Manufacturing method for manufacturing strip of composite material intended to form tubular structure, and corresponding device

Abstract

Manufacturing method and corresponding apparatus for manufacturing a strip of composite material intended to form a tubular structure. The method comprises:-docking the end regions (64A, 64B) of the unconnected band portions (60A, 60B); -applying heat and pressure to form a weld joint between the end regions (64A, 64B); at least one end region (64A, 64B) has a rear region (72A, 72B) and a front region (66A, 66B) projecting from the rear region (72A, 72B), the front region (66A, 66B) being delimited by two side edges (68, 70), each side edge having at least one point spaced from a respective extension of each side edge (74, 76) of the rear region (72A, 72B). When the end regions (64A, 64B) are docked together, the front region (66A) of the end region (60A) of the first belt portion (60A) is opposite the end region (64B) of the second belt portion (60B).

Description

Technical Field

[0001] The invention relates to a manufacturing method for manufacturing a composite material strip intended to form a tubular structure, comprising the following steps:

[0002] - butting together the end regions of unconnected strips, each strip being formed from a polymer matrix and fibers or films embedded in the polymer matrix,

[0003] - Applying heat and pressure to create a weld joint between the end regions. Background Art

[0004] Such composite tapes are intended, for example, to form tubular structures of pipes, in particular thermoplastic composite pipes (TCP) or hybrid flexible pipes (HFP).

[0005] Such a tubular structure is made by winding at least one composite tape around a support and welding together successive tape turns using high temperature welding, for example using a laser.

[0006] This technique is particularly suitable when the composite tape comprises a polyetheretherketone (PEEK) matrix which, in combination with the reinforcing fibers it contains, provides excellent mechanical properties to the tubular structure.

[0007] Such a pipe thus has the advantage of being lightweight but at the same time highly resistant to internal pressures within the pipe or to external pressures applied to the pipe.

[0008] Currently, composite strips intended to form such internal structures are produced by fabricating a plurality of unitary strip portions which are then butt-welded together to produce a greater length of strip compatible with the length of the tube to be produced.

[0009] The welded joint is formed between the free ends of successive strips. In this regard, document WO 2021 / 094718 describes a method for welding on a composite strip. The end regions of the strips are brought close together and butt-welded together after heating.

[0010] Even if the welding is done very carefully, any significant variation in thickness at the joint when the ribbon coils are exposed to the laser to create the tubular structure can result in a local temperature increase at the joint that can reach over 550°C.

[0011] At this temperature, localized burning or flashing may occur. Burnt debris, contaminants or holes may form around the joint. In addition, crack initiation and / or adhesion defects may occur in this area.

[0012] These phenomena occurring at the joints between belt portions are therefore troublesome, since the maximum achievable length of a unit belt portion is typically about 500 meters, which means that if the belt has a considerable length, there will be a plurality of joints along the belt. Summary of the invention

[0013] It is therefore an object of the present invention to provide a method of manufacturing a composite tape from butted elemental tape portions without the need for adhesives or glues, wherein the subsequent welding of the composite tape to form a tubular structure is not significantly affected by the presence of the joints between the elemental tape portions.

[0014] To this end, the invention is directed to a manufacturing method as described above, characterized in that at least one end zone has a rear zone and a front zone, in which the side edges of the strip are parallel to one another, from which the front zone projects, the front zone being delimited by two side edges, each side edge of the front zone having at least one point, in particular at least one section, located spaced apart from and between a respective extension of each side edge of the rear zone,

[0015] When the end regions are butted together, a front region of the end region of the first strap portion opposes the end region of the second strap portion.

