# US 10,766,209 B2 · Hybrid polymer pipe and tile hybrid polymer

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- Number: US 10,766,209 B2
- Document ID: US10766209B2
- Status: Granted
- Kind: B2
- Application number: 16/208,315
- Filed: 2018-12-03
- Published: 2019-04-11
- Granted: 2020-09-08
- Earliest claimed: 2016-10-28
- Applicants: Ron Elkana
- Inventors: Ron Elkana
- Web page: https://patentgrep.com/patent/US10766209B2

## CPC

- B29C 70/347: {combined with compressing after the winding of lay-ups having a non-circular cross-section, e.g. flat spiral windings}
- B29C 48/0015: {producing hollow articles having components brought in contact outside the extrusion die}
- B29C 48/151: Coating hollow articles
- B29C 48/9115: {of hollow articles}
- B29C 70/326: {by rotating the mould around its axis of symmetry}
- F16L 9/133: the walls consisting of two layers
- B29K 2023/0683: {UHMWPE, i.e. ultra high molecular weight polyethylene}
- B29K 2023/14: {Copolymers of polypropylene (B29K2023/16 takes precedence)}
- B29K 2025/06: {PS, i.e. polystyrene}
- B29K 2027/06: PVC, i.e. polyvinylchloride
- B29K 2105/0845: {Woven fabrics}
- B29L 2023/22: {Tubes or pipes, i.e. rigid (bent tubes not for use as pipe couplings B29L2023/004)}
- F16L 9/12: of plastics with or without reinforcement (F16L9/16 - F16L9/22 take precedence)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- F16L: PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

The method for forming from a round shaped cylinder to a square shaped cylinder or flat sheet which can be inserted in a square or rectangular shape metal pipe includes initiating turning of a heated mandrel, extruding heated polymer, wrapping while compressing a first layer of heated polymer or mesh, disposing a mesh or polymer layer over the cylinder encapsulating the cylinder on the turning mandrel while simultaneously laying a second layer of heated polymer over the turning mandrel and compressing the layer of heated polymer into the mesh layer and the mesh layer into the first layer of heated polymer simultaneously, and repeating the layering of the heated polymer and mesh layer until a desired wall thickness is reached.

## Claims

### Claim 1

An accelerated method for making a reduced plastic content hybrid polymer pipe or hybrid flat sheets comprising:
a. initiating turning of a heated mandrel heated to a temperature from 25 percent to 40 percent less in surface temperature than the temperature of a heated polymer, the heated mandrel being turned a rate of speed from 1 to 6 revolutions per minute;
b. extruding the heated polymer from an extruder at a temperature from 400-460 Fahrenheit without deforming or becoming soluble;
c. wrapping while compressing a first layer of the heated polymer over the turning mandrel wherein the first layer of the heated polymer is: disposed as overlapping wrapping on the turning heated mandrel from one edge of the turning heated mandrel to the opposite edge of the turning heated mandrel until from 70 percent to 80 percent of the surface of the turning heated mandrel is covered with the first layer of the heated polymer; and disposing a interstitial layer comprising mesh, glass rope, or metallic wire over the first layer of the heated polymer on the turning heated mandrel while simultaneously laying a second layer of the heated polymer over the turning heated mandrel with a width from 1 inch to 1½ feet and compressing the second layer of the heated polymer into the interstitial layer and the interstitial layer into the first layer of the heated polymer simultaneously;
d. repeating the layering of the heated polymer and the interstitial layer until a desired wall thickness is reached; wherein a quantity of layers of heated polymer are equal to or greater than the interstitial layer, creating a hybrid polymer cylinder;
e. performing one of the following to form a hybrid polymer pipe or a hybrid flat sheet:
(i) while hot, removing the hybrid polymer cylinder from the mandrel and forming one of a warm hybrid polymer oval, square, or rectangular shaped pipe therefrom; and cooling the shaped pipe to form a shaped hybrid polymer pipe; or
(ii) while cool, removing the hybrid polymer cylinder from the mandrel forming a round hybrid polymer pipe; or
(iii) while warm, cutting the hybrid polymer cylinder, setting it flat and cooling it to form the hybrid flat sheet.

### Claim 2 (depends on 1)

The accelerated method for making the reduced plastic content hybrid polymer pipe or hybrid flat sheets of claim 1, wherein the interstitial layer is mesh having a pore size from ¼ inch long to 1 inch long, ¼ inch wide to 1 inch wide.

### Claim 3 (depends on 1)

The accelerated method for making the reduced plastic content hybrid polymer pipe or hybrid flat sheets of claim 1, wherein the interstitial layer is mesh having a thickness from 0.4 mm to 2 mm.

### Claim 4 (depends on 1)

The accelerated method for making the reduced plastic content hybrid polymer pipe or hybrid flat sheets of claim 1, wherein the interstitial layer is mesh comprising at least one of: carbon steel, carbon steel coated with zinc, galvanized steel; fiberglass, carbon graphite fabric, polyamide (nylon), KEVLAR®, cotton fabric, or stainless steel.

### Claim 5 (depends on 1)

The accelerated method for making the reduced plastic content hybrid polymer pipe or hybrid flat sheets of claim 1, wherein the heated polymer consists of polypropylene, polyethylene, including homopolymers and copolymers thereof, polyvinyl chloride, carbon polyvinyl chloride, polystyrene, or ultra-high molecular weight polyethylene.

### Claim 6 (depends on 1)

The accelerated method for making the reduced plastic content hybrid polymer pipe or hybrid flat sheets of claim 1, wherein a roller gang applies from 90 psi to 140 psi onto at least one of the interstitial layer, the first layer of the heated polymer, or the second layer of the heated polymer.

### Claim 7 (depends on 1)

The accelerated method for making the reduced plastic content hybrid polymer pipe or hybrid flat sheets of claim 1, further comprising welding a top plate and a bottom pan made from a polymer similar to the material used to make the hybrid polymer pipe to an outside surface of the hybrid polymer pipe, thereby enclosing the hybrid polymer pipe.

### Claim 8 (depends on 7)

The accelerated method for making the reduced plastic content hybrid polymer pipe or hybrid flat sheets of claim 7, wherein the top plate and the bottom pan are supported with at least one rib providing pressure control to the interior of the hybrid polymer pipe.

### Claim 9 (depends on 8)

The accelerated method for making the reduced plastic content hybrid polymer pipe or hybrid flat sheets of claim 8, comprising installing flange fittings into the hybrid polymer pipe to allow ingress or egress of fluids, vapors or combinations thereof into or out of the formed hybrid polymer pipe.

### Claim 10 (depends on 8)

The method for making the reduced plastic content hybrid polymer pipe or hybrid flat sheets of claim 8, wherein the hybrid polymer pipe is seamless.

### Claim 11 (depends on 1)

The accelerated method for making the reduced plastic content hybrid polymer pipe or hybrid flat sheets of claim 1, comprising installing a manway into the hybrid polymer pipe.

### Claim 12 (depends on 1)

The method for making the reduced plastic content hybrid polymer pipe or hybrid flat sheets of claim 1, further comprising transforming the hybrid polymer cylinder to the shaped hybrid polymer pipe by putting the hybrid polymer cylinder in a jig, and inserting the jig into a rectangular shaped metal container to achieve over 95 percent volume of the metal container.