Composite tape

Abstract

The composite tape may include a fiber-reinforced tape and a metal barrier layer adhered to the main surface of the fiber-reinforced tape. The fiber-reinforced tape may include a thermoplastic matrix and multiple unidirectional continuous fibers embedded in the thermoplastic matrix. When applied to pipes and storage containers, such as those for hydrogen or other permeable gases, this composite tape can advantageously enhance and reduce gas permeability.

Description

[0001] Priority requirements

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 605,089 (Attorney General’s Case No. 1202331), filed December 1, 2023, which is incorporated herein by reference in its entirety. Technical Field

[0003] This invention relates to a composite tape comprising a fiber-reinforced tape and a metal barrier layer. This composite tape can be used to reinforce pipes and storage containers, and to add a gas barrier layer to them. Background Technology

[0004] Fiber-reinforced tapes can be used in many applications, including reinforcing pipes. Traditional pipes are made of metals, thermoset composites, and thermoplastic composites. Each material combination offers a unique set of positive properties. However, there is still a need to develop fiber-reinforced tapes that balance strength, flexibility, and other properties. Summary of the Invention

[0005] Advantages of this invention include a composite tape with fiber reinforcement and gas barrier properties in a single structure. The composite tape comprises one or more fiber-reinforced tapes, wherein a metal barrier layer is adhered to the main surface of the fiber-reinforced tapes. The fiber-reinforced tapes comprise a thermoplastic matrix and multiple unidirectional continuous fibers embedded within the thermoplastic matrix.

[0006] In some respects, the thermoplastic matrix of the fiber-reinforced tape may include, but is not limited to: polyolefins such as polyethylene (PE), poly(ethylene-vinyl acetate) (PVA), modified polyolefins such as maleic anhydride polyolefins, polyesters such as amorphous polyethylene terephthalate (aPET), polyamides (PA), polyvinyl chloride (PVC), polyurethane (PU), thermoplastic vulcanizates, polyketide ethers (PKE), polyetheretherketone (PEEK), polyetherimide (PEI), polyphenylene sulfide (PPS), polyacrylates such as polymethyl methacrylate (PMMA), or copolymers or blends thereof, or combinations thereof. Based on the total weight of the fiber-reinforced tape, the fiber-reinforced tape may contain 20-60 wt% of the thermoplastic matrix. The thermoplastic matrix advantageously allows the tape to be reprocessed by heating to reshape the fiber-reinforced tape and / or adhere it to a metal barrier layer and / or other surfaces.

[0007] In other respects, the multiple unidirectional continuous fibers can be composed of glass fibers, aramid fibers, basalt fibers, carbon fibers, polymer fibers, or combinations thereof. The fiber-reinforced tape may contain 80-40 wt% of multiple unidirectional continuous fibers by total weight. These fibers may be embedded in a thermoplastic matrix.

[0008] In other aspects, the metal barrier layer may consist of metals such as aluminum, steel, copper, tin, metal alloys, or combinations thereof, and / or of a metallized polymer matrix such as a metal deposited or coated on a polymer matrix. In some aspects, the thickness of the metal barrier layer may be up to about 0.5 mm, for example, about 0.01-0.5 mm and values ​​between therewith.

[0009] In a further embodiment, one or more composite tapes of the present invention can form a reinforcing barrier layer for a pipe or storage container. For example, one or more layers of composite tape can be wound along the outer surface of the pipe to form a reinforcing barrier layer. Such a pipe may also include the composite tape or an outer jacket on the composite tape layer.

[0010] Another embodiment includes a method for reinforcing a pipe, such as completely covering the outer surface of the pipe with the composite tape of the present invention and heating the composite tape and / or the pipe to adhere the composite tape to the pipe.

[0011] Other advantages of the invention will be readily apparent to those skilled in the art from the following detailed description, wherein only certain embodiments are given and described simply by describing some of the subject matter. As will be appreciated, the invention is capable of having other and different embodiments, and some of its details can be adjusted in various respects without departing from the invention. Therefore, the drawings and description should be considered descriptive in nature and not restrictive. Attached Figure Description

[0012] Referring to the accompanying drawings, elements having the same reference numerals represent similar elements, wherein:

[0013] Figure 1 A composite tape structure according to an embodiment of the present invention is described, comprising a fiber-reinforced tape and a metal barrier layer thereon.

[0014] Figure 2 Schematic description Figure 1 The example shown is a four-layer composite strip on the pipe lining.

[0015] Figure 3A , Figure 3B and Figure 3C A perspective view of a composite tape is depicted, which has multiple layers of fiber-reinforced tape with different relative fiber orientations in different layers of the fiber-reinforced tape.

[0016] Figure 4A and Figure 4B A multilayer composite tape is described, in which the seams formed by the outer layer and the lower layer overlap.

[0017] Figure 5A , Figure 5B and Figure 5CThis is a schematic cross-sectional description of a pipe structure including a multi-layer composite strip according to certain embodiments of the present invention.

[0018] Figure 6 The charts described provide the average and maximum peel strength of the composite tape samples.

[0019] Figure 7A The dimensions and test orientation of the sample used to test tear strength are described.

[0020] Figure 7B and Figure 7C The figures show the tear resistance and maximum strength of the composite tape relative to the aluminum foil.

[0021] Figure 8 A schematic diagram of the gas permeability testing unit is shown.

[0022] Figure 9 A schematic diagram of the sample configuration used to estimate the gas permeability of a seam is shown.

