CA2079030A1 - Low pressure porting adapter system - Google Patents

Abstract

LOW PRESSURE PORTING ADAPTER SYSTEM
Abstract of the Disclosure A method and apparatus for repairing and filling cracks in surfaces with a crack filling material using a single low pressure injector and a manifold system of individual porting adapters connected in series by lengths of flexible tubing and having open and closed positions and a self-contained internal bypass.

Description

LOW PRESSURE PORTING ADAPTER SYSTEM
i ntion This invention relates to a porting adapter, and will have special application to porting adapters for resin injection.
Summary of the Invention All structures, regardless of material, are subject to fatigue and stress cracks. In most cases, structures are amenable to repair, as opposed to replacement. A
demand exists in a variety of applications for a dependable and efficient way to fill, seal and repair cracks, faults and similar voids in concrete walls,~
foundations, and support structures. A structural repair method has application in the repair of basement walls and ~loors, earthquake induced cracks in structùre members, and voids due to delineation in timber arches.
These are merely examples of the utility of the invention and are not to be taken as limiting the scope of the invention.
The conventional method of repairing structural imperfections involves filling the voids with epoxy resins. The greater tensile and bonding strength of the inJected epoxy resins restores the designed performance of the structure. The difficulty arises in complete impregnation of the resin material into the small hairllne cracks, the widths of which are often measured in hundredth of inches, but the depths of which may reach many Eeet into the structure. At low injection pressures (1-6 p8i), completely filling the voids may involve several hours.
In the conventional low pressure resin inj2ction process, individual plastic porting adapters are secured to the cracked surface. The porting adapter is a single plastic piece having a hollow column extending from a flat base. The base is desiyned to attach to the surface of the concrete over a fault and provide a conduit Eor res n to flow into the void. The porting adapters are secured to -the cracked surface with an adhesive material over the entire len~th of the crack, spaced apart approximately every eight inches. Once the porting adapters are applled, the cracked surface is sealed to prevent the resin from extruding out of the crack around and between the porting adapters instead of filling the void.
Once the porting adapters are secured and the crack sealed, individual resin injectors are screwed into the porting adapters. Each injector operates in a fashion similar to a common caulking gun, in that it comprises a hollow cylindrical body containing a resin filled pre-batched bladder and a spring loaded plunger. Release of the plun~er forces the resin out of the bladder and injector through the porting adapter into the crack.
The conventional low pressure resin injection process has several inherent drawbacks. The injection of the resin requires constant monitoring to insure that the crack is accepting the maximum resin necessary to completely fill the crack. Frequently, the crack is o~
such a depth that it will accept more resin than is contained in the bladder. In such cases, the injector must be replaced by a co~pletely new injector or the exhausted resin bladder must be refilled with resin or replaced by a new resin filled bladder. The new or reloaded injector is then screwed back into the pedestal and the plunger released. This process is repeated until the crack is filled and cannot accept any additional resin.

