Abstract:
A pipe repair device ( 1 ) is provided for repairing damaged sections of pipe. The device is shaped so as to snugly clip around a major part of the circumference of a damaged pipe ( 6 ) so as to cover the damaged area of the pipe. The device ( 1 ) has on its inner surface a recessed portion ( 3 ) within which a reservoir of solder ( 5 ) is retained.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to device for repairing pipes and in particular a device securable over a breach in a pipe to patch a leak therein. 
       BACKGROUND OF THE INVENTION 
       [0002]    Systems of pipe work are used to facilitate the transport of fluids of various types around domestic and commercial properties. The most common forms of fluid transported by piping are water and gas. 
         [0003]    Over time, or as a result of mechanical stresses, pipe work can become damaged leading to the formation of leaks. Various approaches to repairing such leaks are known, with the approach used being determined by factors such as the size of the hole and its location. 
         [0004]    In situations where the damaged pipe work can be accessed without causing too much disruption a plumber can simply replace all or a large portion of the damaged pipe. Depending on the nature of the repair this may or may not require soldering to seal the joint between the replacement pipe and the rest of the system. 
         [0005]    However in circumstances where the damaged pipe work cannot easily be accessed, or to do so would cause a large amount of disruption which would require subsequent repairs to make the area good again (e.g. plastering, decorating, etc..), there is a need for a more localised repair of the leak. 
         [0006]    One example of a more localised approach to repairing a leak in a pipe without replacing the damaged area of pipe work is described in U.S. Pat. No. 4,890,373. The localised approach makes use of a patch or clip that is fixed, usually by a bonding agent or adhesive, over the damaged area of pipe. 
         [0007]    The use of solder to seal the patch over the damaged area is also described in the US patent. 
       SUMMARY OF THE INVENTION 
       [0008]    The present application seeks to provide an improved pipe repairing means for use in the localised repair of damaged pipe work using solder rather than a bonding agent to secure the repair in place. 
         [0009]    The present invention provides a method of manufacturing a pipe repair device comprising: a) providing a sheet of malleable metal; b) forming a continuous recess or channel in one side of the sheet so as to define a distinct inner central region and outer perimeter region on the sheet; c) providing a solder material in the recess; and d) forming the sheet into an incomplete cylinder shape. 
         [0010]    It will be appreciated that the term incomplete cylinder shape refers to a cylinder with a gap running along it length. 
         [0011]    The sheet material used to manufacture the repair device of the present invention must be malleable so that the recessed portion can easily be formed therein and also so that sheet can be formed into the required shape. Preferably the material used is copper as this is the most common material used in the repair of pipes. Preferably the sheet is rectangular in shape. 
         [0012]    In order to get the solder into the recess preferably the solder may be heated, so that it flows in to the recess, and then allowed to cool so that it solidifies in the recess, 
         [0013]    Preferably the sheet may be formed into the incomplete cylinder shape before the solder is provided. Alternatively the sheet may be formed into the incomplete cylinder shape after the solder is provided. 
         [0014]    Preferably the sheet may be formed in to an incomplete cylinder shape having a gap between the two edges of the sheet that is between 25 to 40%, and further preferably 30% of the entire circumference of the notional complete cylinder. This ensures that the device can be clipped onto the pipe that is being repaired. 
         [0015]    it is appreciated that alternative means of enabling the device to be clipped onto the pipe could be employed without departing from the general concept of the present invention. 
         [0016]    The present invention also provides a pipe repair device for repairing damaged sections of piping, said device being shaped so as to snugly clip around a major part of the circumference of a damaged pipe so as to cover the damaged area of the pipe, and wherein the device is characterised in that an inner surface on the device has a recessed portion within which a reservoir of solder is retained. 
         [0017]    Preferably the recessed portion may be located in from the sides of the device. In this way the outer region of the inner surface can be bonded to the pipe by the solder. It is noted that as soon as the solder begins to seep out from behind the device the plumber can stop heating the device. 
         [0018]    Preferably the recessed portion may comprise a continuous channel that provides a perimeter around a central region of the inner surface of device. In this way the damaged region of the pipe can be completely surrounded by solder when it is aligned with the central region. 
         [0019]    Preferably the recessed portion may also protrude from an outer surface of the device located on the reverse of the inner surface. In this way the protruding portion can be used to guide the plumber when locating the device over the damaged region of the pipe. 