[0023] Figure 10 This is a graph used to simulate the relationship between gas permeability and seam length at a seam. Detailed Implementation

[0024] The invention can be more fully understood by referring to the following specification, which includes the following definitions and examples. Certain features of the disclosed compositions and methods described in the context of various aspects herein may also be provided in combination in a single aspect. Alternatively, for the sake of brevity, various features of the disclosed compositions and methods described in the context of a single aspect may also be provided individually or in any sub-combination.

[0025] Unless otherwise defined herein, scientific and technical terms relating to this application shall have the meanings commonly understood by one of ordinary skill in the art. Furthermore, unless the context requires otherwise, singular terms shall include plural forms, and plural terms shall include singular forms.

[0026] As used above and throughout this disclosure, unless otherwise stated, the following terms and abbreviations shall be understood to have the following meanings.

[0027] As applied in the specification including the appended claims, unless the context clearly requires otherwise, the singular article includes the plural form, and references to a particular numerical value include at least the particular numerical value.

[0028] As used in the specification including the appended claims, when referring to a numerical range, the range includes from one particular value and / or to another particular value. All ranges are inclusive and composable. Furthermore, references to numerical values ​​within a range include every value within that range. When referring to measurable values ​​such as quantity, duration of time, etc., the term "about" as used herein refers to a reasonable variation of that value.

[0029] This invention relates to a composite belt. As used herein, a belt is a continuous narrow strip, and the term may be used interchangeably with a strip or band.

[0030] The composite tape of the present invention comprises a fiber-reinforced tape and a metal barrier layer, such as an aluminum foil layer, on one or more main surfaces of the fiber-reinforced tape. Therefore, the composite tape of the present invention can have both reinforcing and gas-barrier properties in a single structure. In some aspects, the tensile strength (GPa) of the composite tape of the present invention can be about 0.1-10 and / or the modulus (secant) (GPa) can be about 5-900 and / or the ultimate tensile strain (%) can be about 0.1-5. In some aspects, the composite tape of the present invention can have a gas permeability coefficient comparable to that of a barrier layer, i.e., comparable to that of a metal layer of the same thickness and composition. For example, the composite tape of the present invention has a permeability coefficient of less than about 10 for gases such as hydrogen or helium. -12 (cm 3 cm) / (cm 2 s (cmHg), if less than approximately 10 -13 Or about 10 -14 (cm 3 cm) / (cm 2 s (cmHg).

[0031] The composite strip of this invention can be used to reinforce pipes and storage containers, including those for gases such as hydrogen. The transport and storage of hydrogen is challenging due to its extremely low density and extremely high permeability. Ductile carbon steel offers better resistance to hydrogen embrittlement compared to high-strength steel, but its relatively low strength limits operating pressures, thus limiting its effectiveness as a material for hydrogen transport and storage. Thermoplastics are generally less prone to hydrogen embrittlement, but they are more permeable to hydrogen. However, due to their beneficial properties, the composite strip of this invention can be advantageously used to reinforce existing pipes and storage containers for hydrogen.

[0032] For example, fiber-reinforced plastic (FRP) pipes are currently used in the oil and gas industry, which is repurposing existing distribution facilities to transport hydrogen. The composite strip of the present invention can be used both as a reinforcing material and as a hydrogen barrier layer for the FRP.

[0033] Furthermore, the composite tape of the present invention can be used in newly constructed pipelines and storage containers. While pipelines can be constructed with barrier layers such as aluminum layers, these aluminum barrier layers typically require adhesives, bonding layers, or surface modification during the construction of composite pipelines to ensure good adhesion between the aluminum and other composite pipeline components, such as pipe liners or reinforcement layers, which is time-consuming. However, the composite tape of the present invention can be used in new pipeline and storage structures and can be applied without the need for adhesives. Additionally, because the composite tape of the present invention comprises a combination of fiber-reinforced tape and a metal barrier layer, the tear strength of the composite tape is higher than that of typical metal barrier layers. This higher tear strength advantageously allows the composite tape of the present invention to be used for constructing pipelines at higher linear speeds.

[0034] In one embodiment, the composite tape comprises a fiber-reinforced tape having a first primary surface and an opposing second primary surface. The fiber-reinforced tape itself comprises a thermoplastic matrix and a plurality of unidirectional continuous fibers embedded within the thermoplastic matrix. The thermoplastic matrix may comprise approximately 20-60 wt% of the total weight of the fiber-reinforced tape. The plurality of unidirectional continuous fibers may comprise approximately 40-80 wt% of the total weight of the fiber-reinforced tape.

[0035] A variety of thermoplastics can be used as the thermoplastic matrix for the fiber reinforcement tape of the present invention, including, for example, polyolefins such as polyethylene (PE), poly(ethylene-vinyl acetate) (PVA), modified polyolefins such as maleic anhydride polyolefins, polyesters such as amorphous polyethylene terephthalate (aPET), polyamides (PA), polyvinyl chloride (PVC), polyurethane (PU), thermoplastic vulcanizates, polyketide ethers (PKE), polyetheretherketone (PEEK), polyetherimide (PEI), polyphenylene sulfide (PPS), polyacrylates such as polymethyl methacrylate (PMMA), or copolymers, blends, or combinations thereof. Advantageously, many of the polar thermoplastic resins listed herein allow the metal barrier layer to be directly adhered to the fiber reinforcement tape. For example, in some embodiments, a thermoplastic matrix composed of poly(ethylene-vinyl acetate) (PVA), modified polyolefins such as maleic anhydride polyolefins, polyesters such as amorphous polyethylene terephthalate (aPET), polyamide (PA), polyvinyl chloride (PVC), polyurethane (PU), thermoplastic vulcanizates, polyketide ether (PKE), polyether ether ketone (PEEK), polyetherimide (PEI), polyphenylene sulfide (PPS), polyacrylates such as polymethyl methacrylate (PMMA), or copolymers or blends thereof can be used to directly adhere the metal barrier layer to the fiber reinforcement tape without the need for an interlayer, such as an adhesive interlayer.