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The conventional low pressure resin injection process is also somewhat hazardous., because the service of many individual injectors results in resin leakage.
Spillage occurs when exchanging or replacing injectors, especially in overhead or ceiling use. Furthermore, all of the dispensers are disposable and this presents an additional problem. Disposal of waste can be costly as well as hazardous in that the resins may not be catalyzed.
The conventional low pressure resin injection process is inherently labor and cost intensive. The adhesive must be applied carefully to prevent the clogglng of the resin port. Extra care must be applied in securing the porting adapter to the crack to prevent the adhesive from smearing and clogging the resin passage.
Each porting adapter requires an indlvidual resin in~ector. The bladders of the individual in~ectors must be filled separately before use in the injectors.
Because of the limited bladder size, the individual injectors routinely requires continuous refills. The user must carefully and frequently monitor the individual injectors to insure that the crack fills adequately and has sufficient resin to fill deep into the crac~.
Because of the minute ~ize of hair line cracks, the low resin pressure supplied by the injectors and the viscosity of the resin material, complete filling and repairing even relatively small cracks may involve several hours of frequent monitoring. This requires the user to visually monitor every individual injector with no certainty that the crack i5 completely filled. If the bladder is empty, the monitor must refill or replace it, even though the crack may not accept any further resin.
In a typical industrial setting, dozens of porting adapters and injectors may be required for the repair of a single hair line crack. This adds to the cost, as the individual user or users must dewote all his time to monitoring all of the injectors.
In the new method, the individual injectors are replaced by a manifold system fed by a single low pressure injector. A series of simple porting adap~ers are connected by flexible tubing distributing the resin evenly from a single resin source. The individual porting adapters consist of a pedestal port and a valve connector. The pedestal port is designed to attach to the surface over a crack and provide a condu~t for the resin to flow into the void. The pedestal port's triangular base permits placement of the inlet conduit closer to obstructions than would be possible with another configuration of equal stability. The holes ln the base assure a more positive anchor to the surface in two ways. First, resin extruding through the holes billows slightly upon exiting, thus providing a positive mechanical grip upon hardening. Second, the holes assure uniform extrusion of the paste under the pedestal port.
Once all of the pedestal ports are secured ln position along the crack, the valve connectors are press-fit onto the pedestal ports in either an open or closed position. In the closed position, the valve connector pre-~es completely over the pedestal port's head, causing an internal plug to seal off the resin port. In the closed position, the resin is forced to flow around the pedestal head in the space created by the chamfered side walls of the column head to the next porting adapter. In the open position, the valve connector allows the resin to flow through the pedestal port into the crack.
A single low pressure resin injector supplies every porting adapter in the manifold system with a constant F~
supply of resln allowing the crack to accept the maximum quantity without continuous user monitoring and with little chance of spillage or dripping. When the crack CQn accept no more resin, the resin flow simply bypasses that particular porting adapter. An individual porting adapter can be manually shut off by popping the valve connector into the closed position. This feature eliminates -the need for the user to continuously monitor every individual porting adapter and insures that the crack ls completely filled. Once the crack is filled, the system can be left in place, disconnected from the reservoir, and the resin permitted to naturally catalyze.
The entire system can then be readily disposed of without risk of environmental endangerment.
The new porting adapter system elimina~es many of the labor and cost intensive aspect of the above-described prior art, increases reliability and significantly decreases wasta~e and expense. The use of a sin~le resin reservoir to service the entire system is less labor intensive. Resin waste is dramatically reduced ~ince a catalyzed supply needs to be maintained in only one injector, not many. Eliminating the use of individual resin bladders saves labor costs in monitoring and bladder replacement costs. Following injection, the porting adapters and tubing are quickly removed and discarded with minimal labor.
The new method of this invention eliminates the problem of excess adhesive clogging the resin port by using a tapered rod, which is inserted into the resin conduit at the time when the pede~tal ports are adhered to the crack. The tapered rod holds the pedestal ports while an adhesive is quickly applied to the bottom sur~ace. The rod prevents the adhesive from clogging the resin conduit while the pedestal port is positioned on the crack. The rod is then positioned over the crack and the pedestal port is pushed onto the cracked surface.
The holes in the base of the pedestal port allow the adhesive to extrude over and through the base creating a stronger hold, while the resin conduit remains open and clean.
Accordingly, an ob~ect of the method of this invention is to provide a novel crack repair porting system.
Another object is a method of quickly securing a porting adapter to a cracked surface while preventing the securing adhesive from restricting the resin port.
Another object is a method of providing a porting adapter, which uses a single injector to service a multiplicity of porting adapters linked in series with a constant supply of resin.
Another object is a method for a single injector to service any particular porting adapter with a constant supply of resin until the crack can no longer accept resin while the lnjector will continue to serve the remaining porting adapters.
Another object is a method for allowing the user to have manual control over individual porting adapters without disrupting the flow of resin to other porting adapters farther down~tream in the serial chain.
Other objects of this invention will become apparent upon a reading of the following description.
Brief Descri~tion of the Drawin~s A preferred embodiment of the invention has been chosen for purposes of illustration wherein:
Fig. 1 is a bottom perspective view of pedestal port wlth the pedestal port in a side orientation;
Fig. ~ is a side perspective view thereof;

