DE202010017654U1 - Lining material for sewer and / or piping and sewer and / or pipe lining - Google Patents

Abstract

Lining material for the inside of a pipe wall, in particular a sewer or sewer pipe, comprising - a hose made of a textile layer (1) made of a textile carrier material, selected from the group consisting of fleece, woven fabric and knitted fabric, as a carrier containing ECR glass fibers, optionally in a mixture with synthetic fibers, selected from the group consisting of polyester fibers, polyaramid fibers, polyamide fibers, polyurethane fibers, polyolefin fibers or mixtures thereof, polypropylene fibers being particularly preferred, with a material distribution between ECR glass fibers and synthetic fibers in the range of 90:10 wt. -% to 10:90% by weight, in particular in the range from 85:15% by weight to 15:85% by weight, - at least one coating (3) which consists of a synthetic resin selected from the group , which consists of polyurethane, polyvinyl chloride, polyacrylate, polyolefin and which is provided on at least one side of the textile layer (1) - given If necessary, a calibration hose arranged coaxially and freely movable around the coated textile carrier material.

Description

The present invention relates to a tubular lining material, in particular a tubular lining material for rehabilitation-requiring ductwork and / or pipelines as a base material, as well as a pipe liner made of the lining material.

Ducts or pipelines, particularly underground pipes such as sanitary drainage pipes, rainwater pipes, water pipes and gas pipes used for piping liquids and gases, require repairs due to leaks and subsequent leakage of media or they require repairs due to wear. It is known that in the federal state of Bavaria about 12,500 km of sewer pipes must be rehabilitated at the current deadline at short notice, with house connections not yet taken into account.

A first possibility of remediation is the replacement of defective pipe sections. However, if the pipes in the ground or in the masonry are laid hidden, the need for replacement exposing the pipes, for example by Erdaushebung etc., represents a time and cost-intensive measure. Another approach is therefore to rehabilitate the pipelines without having to uncover or replace them by retrofitting the piping with a liner.

In DE 197 18 655 C2 describes the use of knitted hoses, in particular of polyester core knitted fabrics, for trenchless sewer rehabilitation in the so-called "hose-liner method". In this so-called "hose-liner process", the pipe to be rehabilitated is lined with a hose which consists of a plastic hose in which a fabric hose soaked with reactive resin is embedded. In this case, the tube system is pressed by means of a pressure-driven inversion process in the channel to be rehabilitated. Maintaining the pressure that will allow the impregnated liner to press against the pipe wall, the resin is cured using cold and thermosetting systems. A disadvantage of this method using knitted hoses, in particular of polyester core knitted fabrics, the low static, the high creep modulus and the insufficient media resistance.

For lining longer pipe sections, systems are also known which consist of a polyester needle felt hose, a two-component epoxy resin with which the felt hose is impregnated, and a silicone calibration hose. The calibration tube is drawn in a predetermined length in the needle felt tube and closed at the end. After impregnating the needle felt hose with epoxy resin, the system is drawn into the pipe by means of a winch. Then the calibration hose is pressurized with compressed air, whereby the impregnated felt hose is pressed close to the pipe. After curing of the resin, the pressure is released and the calibration tube is removed. A felt / resin composite tube remains in the pipeline. A disadvantage of the use of needle felts, in particular polyester needle felts, is the very low static and a high creep and the too low media resistance.

A tubular lining material for pipelines, which may include bends and curved sections, is also known in DE 35 05 107 disclosed. This lining material consists of a tubular knitted or woven textile sheath which is coated with an air-impermeable coating of a flexible synthetic resin. In order to line a pipe, this lining material is inserted in the pipe in the everting process under pressure, so that the coated side comes to lie on the pipe inner wall and the synthetic resin coating forms the innermost layer of the lined pipe.

The textile jacket is a compact, incompressible woven or knitted fabric of crimped polybutylene terephthalate fibers (warp fibers) and other synthetic fibers (weft fibers). Both the textile sheath and the resin used for its coating are biaxially stretchable, whereby when lining the lining material introduced into the tube, an adaptation of the lining material to the shape of the pipeline takes place, in particular in curvatures and curved sections. This is to avoid wrinkling.