[0036] Unidirectional continuous fibers embedded in a thermoplastic matrix can be composed of glass fibers, aramid fibers, basalt fibers, ultra-high molecular weight polyethylene fibers, liquid crystal polymer fibers, poly(p-phenylene-2,6-benzodioxazole) fibers, cellulose fibers, rayon fibers, carbon fibers, etc.

[0037] In some aspects, the multiple unidirectional continuous fibers embedded in the thermoplastic matrix can be in the form of tows, yarns, monofilaments, filament cakes, or rovings. In some aspects, the multiple unidirectional continuous fibers include a sizing composition. The sizing composition protects the fibers during processing and promotes chemical or mechanical adhesion between the thermoplastic matrix and the continuous fibers. The sizing composition is typically applied by the fiber manufacturer. For example, the sizing composition may include film-forming agents, lubricants, coupling agents, or combinations thereof.

[0038] On the other hand, each of the multiple unidirectional continuous fibers can have an average diameter of approximately 1-40 µm. In other aspects, the average linear mass density of the bundles, yarns, monofilaments, filament cakes, or rovings of the multiple unidirectional continuous fibers can be approximately 100-4400 TEX. (TEX is a unit of measurement in grams per 1000 meters. Furthermore, the above ranges are an overview of various fiber filament diameters and TEX).

[0039] In addition to the fiber-reinforced tape, the composite tape of the present invention also includes a metal barrier layer adhered to a first main surface of the fiber-reinforced tape. In some aspects, the metal barrier layer is continuous and extends along the main surface of the fiber-reinforced tape, and the thickness of the metal barrier layer is sufficient to reduce the permeability of gases passing through the composite tape. For example, the thickness of the metal barrier layer can be up to about 0.5 mm, such as about 0.01-0.5 mm (about 0.4-20 mil) and values ​​between therewith. The metal barrier layer can consist of a metal layer such as aluminum, steel, copper, tin, a metal alloy layer, or a combination thereof, and / or consist of a metallized polymer matrix, such as metal deposited or coated on a polymer matrix, such as metal coated on an oriented (or bi-oriented) polymer matrix such as bi-oriented PET, i.e., a metallized polyester film. In one aspect of the invention, the metal barrier layer is a metal foil, such as a foil composed of aluminum or an aluminum alloy, with a thickness of up to about 0.5 mm, such as about 0.01-0.5 mm and values ​​between therewith.

[0040] Furthermore, the composite tape of the present invention may include two or more layers of fiber-reinforced tape. When the composite tape includes multiple layers of fiber-reinforced tape, the unidirectional continuous fibers in one layer of fiber-reinforced tape may be oriented in a different direction than the unidirectional continuous fibers in another layer of fiber-reinforced tape. Additionally, a metal barrier layer may be adhered to the outer layer of the fiber-reinforced tape or between the layers.

[0041] In some embodiments, an adhesive layer may be used between the fiber-reinforced tape and the metal barrier layer to promote adhesion between the tape and the metal barrier layer, depending on their respective compositions. However, for some materials, adhesives or adhesive layers may be excluded. For example, in some embodiments, the composite tape may include a fiber-reinforced tape and an aluminum foil layer adhered directly to a first primary surface of the fiber-reinforced tape as a barrier layer, said fiber-reinforced tape comprising unidirectional continuous glass fibers embedded in an amorphous polyethylene terephthalate matrix. The amorphous polyethylene terephthalate matrix can advantageously adhere the aluminum foil directly, thus eliminating the need for an adhesive or adhesive layer between the fiber-reinforced tape and the barrier layer. In this embodiment, an adhesive layer may be advantageously excluded between the fiber-reinforced tape and the barrier layer.

[0042] Figure 1 A composite tape structure (100) is described, comprising a fiber-reinforced tape (110) consisting of multiple unidirectional continuous fibers (102) embedded in a thermoplastic matrix (120). A metal barrier layer (130) is directly adhered to the main surface (110a) of the fiber-reinforced tape. For this exemplary structure of the composite tape, there is no adhesive layer between the fiber-reinforced tape (110) and the barrier layer (130).

[0043] As further referenced to the Z, X, and Y axes, the composite tape can have a length in the Z direction, a width in the X direction, and a thickness in the Y direction. The length of the composite tape can be greater than or similar to its width, but the thickness of the composite tape will be significantly less than its length or width. For example, the width of the composite tape in the transverse direction can be approximately 6-1525 mm (approximately 0.25-60 inches), such as from 10 mm, 15 mm, 20 mm, 25 mm, 50 mm, 75 mm, 100 mm, 150 mm, 200 mm, 250 mm to approximately 1525 mm, 1500 mm, 1400 mm, 1300 mm, 1200 mm, 1000 mm, 900 mm, 500 mm, 200 mm, or any value or range between them.