Fig. 3 is a top plan view of the pedestal port;

~ f~ 3 Fig. 4 is a ~ide plan view;
Fig. ~ is a side plan view of the pedestal port and applicator rod showing the aligning position of the pedestal port on the applicator rod with adhesive applied to the base of the pedestal port positioned above a cracked surface;
Fig. 6 is a side plan view of the pedestal port and applicator rod showing the pedestal port slid along the applicator rod, and affixed to the cracked surface;
Fig. 7 is a side cross-sectional view of the porting adapters connected in series to the manifolds in the open position;
Fig. 8 is a side cross-sectional view of the porting adapters connected in series to the manifolds in the closed position; and Fig. 9 is a top cross-sectional view of a porting adapter taken along line 9-9 of Fig. 8.
Descri~tion of the Preferred Embodiment The preferred embodiment herein described is not intended to be exhaustive or to limit the invention to the precise form disclosed. It is chosen and described to explain the principles, application and practical use of the in~ention to thereby enable others skilled in the art to utilize the invention.
Figs. 1-4 show the pedestal port 2 having column 4 perpendicularly extending from a substantially flat hexagonal, quasi-triangular base 12. Base 12 and column 4 are reinforced by members 16 adding strength to pedestal port 2. Base 12 has a multiplicity of holes 14, the reason for and utility of which will be subsequently explained. Column 4 has a longitudinal through bore 6 extending through base 12 with a smooth interior surface, such bore constitutes the r~sin port. Column 4 has a head 10 with chamfered side walls 11 on the opposite end 8 ~ 3 of base 12. Below head 10, column 4 has a first annular journal 8 and a second annular journal 9.
Base 12 of pedestal port 2 i~ depicted in the drawinys having a somewhat exaggerated hexagonal shape, more an e~ullateral trlangle with the pointed tips lopped off, but it must be emphasized and understood that this conEiguration is only one of several utilized in the invention. The quasi-triangular base fits into corners and other areas better than other configurations, but square, round, rectangular, oval and other configurations may be and aGtually are employed. The shape of base 12 is not the invention and is not to ~e construed as a limitation thereon.
Figs. 5 and 6 demonstrate the use of tapered applicator rod 46 in securing pedestal port 2 to cracked surface 50. Rod 46 is inserted into pedestal bore 6 of pedestal port 2. Pedestal port 2 is positioned on rod 46 with pedestal ba~e 12 oriented facing toward the narrow end of rod 46. While pedestal 2 rests on rod 40, the user applies adhesive 42 to the bottom surface of base 12. Rod 46 is positioned perpendicularly against cracked surface 50 directly over crack 52. While rod 46 is held against surface 50, pedestal 2 is manually pressed against surface 50. The force of pedestal 2 being pushed against surface 50 causes adhesive 48 to exude through and about bores 14 and base 12. The extrusion of adhesive 48 around and through base 12 provides a strong bond between pedestal 2 and surface 50. While pedestal 2 is manually pressed against surface ~0, rod 46 is withdrawn from pedestal 2, leaving pedestal port 2 secured in place over cracked surface 50. The diameter of rod 46 prevents adhesive 4B from extruding into the pede~tal port 6 and helps the user accurately align pedestal 2 w:ith crack 52.

