limiting.