[0044] The thickness of the composite tape (100) is the sum of the thicknesses of the fiber-reinforced tape (110) and the metal barrier layer (130). For example, the thickness (Y direction) of the fiber-reinforced tape can be about 0.1-1 mm (about 4-40 mil), such as from about 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm to about 0.7 mm, 0.8 mm, 0.9 mm, 1 mm or any value or range therebetween. The thickness (Y direction) of the metal barrier layer can be about 0.01-0.5 mm (about 0.4-20 mil), such as from about 0.01 mm, 0.02 mm, 0.03 mm, 0.04 mm, 0.05 mm, 0.06 mm, 0.08 mm to about 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm or any value or range therebetween. In some respects, the thickness of the composite tape is the sum of the thicknesses of the fiber-reinforced tape and the metal barrier layer, which can be approximately 0.1-1.5 mm. Additionally, for Figure 1 For example, the thickness of the fiber-reinforced tape (110) can be about 0.010 inches (about 0.25 mm) and the thickness of the metal barrier layer (130) can be about 0.002-0.005 inches (about 0.05-0.13 mm), and the thickness of the composite tape can be about 0.012-0.015 inches (about 0.3-0.38 mm) (which is the combined thickness of the fiber-reinforced tape and the metal barrier layer).

[0045] like Figure 1 As shown, multiple continuous fibers are each more or less along a first direction (i.e., the Z direction, longitudinal or length direction) or at an angle of 0 to the Z-axis. Angular orientation. As further shown, multiple unidirectional continuous fibers (102) span the entire or almost the entire width (X direction) of the thermoplastic matrix (120) and the fiber-reinforced strip (110).

[0046] In one implementation, the composite tapes can be stacked to form a multi-layer composite tape structure. Figure 2 The diagram schematically depicts four layers on the pipe liner (240) (e.g., a polyethylene liner). Figure 1 The composite tape (100) is shown. The stacked layers can be achieved by heating and laminating the individual layers of the composite tape. It is understood that such a laminated structure can include more or fewer layers of composite tape. For example, the stacked layers can include four to six layers of composite tape (e.g., four or six layers stacked), which can be used to enhance the strength of the pipe and also as a barrier layer to prevent the permeation of gas transported through the pipe.

[0047] Furthermore, the fibers in each composite tape layer can be oriented in the same or different directions relative to other fibers in the composite tape layer. For example, a stacked layer or laminated structure may include a first composite tape layer and a second composite tape layer, wherein multiple unidirectional continuous fibers in the first composite tape layer are oriented in a first direction, and wherein multiple unidirectional continuous fibers in the second composite tape layer are oriented relative to multiple unidirectional continuous fibers in the first composite tape layer at an angle greater than or equal to 0. And less than or equal to 90 Angle and orientation. Figure 2 A four-layer structure of the composite tape (100) is described, in which the fibers in each layer are oriented in the same direction (Z direction). That is, multiple unidirectional continuous fibers are positioned relative to each other at approximately 0°. Angle and orientation.

[0048] In some embodiments, the composite tape may include multiple layers of fiber-reinforced tape. Furthermore, in a multilayer structure, the orientation of the unidirectional continuous fibers in the fiber-reinforced tape may be the same as or different from the orientation of the unidirectional continuous fibers in adjacent fiber-reinforced tapes. For example, in some aspects, the composite tape may include at least two layers of fiber-reinforced tape, such as at least 3, 4, 5, 6, 7, 8, etc. Additionally, the multiple unidirectional continuous fibers of the first layer of fiber-reinforced tape may be oriented along a first direction. Relative to the first direction of the multiple unidirectional continuous fibers in the first layer of fiber-reinforced tape, the multiple unidirectional continuous fibers in the second layer of the adjacent layer, i.e., the second layer of fiber-reinforced tape, may be oriented at an orientation greater than or equal to about 0. and less than or equal to approximately 90 The angular orientation. The angle of the second fiber relative to the first fiber can be approximately 0°. 10 20 30 40 50 60 67 70 80 90 Or any value or range thereof.

[0049] Figures 3A-3C A composite tape with multiple layers of fiber-reinforced tape and different relative orientations of fibers in each layer of fiber-reinforced tape is described. Figure 3A A perspective view of a composite tape (301) is depicted, comprising two layers of fiber-reinforced tape, such as a first layer of fiber-reinforced tape (310a) and a second layer of fiber-reinforced tape (310b). In this example, the first layer of fiber-reinforced tape (310a) comprises a plurality of unidirectional continuous fibers (302) oriented along a first direction, i.e., at a 90° angle to the Z direction (or a 0° angle to the X direction). As further shown for this example, the second layer of fiber-reinforced tape (310b) comprises a plurality of unidirectional continuous fibers (304) oriented along a second direction, i.e., at a 0° angle to the Z direction (or a 90° angle to the X direction). Thus, the plurality of unidirectional continuous fibers in the second layer are oriented at approximately 90° relative to the first direction of the plurality of unidirectional continuous fibers in the first layer of fiber-reinforced tape. Angular orientation (e.g., the first fiber reinforcement belt rotated 90 degrees from the Z-axis) That is, the fibers in the two adjacent layers are aligned opposite each other at 90° / 0°. A metal barrier layer (330), such as aluminum foil, is adhered to the main surface of the second fiber reinforcement strip.

[0050] Figure 3B A perspective view of a composite tape (303) comprising two layers of fiber-reinforced tapes (310c, 310d) is depicted, wherein the fibers in the tape layers are arranged opposite each other with a 0° / 90° orientation. Specifically, the first fiber-reinforced tape (310c) comprises multiple unidirectional continuous fibers (306) oriented along a first direction, i.e., at a 0° angle to the Z direction (or a 90° angle to the X direction), and the second fiber-reinforced tape (310d) comprises multiple unidirectional continuous fibers (308) oriented along a second direction, i.e., at a 90° angle to the Z direction (or a 0° angle to the X direction). A metal barrier layer (330), such as aluminum foil, is adhered to the main surface of the second fiber-reinforced tape.