         [0020]    The present invention also provides a method of repairing a damaged pipe comprising the steps of: a) locating the device of the present invention over the damaged section of pipe; and b) heating the outer surface of the device on the opposite side of the device to the solder containing recess. 
         [0021]    Preferably the method may further comprise the step of aligning the damaged section of pipe with the central region of the inner surface of the device. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]    The present invention will now be described with reference to the preferred embodiment shown in the drawings, wherein: 
           [0023]      FIG. 1  shows a preferred embodiment of the pipe repair device of the present invention; 
           [0024]      FIG. 2  shows the device of  FIG. 1  in a flattened form; and 
           [0025]      FIG. 3  shows a damaged pipe before and after a repair using the device of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0026]    The pipe repair device of the present invention will be appreciated from consideration of the figures, in which in can be seen that the device  1  takes the form of a patch or clip which has an incomplete cylinder shaped formed from a suitable material such as copper. 
         [0027]    It will be appreciated that pipes, such as gas and water pipes, come in a ranged of different standard sizes. In view of this fact it is envisaged that the actual dimensions (e.g. internal and external diameter) of the device of the present invention used to affect a repair will vary accordingly without departing from the scope of the present invention. 
         [0028]    However it is considered important that the device must be shaped so as to ensure it can be ‘clipped’ around the pipe that is to be repaired. In order to achieve this it is envisaged that gap between the two edges of the incomplete cylinder shaped body  2  of the device  1  must extend around less that half of the circumference. It is envisaged that the gap would extend around 25-40% of the cylinder&#39;s circumference and more preferably about 30%. 
         [0029]    Also, in order that the device might be ‘clipped’ on to the pipe, the gap between the two edges of the incomplete cylinder shaped body  2  of the device  1  must not be too small to enable the device to be forced on to a section of pipe without causing damage. 
         [0030]    On the inner surface of the body  2  is provided a recessed region or recess  3 . The recess  3 , which preferably projects outwards from the outer surface of the body  2 , defines a continuous perimeter around a central region  4  of the inner surface. This can be better appreciated from  FIG. 2 , which shows the device of  FIG. 1  in its flattened form prior to being shaped into the above described incomplete cylinder shape. 
         [0031]    Within the recess  3  is a reservoir of solder material  5 . Preferably the recess  3  is located in from the edges of the device  1  so as to provide a surface which the solder can seal to the surface of the pipe being repaired. 
         [0032]    A method of manufacturing the device of the present invention will now be described. The process starts by selecting a rectangular sheet of suitable material, such as copper, having suitable dimensions to form an incomplete cylinder body  2  in accordance with the physical characteristics described above. 
         [0033]    The sheet is then pressed using a suitable machine to form the recess  3  in a generally central location on the sheet. Once the recess is formed solder  5  can be introduced into the recess  3 . This can be done by heating the solder until it is fluid enough to flow into the recess. 
         [0034]    Once the recess has been filed by the solder the sheet can be allowed to cool, thus allowing the solder to solidify in the recess. Any excess solder can be removed at this time 
         [0035]    Once the solder has cooled the sheet can be bent into the required incomplete cylinder shape, possibly using a standard length of pipe (or a mould with identical dimensions). Once formed the device  1  can be slid off the end of the pipe/mould to ensure the device retains its shape. 
         [0036]    Referring now to  FIG. 3  the actual repair of a damaged pipe using the device of the present invention will now be described. A pipe  6  has been damaged and as a result is suffering from a leak  7 . 
         [0037]    The repair of this damaged pipe would normally be a time consuming job, which would typically require a plumber to cut out the damaged pipe and replace it with a new piece. 
         [0038]    The device  1  of the present invention enables a much quicker and easier repair to be carried out by the plumber. To repair the damaged pipe  6  a plumber first selects the appropriate size of repair device  1  and then clips it on to the damaged pipe  6 . 
         [0039]    The plumber then slides or rotates the device until it is located over the leak. In order for the device to effectively seal the leak the device must be positioned so that the recess  3  completely surrounds the hole in the pipe. This alignment process is assisted by opposing side of the recess which extend from the outer surface of the device  1 . 
         [0040]    Once the device  1  is in position the plumber can apply heat to the outer surface of the device around the area of the recess. In this way the solder  5  is caused to melt and form a bond between the pipe and the device, thereby affecting a repair of the pipe once the solder cools again. 
         [0041]    The device of the present invention is considered particularly useful when repairing hard to reach pipe work or damaged areas of pipes that face towards walls for example.