[0016] The method according to the invention may include one or more of the following features, taken alone or in any technically possible combination:

[0017] - applying heat and pressure comprises inductively heating a heating zone of the metal support, on which the end zone of the strip is arranged;

[0018] - the method comprises arranging an induction coil opposite to a heating zone of the metal support and circulating a variable current through said induction coil to generate heat by the Joule effect through the current induced in the heating zone;

[0019] The method comprises moving a wedge for exerting pressure on the heating zone, exerting pressure on the end zone of the belt between the metal support and the wedge;

[0020] at least one side edge of the front region is an inclined side edge, the inclination of which in the end region is between 20° and 80°, in particular between 30° and 60°, even more particularly between 35° and 55°, relative to the longitudinal axis of the belt portion, when the end regions are butted together;

[0021] - when the end regions are butted together, the front region of the end regions comprises an inclined side edge and an additional inclined side edge, the additional inclined side edge being inclined relative to the longitudinal axis of the belt portion at an angle opposite to the angle of inclination of the inclined side edge relative to the longitudinal axis of the belt portion;

[0022] - said additional inclined side edge intersects said inclined side edge at the end point of the strip portion;

[0023] - each end region has a rear region in which the side edges of the belt portions are parallel to each other, and a front region protruding from the rear region, the front region being delimited by two side edges, each side edge of the front region having at least one point, in particular at least one section, located spaced from a corresponding extension of each side edge of the rear region and between these corresponding extensions of each side edge of the rear region, the front region of the end region of the first belt portion being opposite the rear region of the end region of the second belt portion when the end regions are butted together;

[0024] - the application of heat and pressure to weld the end regions together is performed without applying material, in particular without applying a film to the surface of each end region;

[0025] - when the end regions are butted together, the overlap between the end region of the first belt portion and the end region of the second belt portion, measured along the longitudinal axis of each end region, is greater than 10 mm, in particular between 15 mm and 30 mm;

[0026] - the polymer matrix is ​​made of a polymer selected from the following materials: PEK (polyetherketone), PEEK (polyetheretherketone), PEEKK (polyetheretherketoneketone), PEKK (polyetherketoneketone), PEKEKK (polyetherketoneetherketoneketone), PAI (polyamideimide), PEI (polyetherimide), PSU (polysulfone), PPSU (polyphenylsulfone), PES (polyethersulfone), PAS (polyarylsulfone), PPE (polyphenylene ether), PPS (polyphenylene sulfide), LCP (liquid crystal polymer), PPA (polyphthalamide), their copolymers and / or mixtures; wherein the fibers are selected from carbon fibers, glass fibers, aramid fibers and / or basalt fibers, the fibers advantageously forming a mat, or wherein the membrane is an unfilled polyketone yarn, in particular PEEK (polyetheretherketone) yarn.

[0027] The invention also aims at the use of at least one composite material strip produced by the manufacturing method as described above for forming, advantageously by winding and heating, a tubular structure, in particular a flexible pipe.

[0028] The invention also relates to a plant for manufacturing a composite material strip intended to form a tubular structure, comprising:

[0029] a supply or manufacturing station capable of supplying unconnected belt portions, each belt portion being formed of a polymer matrix and fibers embedded in the polymer matrix,

[0030] A welding station comprising: a support having a heating zone intended to butt the end zones together; and heat and pressure applying means for producing a welded joint between the end zones,

[0031] It is characterized in that the supply and manufacturing station comprises a cutting device, which is configured to form at least one end area, the at least one end area having a rear area in which the side edges of the belt portion are parallel to each other, and a front area protruding from the rear area, the front area being delimited by two side edges, each side edge of the front area having at least one point, in particular at least one section, which is positioned to be spaced apart from a corresponding extension of each side edge of the rear area and between these corresponding extensions of each side edge of the rear area.