[0051] Figure 3C Another perspective view depicts a composite tape (305) comprising two layers of fiber-reinforced tapes (310a, 310b), wherein the fibers in the tape layers are arranged opposite each other with a 90° / 0° orientation. The orientations of the first and second fiber-reinforced tapes are... Figure 3AThe same as shown in Figure 3. However, in this example structure, the metal barrier layer (330) is sandwiched between two layers of fiber reinforcement strips. That is, the metal barrier layer (330) has a first main surface (330a) and an opposing second main surface (330b), wherein the first layer of fiber reinforcement strip (310a) is adhered to the first main surface (330a) of the metal barrier layer (330), and the second layer of fiber reinforcement strip (310b) is adhered to the opposing second main surface (330b) of the metal barrier layer (330). Although the structure in Figure 3 shows two layers of fiber reinforcement strips, more layers may be included in the structure. Additionally, although the structure in Figure 3 shows that the relative orientation of the fibers of adjacent layers of fiber reinforcement strips is 90°. However, the angle between the second fiber and the first fiber can be approximately 0°. 10 20 30 40 50 60 67 70 80 Or any value or range thereof. Additionally, the fiber-reinforced tapes shown in the figure can be laminated to each other and onto a metal barrier layer by applying heat to form a composite tape with multiple fiber-reinforced tapes.

[0052] In some embodiments, the composite tape of the present invention can form a reinforcing barrier layer for a pipe or storage container. For example, the composite tape can be wound along a pipe to form a reinforcing barrier layer for said pipe. The composite tape can be wound as a single layer or multiple layers, wherein an outer composite tape overlaps with a lower composite tape. The fibers of the outer composite tape have approximately 0° along the longitudinal (length direction) relative to the lower composite tape. To approximately 90 The offset angle. Different winding angles of the composite tape can provide different mechanical or chemical advantages. For example, the composite tape can be spirally wound along the longitudinal direction of the pipe onto the outer surface of the pipe. In some aspects, the pipe may include another composite tape, i.e., a second composite tape, which is spirally wound onto the first composite tape. The pipe or container may include 2-12 layers of composite tape, such as 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or 12 layers of composite tape or any number or range thereof. Composite tape or composite tape layers can be laminated onto the pipe and / or laminated onto each other by applying heat.

[0053] In addition to composite tapes having multiple fiber-reinforced tape layers, or as an alternative, the composite tape itself can be formed as a multilayer composite tape stack. For example, the composite tape of the present invention can be applied to pipes in multiple layers, and various tape layers can be applied such that the joints formed by the outer layers and the lower layers overlap. Figure 4A and Figure 4B Examples are described where the lining can have multiple layers of composite strips. Figure 4A and Figure 4B A first composite strip (460a) forming a first strip layer (460) on a liner 440 is shown, wherein adjacent composite strips (460b) in the strip layer (460) form a first seam (462). As further shown in the figure, a second composite strip (470a) can be applied to the first composite strip to form a second strip layer (470). Other composite strips can be applied to the second composite strip layer (470) to form additional strip layers (e.g., 480). Advantageously, the second composite strip (470a) forming the second strip layer (470) can overlap with the seam (462) in the first strip layer 460. The overlap range of the second composite strips in the second layer can be about 10-50% of the width of the second composite strip. Figure 4A As shown, the second composite strip (470b) overlaps the seam (462) by about half the width of the second composite strip (464). Figure 4B It is described that the second composite strip (470b) overlaps the seam (462) by at least about one-third of the width of the second composite strip (466).

[0054] Although Figure 4A and Figure 4B A first composite strip on the liner is shown, but the first composite strip can be longitudinally wound along the outer surface of the pipe to which another strip layer is covered, forming a reinforcing barrier layer around the outer surface of the pipe. In this case, the first composite strip can form a first strip layer, wherein adjacent composite strips in the strip layer form a first seam. A second composite strip can be wound around the first strip layer, forming a second strip layer on the first strip layer. Advantageously, the second composite strip can overlap the seam formed by the first composite strip in the first strip layer by about 10-50% of the width of the second composite strip, for example, at least about one-third to about half the width of the second composite strip. In addition, in the multilayer structure, the orientation of the unidirectional continuous fibers in the composite strip can be the same or different from the orientation of the unidirectional continuous fibers in the adjacent composite strips. Furthermore, the reinforcing barrier layer constructed of overlapping composite strips of the present invention can advantageously reduce the permeability of gases escaping from the outer surface of the pipe or liner to the permeability of the composite strip, for example, the permeability coefficient of helium or hydrogen is less than about 10. -12 (cm 3 cm) / (cm 2 s (cmHg), if less than approximately 10 -13 Or about 10 -14 (cm 3 cm) / (cm 2 s (cmHg).

[0055] In some embodiments of the invention, the pipe may include an inner liner and an outer jacket. The composite tape of the invention may be wound around the outer surface of the liner or jacket. Advantageously, the composite tape of the invention has sufficient flexibility to allow the tape to be installed on existing pipes in the field, thereby allowing for the repair and / or maintenance of existing pipes in the field. The metallic barrier layer of the composite tape can provide a barrier layer for gases transported through the pipe.

[0056] Figure 5A A cross-sectional view of a pipe structure (pipe structure I (500A)) reinforced with the composite tape of the present invention is depicted. In this example, pipe 500A includes an outer jacket 550 and two layers of composite tape (510a, 510b), each layer of composite tape consisting of a fiber-reinforced tape layer (512) and a metal barrier layer (514). The pipe also includes an inner layer or liner (540). In some aspects, the inner layer or liner (540) and the outer jacket layer (550) are composed of thermoplastics such as polyolefins (e.g., polyethylene or blends thereof). As shown in the figure, the composite tape layers (510a, 510b) do not require an adhesive layer but are directly adhered to each other, and can also adhere to the surfaces of the pipe liner and the outer jacket. This adhesion can be promoted by heating the composite tape and / or the pipe layers. For example, a composite tape consisting of fibers in an aPET matrix and an aluminum barrier layer can be directly wound onto a thermoplastic liner and can be cured by heat without the use of an adhesive.