Previous studies by the inventors of the present application have shown that even a lining material consisting of a biaxially stretchable textile sheath coated with a flexible synthetic resin does not satisfactorily wrinkle a lining of complicated tubulars, such as curves of 90 ° achieved. Rather, such a composite in the region of strong bends such as 90 ° leads to wrinkles in the inner bow or for detachment of the lining material from the inner wall of the tube in the outer bow.

The invention is therefore based on the object to develop and produce a lining material, which is the wrinkle-free lining suitable for rehabilitation-needy pipelines, which have a complicated structure, in particular curvatures of 90 °, changes in the pipe inner diameter along the pipeline to be lined (dimensional jump) or twisted sections with complicated geometry in the range of branching connections.

Furthermore, the lining material should ensure a sufficient combination of resin and support material. The residues of the resins should no longer form any flow obstacles and material detachment should no longer occur.

• – einen Schlauch aus einer Textilschicht aus einem textilen Trägermaterial, ausgewählt aus der Gruppe, bestehend aus Vlies, Gewebe und Maschenware als Träger,
• – enthaltend ECR-Glasfasern, gegebenenfalls in Mischung mit Synthesefasern, ausgewählt aus der Gruppe, bestehend aus Polyesterfasern, Polyaramidfasern, Polyamidfasern, Polyurethanfasern, Polyolefinfasern oder Gemischen davon, wobei Polypropylenfasern besonders bevorzugt sind, wobei gegebenenfalls eine Materialverteilung zwischen ECR-Glasfasern und Synthesefasern im Bereich vom 90:10 Gew.-% bis 10:90 Gew.-%, insbesondere im Bereich von 85:15 Gew.-% bis 15:85 Gew.-% vorliegt,
• – mindestens eine Beschichtung, die aus einem Kunstharz besteht, ausgewählt aus der Gruppe, die aus Polyurethan, Polyvinylchlorid, Polyacrylat, Polyolefin, besteht und die auf mindestens einer Seite der Textilschicht vorgesehen ist
• – gegebenenfalls einen um den beschichteten und gegebenenfalls kaschierten Schlauch aus textilem Trägermaterial koaxial und frei beweglich angeordneten Kalibrierschlauch.

The above objects could be achieved according to the invention by providing a lining material for the inside of a pipe wall, in particular a sewer or sewer pipe comprising

• A tube of a textile layer of a textile carrier material selected from the group consisting of nonwoven, woven fabric and knitted fabric as the carrier,
• Containing ECR glass fibers optionally mixed with synthetic fibers selected from the group consisting of polyester fibers, polyaramid fibers, polyamide fibers, polyurethane fibers, polyolefin fibers or mixtures thereof, polypropylene fibers being particularly preferred, optionally having a material distribution between ECR glass fibers and synthetic fibers in the range from 90:10 wt% to 10:90 wt%, especially in the range of 85:15 wt% to 15:85 wt%,
• - At least one coating consisting of a synthetic resin selected from the group consisting of polyurethane, polyvinyl chloride, polyacrylate, polyolefin, and which is provided on at least one side of the textile layer
• - If necessary, a coaxially and freely movably arranged around the coated and optionally laminated tube of textile substrate calibration tube.

In contrast to the seamless knit tube material of the prior art, the lining material according to the invention contains seams at the collision of the two ends of the textile layer, resulting in a tube, wherein the seams may in particular also be laser-welded and also have a suitable seam covering.

The ECR glass fibers are preferably fibers with increased corrosion resistance (ECR: E-Glass Corrosion Resistant). Alternatively, other glass fibers or other fibers may be used.

The above objects could also be achieved according to the invention by providing a coated lining material, wherein the coating of the synthetic resin has a coating thickness between about 100 microns and about 400 .mu.m, in particular between about 100 .mu.m and about 250 .mu.m, and in particular by means of a nozzle or in Form of a synthetic resin film is applied.

In a preferred embodiment, at least one lamination or coating of a foam is provided on at least one side of the textile layer.

