Patent Publication Number: US-2018031166-A1

Title: Pipe repair apparatus and method

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This PCT Patent Application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 62/119,490 filed Feb. 23, 2015, the entire disclosure of the application being considered part of the disclosure of this application, and hereby incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The subject invention relates generally to an apparatus for use in repairing main line and lateral line pipes. The subject invention is also related to a method of repairing a main pipe and a lateral pipe extending from the main pipe. 
     2. Description of the Prior Art 
     Pipes including at least one main pipe and a lateral pipe extending transversely or laterally from the main pipe are commonly used in both fluid supply and return pipe systems and may also be used for sewer pipes, for example. In a collection sewer pipe system, for example, junctions at which lateral pipes intersect with main pipes are generally known to be one of the weakest points. Consequently, leaks can develop at this junction due to damage or when a junction is not properly formed. 
     It is known to repair pipes from inside and/or outside of the pipe with patches or by removing and replacing a damaged or leaking portion. In addition, pipes used historically and those currently available in new construction are known to be a wide variety of different sizes. Thus, equipment to patch or repair the pipes must be sized accordingly to be used in any repairs that are undertaken, leading to a proliferation of equipment that a repair person must bring to a worksite. Many known solutions for repairing pipes are also not designed to properly repair junctions of lateral pipes and main pipes. As a result, such repaired junctions may remain a weak point in the pipe system, prone to leaking in the future. Accordingly, there remains a significant need for a pipe repair apparatus and method that may be used to properly repair junctions of lateral pipes and main pipes of varying sizes. 
     SUMMARY AND ADVANTAGES OF THE INVENTION 
     The invention provides for such a pipe repair apparatus including a packer assembly having a main bladder body. The main bladder body has a cylindrical shape that extends radially from and along a first axis and is adapted to be inflated with a pressurized fluid from a first circumference narrower than an inner diameter defined by an inner surface of a main pipe to a second circumference at least equal to the inner diameter of the main pipe. A first roller assembly and a second roller assembly are each coupled to the bladder bodies and include at least one rotator motor for rotating the main bladder body. At least one camera is attached to the packer assembly for capturing imaging to determine a position and alignment of the packer assembly. 
     The invention also provides for a method of repairing a main pipe and a lateral pipe extending transversely from the main pipe including the step of wrapping at least one of a main liner around a main bladder body of a packer assembly and a lateral liner around a lateral bladder body of a packer assembly. The method proceeds by moving the packer assembly into the main pipe and capturing imaging to determine a position of the packer assembly in the main pipe with at least one camera. Then, locating the packer assembly proximate a damaged section of the main pipe. Next, rotating the main bladder body and the lateral bladder body of the packer assembly with at least one rotator motor. The next step of the method is inflating at least one of a main bladder body and a lateral bladder body of the packer assembly with a pressurized fluid. The method concludes by applying at least one of the main liner to an inner surface of the main pipe in response to the inflation of the main bladder body and the lateral liner to an inside surface of the lateral pipe in response to the inflation of the lateral bladder body. 
     Thus, several advantages of one or more aspects of the pipe repair apparatus and method of repairing a main pipe and a lateral pipe extending from the main pipe are that the apparatus and method may be used for pipes of varying sizes. The pipe repair apparatus and method also advantageously provide for strong repairs of the junction of the lateral pipe and main pipe, thereby preventing future leaks. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
         FIG. 1  is a perspective view of a pipe repair apparatus illustrating a packer assembly constructed in accordance with an embodiment of the invention; 
         FIG. 2  is a perspective view of the pipe repair apparatus of a pipe repair apparatus illustrating a packer assembly constructed in accordance with an embodiment of the invention; 
         FIG. 3  is a perspective view of the pipe repair apparatus of  FIG. 1  illustrating a main bladder body of the packer assembly inflated to a second circumference; 
         FIG. 4  is an enlarged partial view of the pipe repair apparatus of  FIG. 1  illustrating a first roller assembly with a plurality of first actuator arms in a deployed position; 
         FIG. 5  is an enlarged partial view of the pipe repair apparatus of  FIG. 1  illustrating the first roller assembly with the plurality of first actuator arms in a stowed position; 
         FIG. 6  is an enlarged partial view of the pipe repair apparatus of  FIG. 1  illustrating a first adjustable platform and locker assembly of the first roller assembly; 
         FIG. 7  is a perspective view of a control unit of the pipe repair apparatus configured to connect to the packer assembly of  FIG. 1 ; 
         FIG. 8  is a perspective view of the control unit of  FIG. 7  illustrating a reel for a control cable; 
         FIG. 9  is an enlarged partial view of the control unit of  FIG. 7  illustrating a first control and a second control; 
         FIG. 10  is a flow chart illustrating steps of repairing a main pipe and a lateral pipe extending from the main pipe; and 
         FIGS. 11A and 11B  are flow charts illustrating steps of repairing the main pipe and the lateral pipe extending from the main pipe. 
