# Patent

## Title
Rivet plumbing repair apparatus and method

## 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.

## Background
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.

## Claims

1. A pipe repair process, the method comprising the steps of:
enlarging and shaping a perforation of a pipe wall to a sized hole having a diameter for receiving a blind rivet, the blind rivet comprising:
a body having a tubular section, a flange formed about a perimeter of a flange end of the body, and a tubular end seal spanning across and contiguous about a distal edge of the tubular section providing a seal at a distal end of and enclosing the tubular section, and
a mandrel comprising a mandrel shank having a body expander at an expansion end of the mandrel, wherein the mandrel is assembled through the tubular section positioning such to expand a diameter of the body when the mandrel shank is drawn away from the body;

inserting the tubular section into the sized hole;
securing the blind rivet into the sized hole by mechanically deforming the rivet body by drawing the mandrel away from the rivet; and
forming a watertight seal between the blind rivet and the pipe.

2. A pipe repair process as recited in claim 1, the process further comprising a step of fabricating the blind rivet having a solderable surface.

3. A pipe repair process as recited in claim 2, wherein the step of forming a watertight seal is accomplished by soldering the blind rivet to the pipe.

4. A pipe repair process as recited in claim 1, the process further comprising a step of fabricating the blind rivet having a sealed body.

5. A pipe repair process as recited in claim 1, the process further comprising a step of placing a sectioned coupling member, the sectioned coupling member having a second sized hole, about the pipe, aligning the second sized hole with the sized hole of the pipe.

6. A pipe repair process as recited in claim 5, the process further comprising a step of forming a watertight seal between the blind rivet, the sectioned coupling member, and the pipe.

7. A pipe repair process as recited in claim 6, the process further comprising the step of repairing a second perforation wherein the sectioned coupling member is sized to cover both the sized hole and the second perforation, the step consisting of placing the sectioned coupling member in a manner to additionally cover the second perforation.

8. A pipe repair process, the method comprising the steps of:
enlarging and shaping a perforation of a pipe wall to a sized hole having a diameter for receiving a solderable blind rivet, the solderable blind rivet comprising:
a body having a tubular section and flange formed about a perimeter of a flange end of the body, wherein at least the flange portion of the rivet has a solderable surface, and
a mandrel comprising a mandrel shank having a body expander at an expansion end of the mandrel, wherein the mandrel is assembled through the tubular section positioning the body expander against an expansion end of the tubular section;

applying flux to the flange portion prior to insertion into the sized hole;
inserting the tubular section into the sized hole;
securing the solderable blind rivet into the sized hole by mechanically deforming the rivet body by drawing the mandrel away from the rivet; and
forming a watertight seal between the solderable blind rivet and the pipe by soldering the solderable blind rivet and the pipe together.

9. A pipe repair process as recited in claim 8, wherein the mandrel is fabricated having a solderable surface and the process further comprising a step of soldering a portion of the mandrel to the flange portion.

10. A pipe repair process as recited in claim 8, the process further comprising a step of snapping a majority of the mandrel off during the drawing process.

11. A pipe repair process as recited in claim 8, the process further comprising a step of placing a sectioned coupling member, the sectioned coupling member having a second sized hole, about the pipe, aligning the second sized hole with the sized hole of the pipe.

12. A pipe repair process as recited in claim 11, the process further comprising a step of forming a watertight seal between the solderable blind rivet, the sectioned coupling member, and the pipe by soldering the solderable blind rivet, the sectioned coupling member, and the pipe together.

13. A pipe repair process as recited in claim 12, the process further comprising the step of repairing a second perforation wherein the sectioned coupling member is sized to cover both the sized hole and the second perforation, the step consisting of placing the sectioned coupling member in a manner to additionally cover the second perforation.

14. A pipe repair process as recited in claim 8, the process further comprising the step of fabricating the solderable blind rivet of a surface selected from the following group:
a) Copper
b) Brass
c) Nickel plating
d) Gold plating
e) Gold plating over nickel, and
f) an organic coating over a Copper base material.

15. A pipe repair process as recited in claim 8, the process further comprising the step of fabricating the flange portion of the solderable blind rivet of a surface selected from the following group:
a) Copper
b) Brass
c) Nickel plating
d) Gold plating
e) Gold plating over nickel, and
f) an organic coating over a Copper base material.

16. A pipe repair process, the method comprising the steps of:
enlarging and shaping a perforation of a pipe wall to a sized hole having a diameter for receiving a sealed blind rivet, the sealed blind rivet comprising:
a body having a tubular section, a flange formed about a perimeter of a flange end of the body, and a tubular end seal spanning across and contiguous about a distal edge of the tubular section providing a seal at a distal end of and enclosing the tubular section, and
a mandrel comprising a mandrel shank having a body expander at an expansion end of the mandrel, wherein the mandrel is assembled through the tubular section positioning the body expander against an interior diameter reduction section of the tubular section;

positioning the tubular section through a gasket seal and seating the gasket seal against a contact surface of the flange to provide a watertight seal between the flange and the pipe;
inserting the tubular section into the sized hole;
securing the sealed blind rivet into the sized hole by mechanically deforming the rivet body by drawing the mandrel away from the rivet; and
forming a watertight seal between the sealed blind rivet and the pipe.

17. A pipe repair process as recited in claim 16, the process further comprising a step of soldering the rivet to the pipe to create the watertight seal.

18. A pipe repair process as recited in claim 16, the process further comprising a step of snapping a majority of the mandrel off during the drawing process.

19. A pipe repair process as recited in claim 16, the process further comprising a step of placing a sectioned coupling member, the sectioned coupling member having a second sized hole, about the pipe, aligning the second sized hole with the sized hole of the pipe.