In a further preferred embodiment, the foam is arranged on the side of a foam layer facing away from the textile layer, wherein the foam layer may also have a coating consisting of a synthetic resin, which is in particular selected from the group consisting of polyurethane, polyvinyl chloride, polyacrylate, polyolefin The lamination or coating of the foam preferably has a lining thickness or coating thickness of between 2 mm and 5 mm.

The foam is preferably an open-cell or open-cell foam, which can be obtained, for example, by subsequent blasting. Since the cell walls of such a foam are not closed, this can be defined, absorb liquids evenly. This enables the homogeneous impregnation of the coated lining material with a curable resin composition.

The foam preferably comprises a polyolefin, in particular polypropylene. Such a foam can be prepared, for example, by adding molten polyolefin in an extruder with a blowing agent, for example a propellant gas. The melt then expands upon exiting a nozzle.

Furthermore, it is possible, for example, to apply a foam coating in situ to the textile layer by carrying out a foam coating with a suitable polymer dispersion. This dispersion is preferably loaded with air with a foam mixer. By suitable choice of the process parameters, coatings can be produced from small-cell open-cell foams.

The above objects may also be achieved according to the invention by providing a lining material, wherein the textile substrate is a nonwoven fabric consisting of a material mixture containing ECR glass fibers and Polyolefin fibers in the range of 70:30 wt .-% to 30:70 wt .-%, in particular in the range of 85 wt .-% ECR glass fibers and 15 wt .-% polypropylene fibers.

The above objects could also be achieved according to the invention by providing a lining material, wherein the textile layer is a nonwoven fabric layer reinforced with continuous filaments of ECR glass fibers.

The above objects could be achieved according to the invention by the provision of a lining material, wherein the textile substrate is a non-woven, which is mechanically, in particular by needles, solidified.

The above objects could furthermore be achieved according to the invention by providing a lining material, wherein the tube of textile carrier material has seams, in particular laser-welded seams or ultrasonically welded or glued seams, and optionally a seam covering. The seam cover may be different inside or outside (reinforcement, overlap, additional tape, etc.).

The above objects could also be achieved according to the invention by providing a channel and / or tubular lining containing an inversed lining material, comprising a tube of an optionally reinforced textile support material as a carrier, optionally a one-sided film coating, which adheres well to the carrier and optionally one calibration hose. Preferably, the hose is made of an optionally reinforced textile carrier material with a coating or lamination of foam.

• a) Beschichten des Auskleidungsmaterials mit einem Kunstharz, insbesondere mittels einer Düse oder in Form einer Folie,
• b) Herstellen eines Schlauchmaterials aus der beschichteten Flächenware,
• c) Imprägnieren des beschichteten Auskleidungsmaterials mit einer härtbaren Harzzusammensetzung, ausgewählt aus kalthärtenden Epoxidharzen, kalthärtenden UP-Harzen, lichthärtenden UP-Harzen, PU-Harzen, Polyester-Harzen, Vinylesterharzen, Polyacrylatharzen,
• d) Einpressen der Anordnung aus Schritt b) in den auszukleidenden Kanal- oder Rohrabschnitt mittels eines druckbetriebenen Inversionsverfahrens,
• e) und gegebenenfalls Einbringen eines Kalibrierschlauchs mit der obigen Inversionsvorrichtung in das bereits inversierte Auskleidungsmaterial, Aushärten der härtbaren Harzzusammensetzung aus Schritt b) unter Beibehaltung des Drucks der das Andrücken des beschichteten und imprägnierten Auskleidungsmaterials an die Wandung des Kanals- oder Rohrabschnitts gewährleistet ohne die vorgegebene Wandstärkentoleranz zu unterschreiten, d. h. ohne dass es zu einer Verengung oder Aufweitung des Rohrdurchmessers kommt welche außerhalb dieser Toleranz liegt.