[0057] Figure 5B A cross-sectional view of another pipe structure (pipe structure II (500B)) reinforced with the composite tape of the present invention is described. In this example, pipe 500B includes an outer jacket 550 and two layers of composite tape (510c, 510d), each layer of composite tape consisting of a fiber-reinforced tape layer (512) and a metal barrier layer (514). For this structure, an adhesive layer (516), such as an bonding layer, is included between the fiber-reinforced tape layer (512) and the metal barrier layer (514). In this example, the fiber-reinforced tape layer (512) may include a polyethylene matrix and an adhesive layer (516) to adhere the fiber-reinforced tape and the metal barrier layer (such as aluminum foil). The outer and inner lining layers are each composed of thermoplastics (such as polyethylene), which can be cured and adhered to the composite tape by heating.

[0058] Figure 5C A cross-sectional view of another pipe structure (pipe structure III (500C)) that can be reinforced with the composite tape of the present invention is described. In this example, pipe 500C includes an outer jacket 550 and two layers of composite tape (510e, 510f), each layer of composite tape consisting of a fiber-reinforced tape layer (512), an adhesive layer (516), and a metal barrier layer (514). Figure 5C and Figure 5BThe difference lies in the fact that the metal barrier layer of the first composite tape 510f contacts the outer surface of the inner liner 540, and the relative main surface of the fiber-reinforced tape of the composite tape 510e contacts the inner surface of the outer jacket layer 550. The outer and inner layers are each composed of thermoplastic plastics (such as polyethylene), which can be cured and adhered to the composite tape by heating.

[0059] Example

[0060] The following examples are provided to further describe certain aspects of the subject matter and are not intended to be limiting. Those skilled in the art will recognize or be able to determine multiple equivalent schemes of the particular substances and processes described herein using only conventional experiments.

[0061] Example 1

[0062] Fiber-reinforced tapes are prepared using E-glass roving and amorphous polyethylene terephthalate (aPET) granules. The glass roving used in this process has a fineness (TEX) of 56-675. Unidirectional (UD) glass fiber reinforced tapes are used, comprising aPET matrix resin reinforced with 58 wt% glass fibers, an areal density of 0.0803 lb / ft², and a thickness of approximately 0.0100 inches. Aluminum foil (1100 series) with an areal density of 0.028 lb / ft² and a thickness of 2.0 mil is used. The unidirectional glass fiber tape and aluminum foil are thermally bonded together using a twin-belt thermoforming press. Before being introduced into the belt press, both the fiber-reinforced tape and the metal layer are stretched and aligned along their length. Due to the properties of the aPET matrix, the fiber-reinforced tape and the metal layer adhere directly. Both layers are heated and cooled under pressure to implement the curing process. After the aPET is cured onto the aluminum layer, the final composite tape is wound under tension after leaving the press. Overall, the total areal density of the laminated composite tape is 0.108 lb / ft², with a corresponding thickness of approximately 0.012 inches.

[0063] The composite tape can be fed onto a continuous slitting machine to cut it to the desired width and then wound.

[0064] The process parameters for dual-belt lamination include: process temperature of 160-260℃; pressure range of 1-100psi during heating and curing; and lamination linear speed of 0.2-10m / min.

[0065] Example 2

[0066] Another fiber-reinforced tape was prepared as described in Example 1, wherein a unidirectional glass fiber tape comprising an aPET matrix resin reinforced with 58 wt% glass fiber, having an areal density of 0.0803 lb / ft² and a thickness of approximately 0.0100 inches, was used. A 1100 series aluminum foil with an areal density of 0.070 lb / ft² and a thickness of 5.0 mil was used. The combined unidirectional glass fiber tape and aluminum foil were thermally bonded together using a two-belt hot press as described in Example 1. Overall, the laminated composite tape had a total areal density of 0.151 lb / ft² and a corresponding thickness of approximately 0.015 inches.

[0067] Mechanical and permeability properties of composite belts

[0068] The tensile properties of the sample strips were measured on a universal testing machine according to ASTM D3039 (Standard Test Method for Tensile Properties of Polymer Matrix Composites). Prior to measurement, the samples were conditioned at 23.0°C and 50% humidity. A 0°C test orientation was used, and the crosshead speed was 50 mm / min. Table 1 below shows the tensile measurement data.

[0069] Table 1. aPET / Al at 0 Or ASTM D3039 tensile test data parallel to the fiber direction

[0070]

[0071] Sample dimensions: width 0.9341 inches (SD 0.0102), thickness 0.0113 inches (SD 0.0002), area 0.0105 in. 2 (SD is 0.0002).

[0072] Table 2 below compares the tensile measurements of the fiber-reinforced tape of Example 1 and the composite tape including a 2mil aluminum barrier layer.