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~ -;`aow the connectio:n of pedestal ports 2 and valve connectors 20. The connected pedestal port 2 and valve connector 20 form porting adapter 40. Valve connector 20 is generally T-shaped in cross-section with a cylindrica:l body 22 and two branch arms 24. A
longitudinal bore through connector body 22 d~fines connector well 30. The interior diameter of well 30 closely approximates the outside diameter of column 4, in order to achieve a relatively tight fit when pedestal port 2 is mated with connector body 22. Interior wall 32 of connector well 30 is smooth and has annular ring 34 extending into connector well 30. Each of two branch arms 24 having through bores 26 laterally extending into connector well 30. Lateral bores 26 of branches 24 and connector well 30 constitute a resin flow passage across and through valve connector 20. Cylindrical projection 36 extends downward from the upper surface of valve connector body 22 towards and on the same longitudinal axis as connector well 30. Lowermost end 37 of projection 36 is chamfered to facilitate the mating of connector body 22 with pedestal port 2. The diameter of cylindrical projection 36 closely approximates the inner dlameter of resin port 6 so that, when pedestal port 2 is fully inserted into connector well 30, resin port 6 tightly surrounds tab 36, thereby preventing any further flow of resin into and through re~in port 6.
Pedestal 2 is pre~s fit into manifold well 30. The engagement of annular recesses B and 9 and annular ring 34 of valve connector 20 create a dual position connection. With annular rib 34 in engagement with first recess 8, the connection is in the open position, allowing resin to flow across branch arms 24 into and down through resin port 6 of pedestal 2. The lower ed~e of chamfered side wall 11 of head 10 of column 4, F~ ~ n pressing ayainst side wall 32 of well 30 and the en~agement of annular ring 34 into recess 8, combine to prevent seepage of resin from around column 4 and out of connector well 30.
With annular rib 34 in engagement with second recess 9, the connection i5 in the closed position. In the closed position, pedestal column 4 extends fully into connector well 30 with resin port 6 in surrounding engagement with cylindrical projection 36 of connector body 22, thereby sealing off any further resin flow through pedestal port 6. Annular rib 34 engages second recess 9, thereby preventing pedestal port 2 from slipping back into the first position or disengaging from manifold 20. In the closed position, chamfered edge 11 of column 10 provide space for the resin flow to by-pass column 4 and to pass directly through valve connector 20.
Porting adapters 40 are interconnected in series by flexible tubing 42 constituting porting manifold 44. A
sin~le low pressure injector (not shown) supplies the resin flow for porting manifold 44. Manifold 44 distributes res.in under pressure P even to reach portin~
adaptor 40 in the series, assurin~ proper repair and fill of the entire crack and surface.
It is understood that the above description does not limit the invention to the embodiment herein described, but that it may be modified within the scope of the appended claims.

Claims (17)

1. An apparatus for repairing and filling a surface crack with a crack filling material comprising in combination a pedestal port adapted for mounting to said surface over said crack, a manifold, said pedestal port connected to said manifold to enable said crack filling material to be injected through said pedestal port into said crack when said pedestal port is attached to said surface over said crack, said manifold including valving means for controlling the flow of said crack filling material through said pedestal port and having an open position and a closed position.

2. The combination of Claim 1 wherein said pedestal port includes a column and a base, said column extending from said base, a bore through said column and said base, said base having a flattened portion and a multiplicity of holes through said flattened portion, said through bore constituting means for the passage of said crack filling material, said holes constituting means for receiving an adhesive for attaching said base to said surface.

3. The combination of Claim 1 wherein said pedestal port includes a column and a base, said column extending from said base, and a bore through said column and said base, said manifold having at least two branches, a said pedestal port connected to each branch, said valving means including a plurality of valve parts, said valve parts interconnected by tube parts, each pedestal port being connected at its column to a said valve part and being shiftable relative to said connected valve part between said open position permitting said passage of crack filling material through said pedestal port into said crack and said closed position for blocking said passage of said crack filling material through said pedestal port.

4. The combination of Claim 3 wherein each valve part includes a body and at least one arm connected to one of said tube parts, said body having an internal chamber defining in conjunction with said arm a flow passage for said crack filling material through said body and arm.

5. The combination of Claim 3 wherein each pedestal port column has an external annular groove, each valve part including an internal chamber having an annular internal rib, each pedestal port being connected to a said valve part with its said pedestal port column being located inside the internal chamber of said valve part and shiftable therein between said open position and said closed position, said annular rib restrictively seating within a said annular groove when said pedestal port is in one of said open position and closed position.