The above objects could also be achieved according to the invention by providing a sewer and / or pipe liner, in particular a sewer and / or pipe liner according to one of claims 12 or 13, obtainable by a process comprising the following steps:

• a) coating the lining material with a synthetic resin, in particular by means of a nozzle or in the form of a film,
• b) producing a hose material from the coated fabric,
• c) impregnating the coated lining material with a curable resin composition selected from cold-curing epoxy resins, cold-curing UP resins, light-curing UP resins, PU resins, polyester resins, vinyl ester resins, polyacrylate resins,
• d) pressing in the arrangement from step b) into the channel or pipe section to be lined by means of a pressure-operated inversion method,
• e) and optionally introducing a Kalibrierschlauchs with the above inversion device in the already inversed lining material, curing the curable resin composition of step b) while maintaining the pressure of the pressing of the coated and impregnated lining material to the wall of the channel or pipe section ensured without the predetermined wall thickness tolerance to fall below, ie without causing a narrowing or widening of the pipe diameter which is outside this tolerance.

The foam serves as a seal and thus increases the tightness of the entire system. This is achieved by the fine distribution of the pores in a foam. The interaction of the pores with the curable resin composition prevents trapped air from passing through this barrier. Without the use of the foam, microchannels would always be created by the air which is always present due to the impregnation process, which would lead to a leakage of the entire system. The foam layer prevents the formation of these microchannels or ensures that they close again immediately.

• – Bereitstellen eines Auskleidungsmaterials, das enganliegend und faltenfrei auch in komplizierten Rohrleitungssystemen installiert werden kann.
• – Bereitstellen eines medienbeständigen Materials, welches mittels Dampfhärtung ohne Zusatzkalibrierschlauch eingebaut werden kann.

By the above surprising manufacturing technology solution, a new lining material and a new pipe lining could be provided for in particular in the field of public and private line renovation, which is not only a nuance to the prior art, but this considerably extended by the following advantages:

• - Provide a lining material that can be installed tightly and wrinkle-free even in complicated piping systems.
• - Providing a media-resistant material, which can be installed by means of steam curing without Zusatzkalibrierschlauch.

The material is resistant to silicate resin, dimensionally jumpable, bow-shaped and can be installed with wall thicknesses of 4 mm (production dimension).

• – einen niedrigen Kriechmodul,
• – gute Bogengängigkeit,
• – wenig Dehnung in Längsrichtung,
• – hohe Dehnung in Querrichtung (Dimensionssprung von z. B. Rohrdurchmesser DN 100 auf DN150,
• – Wandstärke (nach Einbau mindestens vier Millimeter),
• – hohe Medienbeständigkeit, und
• – hohe Druckstabilität auf.

The "liner base materials" according to the invention fulfill the following requirements:

• A low creep modulus,
• - good bowability,
• - little stretch in the longitudinal direction,
• - high elongation in the transverse direction (dimensional jump from eg pipe diameter DN 100 to DN150,
• - wall thickness (after installation at least four millimeters),
• - high media resistance, and
• - high pressure stability.

The liner base material according to the invention consists in a preferred embodiment of the invention of a nonwoven 85% ECR glass fibers and 15% polypropylene fibers, which is additionally reinforced with continuous filaments of ECR glass fibers. The threads are needled during the needle process in the nonwoven fabric.

Brief description of the drawings

1 shows the cross section of a lining material according to a first embodiment of the invention.

2 shows the cross section of a lining material according to a second embodiment of the invention.

Example 1 (according to the invention):

• 1. Herstellen einer homogenen Fasermischung aus 85 Gew.-% ECR-Glasfasern und 15 Gew.-% Polypropylen.
• 2. Herstellen eines Faserflors mittels einer Krempelanlage.
• 3. Legen von mehreren Lagen des Faserflors zu einem Lagenpaket von 500 g/m².
• 4. Vernadeln des Lagenpakets auf eine resultierende Dicke von 4 mm.
• 5. Optional können in einer bevorzugten Variante in Längsrichtung Endlosfasern aus ECR-Glas parallel zur Produktionsrichtung mit eingebracht werden. In der bevorzugten Variante erfolgt dies durch einen Kettbaum der dementsprechend vor der Nadeleinheit installiert ist.
• 6. Das so hergestellte Vliesmaterial (Träger, (1)) wird geschnitten und auf einer Seite mit Polyurethan (3) beschichtet, so dass eine Beschichtungsdicke von 100 μm bis 400 μm resultiert.
• 7. Auf der anderen Seite wird das Vliesmaterial mit offenzelligem Polypropylen-Schaumstoff (2) kaschiert, so dass eine Kaschierungsdicke des Schaums von 3 mm resultiert.
• 8. Das Laminat (Träger, Folienbeschichtung und Schaumstoffkaschierung) wird zu einem Schlauch umgearbeitet und mit einer Nahtabdeckung versehen.