     
    
    
     DESCRIPTION OF THE ENABLING EMBODIMENT 
     Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a pipe repair apparatus  20  is generally shown in  FIGS. 1 and 3  and extends along a first axis A for repairing a main pipe  22  and/or a lateral pipe  24  connected to the main pipe  22  and extending along a second axis B that is transverse to the first axis A. The lateral pipe  24  may extend at any angle laterally from the main pipe  22  including, for example, at a 90 degree angle or at a 45 degree angle. The industry may describe both the foregoing types of repairs of such lateral pipe  24  and main pipe  22  junctions as a “T” repair and a “Y” repair, respectively. The pipe repair apparatus  20  includes a packer assembly  26  having a main bladder body  28  and a lateral bladder body  30 . The packer assembly  26  also includes a first end cap  32  and a second end cap  34  disposed at opposite ends of the main bladder body  28  for encapsulating the bladder bodies  28 ,  30 . More specifically, both of such end caps  32 ,  34  are provided to form the final encapsulation of the bladder bodies  28 ,  30  along with routing lines for inflation with the pressurized fluid, transportation (i.e., motors  36 ,  38  and/or cables), and vision, to be described in more detail below. 
     The packer assembly  26  is intended to be used in connection with inflation equipment, so as a result, both the main bladder body  28  and the lateral bladder body  30  are adapted to receive a pressurized fluid. The pressurized fluid may be a gas, a liquid, or a combination of a gas and a liquid. The first end cap  32  includes a first pressurized fluid port  40  in fluid communication with the main bladder body  28 . The first end cap  32  also includes a second pressurized fluid port (not shown) in fluid communication with the lateral bladder body  30 . It should be understood that, while the main bladder body  28  and lateral bladder body  30  can receive the pressurized fluid through separate fluid ports, the main bladder body  28  and lateral bladder body  30  could alternatively be connected so that a single pressurized fluid port could provide both bladder bodies  28 ,  30  with the pressurized fluid. 
     The main bladder body  28  has a cylindrical shape that extends radially from and along the first axis A and is adapted to be inflated with the pressurized fluid from a first circumference narrower than an inner diameter defined by an inner surface  44  of the main pipe  22  to a second circumference at least equal to the inner diameter of the main pipe  22 . A main liner  46  is disposed about the main bladder body  28  for engaging and adhering to the inner surface  44  of the main pipe  22  to repair the main pipe  22  in response to the main bladder body  28  being inflated to the second circumference, as best shown in  FIG. 3  (i.e., the main liner  46  is pressed against the portion of the main pipe  22  requiring repair). In detail, the main liner  46  comprises a flat sheet of fiberglass impregnated with a curable resin. A main film  48  of plastic is wrapped around the main bladder body  28  for separating the curable resin of the main liner  46  from the main bladder body  28  (i.e., to prevent the curable resin from adhering to the main bladder body  28 ). The main film  48  and/or main liner  46  can be secured to the main bladder body  28  with any suitable fastener, such as but not limited to zip ties and/or tape. Once the main liner  46  is left in contact with the inner surface  44  of the main pipe  22 , the resin of the main liner  46  can begin to cure. 