[0032] The device according to the invention may include one or more of the following features, taken alone or in any technically possible combination:

[0033] - the support is a metal support, the heat and pressure applying means are capable of inductively heating a heating area of ​​the metal support, the end area of ​​the belt portion is arranged on the heating area, the heat and pressure applying means comprises an induction coil positioned opposite to the heating area of ​​the metal support, and a variable current source capable of supplying power to the induction coil to generate heat by the Joule effect through the current induced in the heating area;

[0034] - the heat and pressure applying means comprise a movable wedge for applying pressure on the heating zone, the movable wedge being able to apply pressure on the end zone of the belt located between the metal support and the wedge;

[0035] The cutting device comprises a base defining a recess for receiving the belt portion, a cutting wedge movably mounted relative to the base between a position for loading / unloading the belt portion and a position for cutting the belt portion, the cutting device advantageously also comprising a guide for guiding the movement of the cutting wedge. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The invention will be better understood by reading the following description, given by way of example only and made with reference to the accompanying drawings, in which:

[0037] - Figure 1 is a schematic diagram of a composite material tape obtained by the manufacturing method according to the present invention;

[0038] - Figure 2 is a schematic representation of two composite strip portions, each having a free end region in the form of a pointed end, to be butt-welded together when carrying out the method according to the invention;

[0039] - Figure 3 is a partial schematic perspective view of a welding station of a first apparatus for manufacturing a composite strip according to the present invention;

[0040] - Figure 4 is a schematic diagram showing a block diagram of an apparatus for manufacturing a flexible pipe, the flexible pipe comprising Figure 1 A tubular structure made of a composite tape;

[0041] - Figure 5 is a schematic diagram of a laser welding station for a composite strip manufactured by the method according to the present invention;

[0042] - Figure 6 is a partially exploded perspective view of an example of a flexible pipe comprising a tubular structure made of a plurality of composite strips obtained by the method according to the present invention; and

[0043] - Figure 7 is a schematic perspective view of a cutting device for producing composite strip portions to be welded together. DETAILED DESCRIPTION

[0044] The method according to the invention aims at producing a composite material strip 2, an example of which is Figure 1 The composite tape will be referred to as "composite tape" hereinafter.

[0045] The composite tape 2 is intended to be wound and welded to produce a tubular structure 4 , in particular an inner tubular structure 4 of a flexible fluid-conveying pipe 10 , an example of which can be seen in FIG. 6 .

[0046] exist Figure 6 In the example of FIG. 1 , the flexible pipe 10 is, for example, a thermoplastic composite pipe (TCP) or a hybrid flexible pipe (HFP).

[0047] The tubular structure is, for example, a tubular structure 4 for reinforcing a flexible pipe 10 .

[0048] The flexible pipe 10 comprises Figure 6 The central section 12 is partially shown in FIG. 1 . The flexible tube comprises a terminal fitting (not visible) at each axial end of the central section 12 .

[0049] Reference Figure 6 The tube 10 defines an internal passage 13 for the circulation of a fluid, advantageously a petroleum fluid. The internal passage 13 extends along the axis AA' between the upstream and downstream ends of the tube 10. The internal passage leads out through a terminal fitting.

[0050] The flexible pipe 10 is intended to be arranged in a fluid, in particular hydrocarbon production facility, across a body of water. The body of water is, for example, a sea, a lake or an ocean. The depth of the body of water below the fluid production facility is, for example, between 500 and 4000 meters. The fluid production facility comprises a surface component and a bottom component (not shown) or two surface components, which are advantageously connected to each other by the flexible pipe 10.

[0051] For example, the surface component is floating. It is advantageously formed by a floating production, storage and offloading (FPSO) unit, a floating liquefied natural gas (FLNG) unit, a semi-submersible platform or an offloading buoy. Alternatively, the surface component may be a rigid, fixed jacketed structure or a swinging structure attached to the seabed, such as a TLP (tension leg platform).

[0052] In this example, the flexible pipe 10 is a partially or fully submerged riser connecting a bottom assembly to a surface assembly. Alternatively, the flexible pipe 10 is fully submerged in a body of water, for example connecting two bottom assemblies (not shown) to each other.

[0053] Another alternative is a flexible pipe 10 partially submerged in the water body, for example connecting two surface components (usually an offloading buoy and a FPSO). This is especially true for flexible OOL pipelines (Oil Offloading Lines).