A variant of this inventive base material according to the invention is prepared as follows:

• 1. Prepare a homogeneous fiber blend of 85 wt% ECR glass fibers and 15 wt% polypropylene.
• 2. Producing a batt by means of a carding machine.
• 3. Laying several layers of the batt to a layer package of 500 g / m ² .
• 4. Needling the sheet package to a resulting thickness of 4 mm.
• 5. Optionally, in a preferred variant, endless fibers made of ECR glass can be introduced in the longitudinal direction parallel to the production direction. In the preferred variant, this is done by a warp beam which is accordingly installed in front of the needle unit.
• 6. The nonwoven material (carrier, ( 1 )) and cut on one side with polyurethane ( 3 ), so that a coating thickness of 100 .mu.m to 400 .mu.m results.
• 7. On the other hand, the nonwoven material with open-cell polypropylene foam ( 2 ), so that a lamination thickness of the foam of 3 mm results.
• 8. The laminate (backing, foil coating and foam lamination) is made into a tube and provided with a seam cover.

A cross section of the lining material thus obtained is shown in FIG 1 shown.

Example 2 (according to the invention):

• 1. Herstellen einer homogenen Fasermischung aus 85 Gew.-% ECR-Glasfasern und 15 Gew.-% Polypropylen.
• 2. Herstellen eines Faserflors mittels einer Krempelanlage.
• 3. Legen von mehreren Lagen des Faserflors zu einem Lagenpaket von 500 g/m².
• 4. Vernadeln des Lagenpakets auf eine resultierende Dicke von 4 mm.
• 5. Optional können in einer bevorzugten Variante in Längsrichtung Endlosfasern aus ECR-Glas parallel zur Produktionsrichtung mit eingebracht werden. In der bevorzugten Variante erfolgt dies durch einen Kettbaum der dementsprechend vor der Nadeleinheit installiert ist.
• 6. Das so hergestellte Vliesmaterial (Träger, (1)) wird geschnitten und auf einer Seite mit offenzelligem Polypropylen-Schaumstoff (2) beschichtet, so dass eine Beschichtungsdicke von 3 mm resultiert.
• 7. Die Schaumstoffschicht (2) wird mit Polyurethan (3) beschichtet, so dass eine Beschichtungsdicke der Polyurethanschicht von 100 μm bis 400 μm resultiert.
• 8. Das Laminat (Träger, Schaumstoffbeschichtung und Folienbeschichtung) wird zu einem Schlauch umgearbeitet und mit einer Nahtabdeckung versehen.

A further variant according to the invention of this base material according to the invention is prepared as follows:

• 1. Prepare a homogeneous fiber blend of 85 wt% ECR glass fibers and 15 wt% polypropylene.
• 2. Producing a batt by means of a carding machine.
• 3. Laying several layers of the batt to a layer package of 500 g / m ² .
• 4. Needling the sheet package to a resulting thickness of 4 mm.
• 5. Optionally, in a preferred variant, endless fibers made of ECR glass can be introduced in the longitudinal direction parallel to the production direction. In the preferred variant, this is done by a warp beam which is accordingly installed in front of the needle unit.
• 6. The nonwoven material (carrier, ( 1 )) and cut on one side with open-celled polypropylene foam ( 2 ) so that a coating thickness of 3 mm results.
• 7. The foam layer ( 2 ) is treated with polyurethane ( 3 ), so that a coating thickness of the polyurethane layer results from 100 μm to 400 μm.
• 8. The laminate (carrier, foam coating and film coating) is converted into a tube and provided with a seam cover.