[0073] Table 2 Comparison of tensile tests for D3039

[0074]

[0075] Peel strength.The adhesion strength of the composite tape to aluminum foil was measured by performing a T-peel test. The fiber-reinforced tape was adhered to the aluminum foil using a continuous laminator operating at 240°C, 85 psi, and a speed of 1.0 m / s. The fiber-reinforced tape and aluminum foil were adhered under uniform heat and pressure to form the composite tape, with the fiber-reinforced tape directly adhered to the aluminum foil without adhesive. Samples for testing were prepared by cutting the composite tape into 1-inch strips. These strips had a 5-inch adhered length and several inches of non-adhesive ends for mounting in a T-peel testing apparatus. The T-peel test was performed according to ASTM D1876 (Standard Test Method for Adhesive Peel Resistance (T-Peel Test)), peeling the samples at room temperature at a speed of 5 inches / min. Figure 6 The average and maximum peel strength of the composite tape samples are described.

[0076] Tear strength. The tear strength of composite tapes is measured by performing a tear test on samples cut using a pre-measured and calibrated cutting die. The samples are cut using a die according to ASTM D624 C (Standard Test Method for Tear Strength of Conventional Vulcanized Rubbers and Thermoplastic Elastomers). Figure 7A The document describes the specific dimensions of the sample and the testing orientation. As shown in the figure, the sample was prepared with a measurement length (L) of approximately 102 mm and a width (W) of 19 mm, and was curved outwards to create a 90° angle in the middle. Notch (N). Stretch each sample in opposite directions along its length at a speed of 2 inches / minute. Orient the fibers in the fiber-reinforced band of the composite tape sample so that the fibers pass through the sample length. Figure 7B and Figure 7C The figures show the tear resistance and maximum tear strength of the composite tape relative to the aluminum foil.

[0077] Permeability measurement. Gas permeability testing equipment is used to test the gas permeability of composite tapes and other materials. Figure 8 A schematic diagram of this testing apparatus is described. As shown, a test sample is used to form a seal between the upper and lower chambers (cavities). One chamber, the lower chamber, is evacuated by subjecting it to a vacuum for a specified time, while the other chamber is filled with a test gas at a specific pressure. The sample is cut using a calibrated cutting die; the sample is circular with a diameter of approximately 97 mm. For each test, a vacuum is applied for 6 hours using helium test gas at 100 kPa and 23°C and 50% relative humidity. The test continues until the pressure in the measuring chamber stabilizes. Helium is used to test permeability because it is safer to handle than hydrogen. Helium permeability is determined by the permeability coefficient (P), which is the volume of gas passing through a unit thickness of sample. Table 3 below provides the permeability coefficients for some test samples.

[0078] Table 3 Helium permeability of the samples

[0079]

[0080] As shown in Table 3 above, the gas permeability of the composite tape with the aluminum foil barrier layer is comparable to that of the aluminum foil itself. The performance of the composite tape is also superior to that of unattached aPET film + aluminum foil, and several orders of magnitude better than other materials.

[0081] Patch / seam testing. Through... Figure 8 The test chamber shown simulates a seam by testing samples. The testing procedure involves cutting a hole in the center of an aluminum foil and covering the foil and hole with a sample of the material to be tested, such as a composite tape. Figure 9 The sample configuration is illustrated. As shown, the base aluminum foil serves as the impermeable layer. When the composite tape sample is placed on the aluminum base, gas flows through a relatively highly permeable thermoplastic matrix, such as the aPET matrix of the aPET composite tape, and exits through a hole in the center of the base aluminum foil. This experiment is believed to simulate the formation of a seam by wrapping the composite tape around a pipe. The hole in the center of the aluminum foil is approximately 0.25 inches in diameter and is cut using a calibrated cutting die. The diameters of the composite tape samples are 0.56 inches, 0.88 inches, 1.0 inches, 1.19 inches, 1.38 inches, and 1.75 inches, to approximate seam widths of 0.31 inches, 0.63 inches, 0.75 inches, 0.94 inches, 1.13 inches, and 1.50 inches. The patch is located in the center of the hole and is heat-sealed onto the aluminum foil using a continuous laminating press or a flatbed press at 240°C, 1.0 m / s, or 1 minute cycle time. The patch was tested in a permeability testing apparatus by evacuating for 6 hours and applying helium test gas at 100 kPa and 23°C and 50% relative humidity. The test continued until the pressure in the measuring chamber stabilized. Figure 10 The results of the patch test are presented, showing the relationship between the gas permeability of the simulated seam and the seam length. As expected, the gas permeability increases as the seam length decreases. However, the gas permeability of the composite strip with the minimum seam length is still significantly lower than that of the samples in Table 3 that do not include the metal barrier layer.

[0082] This document only provides and describes certain features and aspects of the invention, as well as examples of their versatility. It is understood that the techniques disclosed herein can be used in a variety of other combinations and environments, and can be modified or adapted. Therefore, for example, those skilled in the art will recognize or be able to determine many equivalents of the particular substances, procedures, and arrangements described herein through conventional experimentation. These equivalents are considered to be within the scope of the invention and are covered by the following claims.

Claims

1. A composite belt, comprising: A fiber-reinforced strip having a first primary surface and an opposing second primary surface, the fiber-reinforced strip comprising a plurality of unidirectional continuous fibers embedded in a thermoplastic matrix; and A metal barrier layer is adhered to a thermoplastic matrix on the first main surface of the fiber-reinforced tape.

2. The composite tape of claim 1, wherein the fiber reinforcement tape has a width, and the plurality of unidirectional continuous fibers span the entire width or substantially the entire width of the fiber reinforcement tape.

3. The composite strip according to any one of the preceding claims, wherein the thickness of the metal barrier layer is about 0.01-0.5 mm.

4. The composite tape according to any one of the preceding claims, wherein the thermoplastic matrix comprises a polyolefin.

5. The composite tape according to any one of the preceding claims, wherein the thermoplastic matrix comprises polyethylene terephthalate and the metal barrier layer is directly adhered to the thermoplastic matrix.