[0054] like Figure 6 As shown, the tube 10 defines, around the axis AA′, a plurality of concentric layers which extend continuously along a central zone 12 to terminal fittings situated at the ends of the tube.

[0055] exist Figure 6 In the example of the embodiment of the present invention, the tube 10 comprises: at least one tubular inner sheath 20 based on polymer material, which advantageously constitutes a pressure sheath; and a reinforcing tubular structure 4, applied around the tubular sheath 20, bonded to the sheath. Alternatively, the tube 10 has no tubular inner sheath 20, so that the reinforcing tubular structure 4 is watertight.

[0056] The tube 10 also advantageously comprises a plurality of tensile armour layers 24 , 25 arranged externally with respect to the reinforcing tubular structure 4 , not bonded thereto.

[0057] Advantageously, depending on the intended use, the tube 10 also comprises an anti-wear layer 26 interposed between the reinforcing tubular structure 4 and the tensile armour layers 24, 25, as well as within these tensile armour layers 24, 25. It also advantageously comprises a reinforcing tape 28 wound around the tensile armour layers 24, 25 and an outer sheath 30 intended to protect said tube 10.

[0058] As is known, the tubular sheath 20 is intended to contain sealingly the fluid conveyed in the channel 13. The tubular sheath 20 also has the function of protecting the reinforcing tubular structure 4 from wear caused by abrasive particles present in the fluid conveyed through the channel 13, such as sand.

[0059] The tubular sheath 20 is formed of a polymer material, preferably a thermoplastic. For example, the polymer forming the tubular sheath 20 is based on a polyolefin such as polyethylene, on a polyamide such as PA11 or PA12, or on a fluoropolymer such as polyvinylidene fluoride (PVDF).

[0060] Alternatively, the tubular sheath 20 is formed of a high-performance polymer such as PEK (polyetherketone), PEEK (polyetheretherketone), PEEKK (polyetheretherketoneketone), PEKK (polyetherketoneketone), PEKEKK (polyetherketoneetherketoneketone), PAI (polyamideimide), PEI (polyetherimide), PSU (polysulfone), PPSU (polyphenylsulfone), PES (polyethersulfone), PAS (polyarylsulfone), PPE (polyphenylene ether), PPS (polyphenylene sulfide), LCP (liquid crystal polymer), PPA (polyphthalamide) and / or mixtures thereof, or mixtures with PTFE (polytetrafluoroethylene) or PFPE (perfluoropolyether).

[0061] The thickness of the tubular sheath 20 is, for example, between 1 mm and 20 mm.

[0062] The tubular sheath 20 is formed from a tube of polymer material, an assembled polymer material strip, or an impregnated polymer mat.

[0063] When the tubular sheath 20 is formed by a tube, it is advantageously obtained by extrusion of a thermoplastic tube, in particular chosen from the polymers mentioned above.

[0064] When the tubular sheath 20 is formed by assembling a polymer material strip, it is advantageously produced by extruding and winding a thermoplastic strip of polymer material as described above. Preferably, the turns of the first layer are continuous (edge ​​to edge, without overlap), and the turns of the upper layer are arranged so that two adjacent lower strips overlap to ensure the sealing of the tubular sheath 20.

[0065] According to a preferred embodiment, the flexible tube 10 has no internal framework and is referred to as a “smooth bore.” The inner surface of the tubular sheath 20 directly defines the inner passage 13 .

[0066] According to an alternative not shown, the flexible pipe comprises an internal framework, called "coarse hole", located inside the tubular sheath 20. The function of the internal framework is to increase the compression resistance of the flexible pipe and it is formed, for example, by a helically wound profiled metal strip. Advantageously, the turns of the strip are hooked to each other, thus allowing the compression forces to be absorbed.

[0067] exist Figure 6 In the example shown, the flexible pipe 10 includes an outer armour layer 25 and an inner armour layer 24 around which an outer sheath 30 is arranged.

[0068] Each armour layer 24 , 25 comprises longitudinal armour elements 50 wound with a long pitch around the axis AA′ of the tube.