     As best shown in  FIGS. 1 and 3 , the lateral bladder body  30  also has a cylindrical shape that extends radially from and along the second axis B transverse to the first axis A. However, in use, the lateral bladder body  30  may remain folded or rolled up adjacent the main bladder body  28  prior to being inflated. The lateral bladder body  30  attaches to the main bladder body  28  and is adapted to be inflated with pressurized fluid from a first size narrower than an inside diameter defined by an inside surface  50  of a lateral pipe  24  to a second size at least equal to the inside diameter of the lateral pipe  24 . The lateral bladder body  30  is adapted to be attached to the main bladder body  28  at a junction including fittings such as male and female fasteners. A lateral liner  52  ( FIG. 3 ) is disposed about the lateral bladder body  30  for engaging and adhering to the inside surface  50  of the lateral pipe  24  to repair the lateral pipe  24  in response to the lateral bladder body  30  being inflated to the second size. As with the main liner  46 , the lateral liner  52  comprises a flat sheet of fiberglass impregnated with a curable resin. A lateral film  54  of plastic is wrapped around the lateral bladder body  30  for separating the curable resin of the lateral liner  52  from the lateral bladder body  30 . The lateral film  54  and/or lateral liner  52  may be secured to the lateral bladder body  30  using zip ties and/or tape, for example. It is important to provide for a smooth and uniform junction between the main bladder body  28  and the lateral bladder body  30 , so that the liners  46 ,  52  are properly adhered and position against that portion of the repaired pipe during inflation. If such a proper junction is not formed, damage or leaking can occur at the junction between the lateral pipe  24  and the main pipe  22 , which is generally known as one of the weakest points in a collection sewer system. While a lateral bladder body  30  may be used, it should be appreciated that the packer assembly  26  may not include a lateral bladder body  30 , as best shown in  FIG. 2 . 
     The packer assembly  26  also includes a first roller assembly  56  coupled to the first end cap  32  for supporting and rotating the first end cap  32  and the bladder bodies  28 ,  30 . The first roller assembly  56  includes a cable tie  58  for attachment to a guide cable that may be used in conjunction with a winch, for example, to move the packer assembly  26  through the main pipe  22 . The first roller assembly  56  includes a first rotator motor  36  coupled with the first end cap  32  for rotating the first end cap  32  and the bladder bodies  28 ,  30 . Additionally, the first roller assembly  56  includes a plurality of first actuator arms  60  movably coupled to the first roller assembly  56  for moving radially outwardly from the first roller assembly  56  (e.g., outwardly to a deployed position shown in  FIG. 4  from a stowed position shown in  FIG. 5 ). A first actuator motor (not shown) is coupled to the first actuator arms  60  for moving the first actuator arms  60  relative to the first roller assembly  56 . The first actuator arms  60  each include a first roller wheel  62  rotatably attached to the first actuator arm  60  to engage the inner surface  44  of the main pipe  22 . The first roller assembly  56  also includes a locker assembly  64  ( FIG. 6 ) coupled to the first roller assembly  56  for locking the packer assembly  26  in position relative to the main pipe  22 . 
     Referring back to  FIGS. 1 and 3 , the packer assembly  26  includes a second roller assembly  66  coupled to the second end cap  34  for supporting and rotating the packer assembly  26 . As with the first roller assembly  56 , the second roller assembly  66  includes a plurality of second actuator arms  68  movably coupled to the second roller assembly  66  for moving radially outwardly from the second roller assembly  66 . The second actuator arms  68  each include a second roller wheel  70  rotatably attached to the second actuator arm  68  to engage the inner surface  44  of the main pipe  22 . The second roller assembly  66  also includes a second rotator motor  38  coupled with the second end cap  34  for rotating the second end cap  34  and the bladder bodies  28 ,  30 . It should be appreciated that while both the first and second rotator motors  36 ,  38  may be used, the packer assembly  26  may instead only include one rotator motor. A second actuator motor (not shown) is coupled to the second actuator arms  68  for moving the second actuator arms  68  relative to the second roller assembly  66 . It should be understood that while the actuator arms  60 ,  68  may be moved by the first and/or second actuator motors  36 ,  38 , the actuator arms  60 ,  68  could alternatively be moved by a fluid or pneumatic force. In any event, the first and second actuator arms  60 ,  68  enable the pipe repair apparatus  20  to easily adapt to pipes of various sizes. 