A cross section of the lining material thus obtained is shown in FIG 2 shown.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 19718655 C2 [0004]
• DE 3505107 [0006]

Claims (14)

Lining material for the inside of a pipe wall, in particular a sewer or sewer pipe, comprising - a hose made of a textile layer ( 1 ) of a textile carrier material selected from the group consisting of nonwoven, woven and knitted fabric, as a carrier, containing ECR glass fibers, optionally mixed with synthetic fibers selected from the group consisting of polyester fibers, polyaramid fibers, polyamide fibers, polyurethane fibers, polyolefin fibers or Mixtures thereof, wherein polypropylene fibers are particularly preferred, wherein optionally a material distribution between ECR glass fibers and synthetic fibers in the range of 90:10 wt .-% to 10:90 wt .-%, in particular in the range of 85:15 wt .-% to 15:85 wt .-% is present, - at least one coating ( 3 ), which consists of a synthetic resin selected from the group consisting of polyurethane, polyvinyl chloride, polyacrylate, polyolefin and on at least one side of the textile layer ( 1 ) is provided - optionally one around the coated and optionally laminated tube of textile substrate coaxially and freely movable calibration tube. Lining material according to claim 1, wherein the coating ( 3 ) of the synthetic resin has a coating thickness of between about 100 microns and about 400 microns, in particular between about 100 microns and about 250 microns, and in particular by means of a nozzle or in the form of a synthetic resin film with the textile layer ( 1 ) is applied. Lining material according to claim 1 or 2, characterized in that at least one lamination or coating ( 2 ) of a foam on at least one side of the textile layer ( 1 ) is provided. Lining material according to one of claims 1 to 3, characterized in that the foam on the textile layer ( 1 ) side of a foam layer is arranged, wherein the foam layer may also have a coating consisting of a synthetic resin, which is in particular selected from the group consisting of polyurethane, polyvinyl chloride, polyacrylate, polyolefin. Lining material according to one of claims 1 to 4, characterized in that the lining or coating ( 2 ) has a lamination thickness or coating thickness of between 2 mm and 5 mm from the foam. Lining material according to one of claims 1 to 5, characterized in that it is the foam is an open-cell foam. Lining material according to one of claims 1 to 6, characterized in that the foam comprises a polyolefin, in particular polypropylene. Lining material according to one of claims 1 to 7, characterized in that the textile carrier material ( 1 ) is a nonwoven fabric consisting of a blend of materials comprising ECR glass fibers and polyolefin fibers in the range of 70:30 to 30:70 wt%, more preferably in the range of 85 wt% ECR glass fibers and 15 % By weight of polypropylene fibers. Lining material according to one of the preceding claims 1 to 8, characterized in that the textile layer ( 1 ) consists of a nonwoven reinforced with continuous filaments of ECR glass fibers. Lining material according to one of the preceding claims 1 to 9, characterized in that the textile layer ( 1 ) consists of a nonwoven fabric which is mechanically, in particular by needles, solidified. Lining material according to one of the preceding claims 1 to 10, characterized in that the hose of textile carrier material ( 1 ) has a laser welded or ultrasonically welded or glued seam, and optionally has a seam covering. Channel and / or pipe liner comprising an inverse lining material according to any one of the preceding claims 1 to 11, comprising a hose of optionally reinforced textile support material ( 1 ), with a film coating ( 3 ) and optionally a calibration tube, and a cured resin composition, with which the textile carrier material ( 1 ) is coated. Ducting and / or pipe lining according to claim 12, characterized in that the hose made of an optionally reinforced textile support material ( 1 ) with a coating or lamination of foam ( 2 ) is provided. Ducting and / or pipe lining according to claim 12 or 13 obtainable by a process comprising the following steps: a) coating the lining material according to one of claims 1 to 11 on a first side with a synthetic resin, in particular by means of a nozzle or in the form of a film, b) producing a tubular material from the coated fabric, c) impregnating the coated lining material with a curable resin composition selected from cold-curing epoxy resins, cold-curing UP resins, light-curing UP resins, D) pressing the arrangement from step b) into the duct or pipe section to be lined by means of a pressure-driven inversion method, and e) optionally introducing a calibration hose into the already inversed lining material, f) curing the curable resin composition of step b) while maintaining the pressure of the pressing of the coated and impregnated lining material to the wall of the channel or pipe section ensured, without falling below the predetermined wall thickness tolerance.

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