[0069] “Wound with a long pitch” means that the absolute value of the helix angle relative to the axis AA is less than 50°, typically between 25° and 45°.

[0070] The armor elements 50 of the first layer 24 are usually wound at an opposite angle relative to the armor elements 50 of the second layer 25. Thus, if the armor elements 50 of the first layer 24 are wound at an angle equal to +φ (where φ is between 25° and 45°) relative to the axis A-A', then the armor elements 50 of the second layer 25 arranged in contact with the first layer 24 are wound at an angle of, for example, -φ (where φ is between 25° and 45°) relative to the axis A-A'.

[0071] The armor element 50 is formed, for example, from metal wires. Alternatively, the armor element 50 is formed from composite flat wires or tapes reinforced with carbon fibers.

[0072] The reinforced tubular structure 4 may have a low tensile strength and tend to stretch under the action of an axial force, while the armour layers 24, 25 bear the axial force and thus prevent the tubular structure 4 from stretching.

[0073] The outer sheath 30 is intended to prevent fluids from penetrating from the outside to the inside of the flexible tube 10. Advantageously, the outer sheath is made of a polymer material, in particular a polyolefin-based material such as polyethylene, a polyamide-based material such as PA11 or PA12, or a fluoropolymer-based material such as polyvinylidene fluoride (PVDF).

[0074] The thickness of the outer sheath 30 is, for example, between 5 mm and 15 mm.

[0075] Each wear layer 26 is formed, for example, of PA (polyamide), PE (polyethylene), PVDF (polyvinylidene fluoride), PEEK (polyetheretherketone), PEKK (polyetherketoneketone). One wear layer 26 is arranged between the reinforcing tubular structure 4 and the first tensile armor layer 24. Another wear layer 26 is positioned between each pair of armor layers 24, 25, advantageously as specified in API Standard 17J (4th edition, May 2014).

[0076] The reinforcement tape 28 is formed, for example, by a high-strength anti-buckling layer. This layer is made, for example, of aramid. Advantageously, as indicated in API Standard 17J (4th edition, May 2014), the reinforcement tape is wound around the outermost armor layer 25, between the armor layer 25 and the outer sheath 30.

[0077] In this example, the reinforcing tubular structure 4 is applied directly to the tubular sheath 20. The reinforcing tubular structure is assembled on the tubular sheath 20 to form an assembly bonded to the tubular sheath 20.

[0078] The reinforced tubular structure 4 is a composite structure, which comprises at least one, preferably a plurality of laminated composite reinforcement layers, and optionally also comprises an anti-delamination layer interposed between at least two reinforcement layers.

[0079] Each laminated reinforcement layer comprises a stack of multiple reinforcement composite layers. The thickness of each reinforcement composite layer is generally between 0.10 mm and 0.30 mm, such as between 0.12 mm and 0.17 mm, or between 0.22 mm and 0.27 mm.

[0080] exist Figure 6 In the example shown, each composite reinforcement layer comprises a polymer matrix 40 and reinforcement fibers 42 embedded in the matrix 40. Alternatively, at least one composite reinforcement layer comprises a membrane embedded in the polymer matrix 40.

[0081] Preferably, the matrix 40 is formed of a polymer, in particular a thermoplastic polymer. The polymer of the tubular sheath 20 is advantageously of the same type as the polymer of the matrix 40. "Same type" in the context of the present invention means that the polymer of the tubular sheath 20 and the polymer of the matrix 40 are capable of melting and forming a homogeneous mixture after cooling without phase separation.

[0082] For example, the polymer forming the matrix 40 is based on a polyolefin, such as polyethylene, on a polyamide, such as PA11 or PA12, or on a fluoropolymer, such as polyvinylidene fluoride (PVDF).