     The first roller assembly  56  includes a first adjustable platform  72  ( FIG. 6 ) coupled to the first roller assembly  56 . A first camera  74  is attached to the first adjustable platform  72  for capturing imaging to determine a position and alignment of the pipe repair apparatus  20 . The second roller assembly  66  similarly includes a second adjustable platform  76  ( FIGS. 1 and 3 ) coupled to the second roller assembly  66  and a second camera  78  is attached to the second adjustable platform  76  for capturing imaging to determine a position and alignment of the pipe repair apparatus  20 . The first end cap  32  includes a first laser  80  attached to the first end cap  32  for projecting a beam axially toward the second camera  78 . The second end cap  34  includes a second laser  82  attached to the second end cap  34  for projecting a beam axially toward the first camera  74 . A handheld device  84  ( FIG. 7 ) is in communication with the first camera  74  and the second camera  78  for receiving imaging from the first camera  74  and the second camera  78  to confirm positioning and alignment of the packer assembly  26 . 
     As best shown in  FIGS. 7-9 , a control unit  86  has a first control  88  and a second control  90  for coupling to and controlling the packer assembly  26 . While the control unit  86  can be used along with separate inflation equipment, the control unit  86  may instead carry out the functions of any separate inflation equipment (e.g., supplying the pressurized fluid). A control line  92  is adapted to couple with the packer assembly  26  with the control unit  86  for providing power and control signals to the packer assembly  26  (e.g., power to the actuator motors  36 ,  38 ). The control unit  86  may also include a reel  94  ( FIGS. 7 and 8 ) to manage the control line  92 . A first pressurized fluid line (not shown) couples the control unit  86  with the packer assembly  26  through the first pressurized fluid port  40  for providing a pressurized fluid to the main bladder body  28  in response to operation of the first control  88 . Likewise, a second pressurized fluid line (not shown) couples the control unit  86  with the packer assembly  26  through the second pressurized fluid port  42  for providing a pressurized fluid to the lateral bladder body  30  in response to operation of the second control  90 . Use of the separate first and second pressurized fluid lines and control unit  86  permits the operator to properly inflate each of the main bladder body  28  and lateral bladder body  30  in order to cause a better seal at the junction. 
     As shown in  FIGS. 10, 11A and 11B , a method of repairing a main pipe  22  and a lateral pipe  24  extending from the main pipe  22  is also disclosed. The method begins with the step of  100  wrapping at least one of a main liner  46  around a main bladder body  28  of a packer assembly  26  and a lateral liner  52  around a lateral bladder body  30  of the packer assembly  26 . Specifically, such a step may include  102  impregnating a main liner  46  with a curable resin and  104  wrapping a main film  48  around the main bladder body  28  of a packer assembly  26 . Next,  106  wrapping the main liner  46  around the main film  48 . The method proceeds by  108  impregnating the lateral liner  52  with a curable resin and  110  wrapping a lateral film  54  around the lateral bladder body  30  of the packer assembly  22 . Then,  112  wrapping the lateral liner  52  around the lateral film  54 . 
     The next steps of the method are  114  connecting the packer assembly  26  to a control unit  86  and  116  moving the packer assembly  26  into the main pipe  22 . For example, the packer assembly  26  can be pulled with use of cables attached to the cable tie  58  to the damaged location. Then,  118  moving a plurality of first actuator arms  60  coupled to a first roller assembly  56  of the packer assembly  26  outwardly ( FIG. 4 ). This can be accomplished by  120  driving at least one first actuator motor coupled to the first actuator arms  60  (i.e., the actuator arms  60 ,  68  move in response to driving the at least one first actuator motor). As described above, the actuator arms  60 ,  68  could instead be moved using a fluid or pneumatic pressure instead. The method continues with  122  positioning a plurality of first roller wheels  62  each attached to one of the first actuator arms  60  to engage an inner surface  44  of the main pipe  22 . As with the first actuator arms  60 , the method includes the step of  124  moving a plurality of second actuator arms  68  coupled to a second roller assembly  66  of the packer assembly  26  outwardly. Such movement can be carried out by  126  driving at least one second actuator motor coupled to the second actuator arms  68 . The method also includes the step of  128  positioning a plurality of second roller wheels  70  attached to each of the second actuator arms  68  to engage the inner surface  44  of the main pipe  22 . 