6. The composite tape according to any one of the preceding claims, wherein the fiber-reinforced tape comprises about 20-60 wt% thermoplastic matrix and about 80-40 wt% multiple unidirectional continuous fibers, based on the total weight of the fiber-reinforced tape.

7. The composite tape according to any one of the preceding claims, wherein the plurality of unidirectional continuous fibers comprises at least one of glass fiber, aramid fiber, basalt fiber, carbon fiber, or a combination thereof.

8. The composite tape according to any one of the preceding claims, wherein the average diameter of each of the plurality of unidirectional continuous fibers is about 1-40 µm.

9. The composite tape according to any one of the preceding claims, wherein the plurality of unidirectional continuous fibers are in the form of filament bundles, yarns, monofilaments, filament cakes or rovings.

10. The composite tape of claim 9, wherein the average linear mass density of the filament bundle, yarn, monofilament, filament cake or roving is 100 TEX to 4400 TEX.

11. The composite tape according to any one of the preceding claims, wherein the plurality of unidirectional continuous fibers are plurality of unidirectional continuous glass fibers.

12. The composite tape of claim 11, wherein the plurality of unidirectional continuous fibers comprises a sizing composition comprising a film-forming agent, a lubricant, a coupling agent, or a combination thereof.

13. The composite tape according to any one of the preceding claims, wherein the composite tape comprises a first layer of fiber reinforcement tape, wherein the plurality of unidirectional continuous fibers are oriented along a first direction, and the composite tape further comprises a second layer of fiber reinforcement tape, wherein the plurality of unidirectional continuous fibers in the second layer are oriented relative to the first direction of the plurality of unidirectional continuous fibers in the first layer of fiber reinforcement tape at an angle greater than 0. And less than or equal to 90 Angle and orientation.

14. The composite tape according to any one of the preceding claims, wherein the composite tape comprises a first layer of fiber reinforcement tape, wherein the plurality of unidirectional continuous fibers are oriented along a first direction, and the composite tape further comprises a second layer of fiber reinforcement tape, wherein the plurality of unidirectional continuous fibers in the second layer are oriented at approximately 90 degrees relative to the first direction of the plurality of unidirectional continuous fibers in the first layer of fiber reinforcement tape. Angle and orientation.

15. The composite tape of claim 13 or 14, wherein the second fiber-reinforced tape is adhered to the opposite second main surface of the first fiber-reinforced tape.

16. The composite tape of claim 13 or 14, wherein the metal barrier layer has a first main surface and an opposing second main surface, the first layer of fiber reinforcement tape is adhered to the first main surface of the metal barrier layer, and the second layer of fiber reinforcement tape is adhered to the opposing second main surface of the metal barrier layer.

17. The composite strip according to any one of the preceding claims, wherein the metal barrier layer comprises aluminum, steel, copper, tin, metal alloys, or combinations thereof.

18. The composite tape according to any one of the preceding claims, wherein the metal barrier layer is directly adhered to the main surface of the first fiber-reinforced tape without the need for an adhesive.

19. The composite strip according to any one of the preceding claims, wherein the helium permeability of the composite strip is less than about 10. -12 (cm 3 cm) / (cm 2 s (cmHg).

20. A fiber-reinforced conduit, comprising: Inner and outer surfaces; and The composite tape as described in any of the preceding claims is wrapped around the outer surface of the pipe.

21. The fiber-reinforced conduit of claim 20, wherein the composite tape is spirally wound along the longitudinal direction of the conduit on the outer surface of the conduit.

22. A fiber-reinforced conduit, comprising: A first layer, a second layer, and an outer layer, wherein the second layer comprises the composite tape as described in any one of claims 1-19.

23. The fiber-reinforced conduit of claim 22, wherein the composite tape is spirally wound along the longitudinal direction of the conduit on the first layer.

24. The fiber-reinforced conduit of claim 22 or 23, wherein the fiber-reinforced conduit is flexible.

25. The fiber-reinforced conduit according to any one of claims 22-24, wherein the composite tape comprises a first composite tape and a second composite tape spirally wound on the first composite tape.

26. The fiber-reinforced conduit of claim 25, wherein the first composite tape is spirally wound on the first layer along the longitudinal direction of the conduit, and the second composite tape is spirally wound on the first composite tape in the opposite direction to the first composite tape.

27. The fiber-reinforced conduit according to any one of claims 22-27, comprising 2-12 layers of composite tape.

28. A fiber-reinforced conduit, comprising: Inner and outer surfaces; and A reinforcing barrier layer surrounding the outer surface of the pipe, The reinforcing barrier layer comprises a first composite strip wound longitudinally along the pipe to form a first layer, wherein adjacent composite strips form a first joint in the layer, and a second composite strip wound along the first layer to form a second layer, wherein the second composite strip overlaps the joint by at least 1 / 3 of its width; and The first and second composite tapes comprise the composite tapes as described in any one of claims 1-19.

29. The fiber-reinforced conduit of claim 28, wherein the helium permeability coefficient of the reinforcing barrier layer on the outer surface of the conduit is less than about 10. -12 (cm 3 cm) / (cm 2 s (cmHg).

30. A method for preparing fiber-reinforced pipes, comprising: The outer surface of the pipe is completely covered with the composite tape according to any one of claims 1-19; and Heat the composite tape and / or pipe to adhere the composite tape to the pipe.

31. The method of claim 30, further comprising applying a jacket layer to the composite tape.

32. The method of claim 30, wherein the helium permeability of the composite band is less than about 10. -12 (cm 3 cm) / (cm 2 s (cmHg).

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