[0083] Alternatively, the matrix 40 is formed based on a high-performance polymer, such as PEK (polyetherketone), PEEK (polyetheretherketone), PEEKK (polyetheretherketoneketone), PEKK (polyetherketoneketone), PEKEKK (polyetherketoneetherketoneketone), PAI (polyamideimide), PEI (polyetherimide), PSU (polysulfone), PPSU (polyphenylsulfone), PES (polyethersulfone), PAS (polyarylsulfone), PPE (polyphenylene ether), PPS (polyphenylene sulfide), LCP (liquid crystal polymer), PPA (polyphthalamide) and / or mixtures thereof, or mixtures with PTFE (polytetrafluoroethylene) or PFPE (perfluoropolyether).

[0084] The reinforcing fibers 42 are, for example, carbon fibers, glass fibers, aramid fibers and / or basalt fibers.

[0085] The maximum tensile strength of the reinforcing fibers 42 , as measured at 23° C. according to ASTM standard D885M-10A (2014) e1 , is generally greater than 2 GPa, advantageously greater than 3 GPa, for example between 3 GPa and 6 GPa.

[0086] In the present application, the terms "ultimate tensile strength" and "tensile strength" have the same meaning, and refer to the tensile breaking limit measured in a test in which tension is applied in the longitudinal direction of the reinforcing fiber.

[0087] Furthermore, the reinforcing fibers 42 advantageously have a tensile modulus greater than 50 GPa, for example in the range of 70 GPa to 500 GPa, in particular between 50 GPa to 100 GPa for glass fibers, between 100 GPa to 500 GPa for carbon fibers, and between 50 GPa to 200 GPa for aramid fibers, as measured at 23° C. according to ASTM standard D885M-10A (2014) e1.

[0088] In the present application, the terms "tensile modulus", "Young's modulus" and "tensile elastic modulus" have the same meaning and refer to the elastic modulus measured in a tensile test.

[0089] The density of the reinforcing fiber 42 is generally 1.4 g / cm 3 Up to 3.0g / cm 3 between.

[0090] The reinforcing fibers 42 are arranged, for example, unidirectionally in the matrix 40. Thus, they are parallel to each other. Alternatively, the reinforcing fibers 42 are crossed in two orthogonal directions, or even randomly arranged in the matrix (not shown).

[0091] The diameter of the reinforcing fibers 42 is, for example, less than 100 micrometers. For carbon reinforcing fibers, the diameter is in particular between 4 micrometers and 10 micrometers.

[0092] Preferably, each composite reinforcement layer of the tubular structure 4 is formed by winding at least one composite tape 2 manufactured by the method according to the invention, examples of which can be found in Figure 1 Seen in.

[0093] Each composite tape 2 has a plurality of layers of fibres 42 embedded in an elongated matrix 40. The length of the composite tape is at least 10 times its width and at least 10 times its thickness.

[0094] For example, the length of each composite tape 2 is greater than 100 meters, typically between 100 meters and 4500 meters. In particular, the width of each composite tape 2 is between 6 mm and 50 mm. The thickness of each composite tape is advantageously between 0.1 mm and 1 mm.

[0095] Thus, at 23°C, each composite tape 2 has a tensile modulus greater than 10 MPa, in particular between 30 GPa and 170 GPa, as measured by standard NF EN 2561 of January 1996, an elongation at break greater than 0.3%, in particular between 1% and 5%, as measured by standard NF EN 2561 of January 1996, and a maximum tensile strength greater than 100 MPa, in particular between 350 MPa and 3500 MPa, as measured by standard NF EN 2561 of January 1996.

[0096] Advantageously, each composite strip 2 comprises a PEEK or PVDF matrix reinforced with unidirectional carbon fibers oriented parallel to the longitudinal axis of the strip.

[0097] As will be seen below, during the production of each reinforcement layer, the or each composite tape 2 is helically wound around the axis A-A' of the tubular sheath 20 and heated so that the matrix 40 partially melts and bonds with successive turns of the composite tape 2 and / or with adjacent layers, which may be other reinforcement layers, anti-delamination layers or the tubular sheath 20.