     The method continues by  130  positioning a first camera  74  coupled to the first roller assembly  56  with a first adjustable platform  72  and  132  positioning a second camera  78  coupled to the second roller assembly  66  with a second adjustable platform  76 . Next,  134  capturing imaging to determine a position of the packer assembly  26  in the main pipe  22  with the first camera  74  and the second camera  78 . The method proceeds by  136  viewing the imaging from the first camera  74  and the second camera  78  with a handheld device  84  and  138  locating the packer assembly  26  proximate a damaged section of the main pipe  22 . 
     Although the packer assembly  26  may be pulled to the longitudinal position of the damaged pipe, the repair required may be at some point inside the main pipe  22  which requires the packer assembly  26  to be rotated about the first axis A. So the method includes the step of  140  rotating the main bladder body  28  and the lateral bladder body  30  of the packer assembly  26  with at least one rotator motor. Next,  142  aligning the main bladder body  28  and the lateral bladder body  30  relative to the first roller assembly  56  and the second roller assembly  66  with a first laser  80  and the first camera  74  and a second laser  82  and the second camera  78  using imaging from the first camera  74  and the second camera  78 . In detail, the operator uses the cameras  74 ,  78  to position the packer assembly  26  and the lasers  80 ,  82  to ensure each of the first and second end caps  32 ,  34  are in the appropriate position, typically aligned. Having the rotational adjustment is particularly important for locating and positioning the lateral bladder body  30  at the opening of a lateral pipe  24  (i.e., “T” or “Y” location). The method continues with  144  locking the packer assembly  26  into position laterally and longitudinally with a locker assembly  64  coupled to at least one of the first roller assembly  56  and the second roller assembly  66 . 
     The method includes  146  inflating at least one of a main bladder body  28  and a lateral bladder body  30  of the packer assembly  26  with a pressurized fluid and  148  applying at least one of a main liner  46  to an inner surface  44  of the main pipe  22  in response to the inflation of the main bladder body  28  and a lateral liner  52  to an inside surface  50  of the lateral pipe  24  in response to the inflation of the lateral bladder body  30 . More specifically, such a steps  146 ,  148  can include inflating the main bladder body  28  of the packer assembly  26  in the main pipe  22  with a first pressurized fluid line using a first control  88  of the control unit  86  ( FIG. 3 ). Then,  152  applying an impregnated fiberglass of the main liner  46  to an inner surface  44  of the main pipe  22  in response to the inflation of the main bladder body  28 . The impregnated fiberglass can then cure against the damaged location of the main pipe  22  to form a properly sealed and repaired main pipe  22 . 
     The steps  146 ,  148  likewise can include the step of  154  inflating the lateral bladder body  30  of the packer assembly  26  in the lateral pipe  24  extending from the main pipe  22  with a second pressurized fluid line using a second control  90  of the control unit  86  to a second diameter. Next,  156  applying an impregnated fiberglass of the lateral liner  52  to an inside surface  50  of the lateral pipe  24  in response to the inflation of the lateral bladder body  30 . The impregnated fiberglass of the lateral liner  52  cures against the damaged location of the lateral pipe  24  to form a properly sealed and repaired lateral pipe  24 . It should be appreciated that while the method described above includes applying both a main liner  46  and a lateral liner  52 , the pipe repair apparatus  20  could be used to apply a main liner  46  only, or a lateral liner  52  only. 
     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. These antecedent recitations should be interpreted to cover any combination in which the inventive novelty exercises its utility. The use of the word “said” in the apparatus claims refers to an antecedent that is a positive recitation meant to be included in the coverage of the claims whereas the word “the” precedes a word not meant to be included in the coverage of the claims.