6. The combination of Claim 5 wherein each pedestal port annular rib seats within a said valve part annular groove when said pedestal port is in its said open position, each pedestal port column including a head within said bore therein, said valve part being spaced apart from said head of said column for permitting said passage of said crack filling material through said valve part and said bore of said pedestal port when the pedestal port is in its open position, said valve part abutting the head of said column for blocking said passage of said crack filling material through said valve part and said bore when said pedestal port is in its closed position.

7. The combination of Claim 6 wherein each valve part has an internal projection extending into its said internal chamber and constituting means for so abutting the head of a said pedestal port column.

8. The combination of Claim 7 wherein each head of a said pedestal port column having a reduced cross section constituting means for permitting said passage of said crack filling material through said manifold when said pedestal port is in its said closed position.

9. The combination of Claim 3 wherein each pedestal port column has two external annular grooves, each valve part including an internal cylindrical chamber having an annular rib, each pedestal port being connected to a said valve part with its said pedestal port column being located inside the internal chamber of said valve part and shiftable therein between said open position with said rib restrictively seated within said first annular groove when in said open position and said closed position with said rib restrictively seated within said second annular groove.

10. A method for mounting a porting device having a bore through which crack filling material is ejected over a crack in an underlying surface for the repair and filling of said crack with said crack filling material, said device including a base, said method comprising the steps:
a. Inserting a rod through said bore in said device;
b. Applying an adhesive to said base;
c. Positioning said rod generally perpendicularly against said surface over said crack;
d. Urging said device towards said surface and along side rod until said base contacts said surface at said adhesive over said crack; and e. Retracting said rod from said bore of the device with the device at said base remaining over said crack.

11. An apparatus for repairing and filling a crack in a surface with a crack filling material comprising in combination a pedestal port adapted for mounting to said surface over said crack, a valve part adapted for mounting to a supply source for said crack filling material, said pedestal port connected to said valve part and being shiftable relative to the valve part between an open position to enable said crack filling material to be injected through said pedestal port into said crack when said pedestal port is attached to said surface over said crack and a closed position terminating the flow of said crack filling material through the pedestal port.

12. The apparatus of Claim 11 wherein said pedestal port includes a column and a base, said column extending from said base, a bore through said column and said base, said base having a flattened portion and a multiplicity of holes through said flattened portion, said through bore constituting means for the passage of said crack filling material, said holes constituting means for receiving an adhesive for attaching said base to said surface, said valve part includes a body and at least one arm, said body having an internal chamber defining in conjunction with said arm a flow passage for said crack filling material through said body and arm, said arm adapted for connection to said supply source of said crack filling material.

13. The apparatus of Claim 12 wherein said pedestal port column has an external annular groove, said valve part including an internal chamber having an annular internal rib, said pedestal port being connected to said valve port with said pedestal port column being located inside the internal chamber of said valve part and shiftable therein between said open position and said closed position, said annular rib restrictively seating within said annular groove when said pedestal port is in one of said open position and closed position.

14. The apparatus of Claim 13 wherein said pedestal port annular rib seats within a said valve part annular groove when said pedestal port is in its said open position, said pedestal port column including a head within said bore therein, said valve part being spaced apart from said head of said column for permitting said passage of said crack filling material through said valve part and said bore of said pedestal port when the pedestal port is in its open position, said valve part abutting the head of said column for blocking said passage of said crack filling material through said valve part and said bore when said pedestal port is in its closed position.

15. The apparatus of Claim 14 wherein said valve part has an internal projection extending into its said internal chamber and constituting means for so abutting the head of a said pedestal port column.

16. The apparatus of Claim 15 wherein said head of the pedestal port column having a reduced cross section constituting means for permitting said passage of said crack filling material through said valve part arm when said pedestal port is in its said closed position.

17. The apparatus of Claim 12 wherein said pedestal port column has two extended annual grooves, said valve part including an internal cylindrical chamber having an annular rib, pedestal part being connected to a said valve part with its said pedestal port column being located inside the internal chamber of said valve port and shiftable therein between said open position with said rib restrictively seated within said first annular groove when in said open position and said closed position with said rib restrictively seated within said second annular groove.