[0098] The absolute value of the winding helix angle γ of each composite tape 2 relative to the axis AA' of the tube 10 is, for example, between 50° and 85°, preferably between 55° and 80°. This ensures that the composite material stretches under the effect of the internal pressure and fully cooperates with the armor layers 24, 25.

[0099] The combination of the winding angle γ of the composite tape 2 having an absolute value between 50° and 85°, advantageously between 55° and 80°, and preferably between 60° and 80°, and the winding angle φ of the reinforcing element 50 having an absolute value between 25° and 45°, prevents the elongation of the reinforced tubular structure 4 through the compensation effect produced by the reinforcing layers 24 and 25.

[0100] The optimal combination between the winding angles γ, φ significantly reduces the stress in the tubular assembly formed by the inner sheath 20 and the reinforcing tubular structure 4, thereby reducing the thickness required to resist bending, internal pressure and / or collapse forces.

[0101] In addition, thanks to the axial rigidity of the reinforced tubular structure 4, the tensile armor layers 24, 25 cooperate with the reinforced tubular structure 4 to better resist axial compression under the external pressure conditions of the deep sea.

[0102] Furthermore, the winding angle φ of the reinforcement element 50 , which is between 25° and 45° in absolute value, combined with the winding angle γ of the composite strip 2 , which is between 50° and 85° in absolute value, allows to compress the reinforced tubular structure 4 , thus reducing the minimum bending radius (“MBR”).

[0103] The permissible tensile deformation at the outer arch of the tubular assembly formed by the inner sheath 20 and the reinforcing tubular structure 4 is greater than 1%, advantageously greater than 2%, preferably greater than 3%. This deformation results in a winding radius compatible with most manufacturing and installation equipment.

[0104] According to the present invention, referring to Figure 1 The composite strip 2 is formed of a plurality of strip portions 60A, 60B, which are butt-welded together to form a joint 62 .

[0105] The number of belt portions 60A, 60B butted together to form belt 2 is, for example, greater than or equal to two, in particular between 2 and 20.

[0106] The number of strip portions 60A, 60B may be equal to two, in particular when strip 2 breaks during the manufacturing process, or if a visible defect in strip 2 is noticed when the machine is stopped.

[0107] The number of belt portions 60A, 60B may be greater, in particular when manufacturing long belts 2, for example with a belt length greater than 350 meters, in particular of the order of 1000 meters. In this case, at least 3 belt portions 60A, 60B of the order of 300 meters are assembled.

[0108] like Figure 2 As shown in FIG. 1 , each belt portion 60A, 60B includes a polymer matrix 40 and reinforcing fibers 42 as described above.

[0109] Each strip portion 60A, 60B has an end region 64A, 64B intended to be applied to the end region 64B, 64A of the other strip portion 60B, 60A in order to form the joint 62 by welding.

[0110] exist Figure 2 In the example shown, each end zone 64A, 64B comprises a convex front zone 66A, 66B having at least one edge 68, 70 inclined relative to the longitudinal axis F-F' of the belt portion 60A, 60B. Each end zone also has a rear zone 72A, 72B having side edges 74, 76 parallel to each other and to the axis F-F', the rear zone 72A, 72B being intended to be brought into contact with the front zone 66B, 66A of the other belt portion 60B, 60A.

[0111] As will be seen below, superimposing two end zones 64A, 64B having convex front zones 66A, 66B surprisingly allows obtaining an assembly that retains sufficient flexibility for winding and unwinding the strip 2, despite the increased thickness relative to a male-female splice.

[0112] The excess thickness is distributed symmetrically and reaches a maximum at the imaginary line 71, which is the intersection of the two convex front areas 66A and 66B. However, this excess thickness is much smaller than the case where the end areas without the bevel overlap. In addition, the shear stress decreases toward the imaginary line 71, but increases until the tip of the front areas 66A, 66B.

[0113] In this example, the length of the end regions 64A, 64B is greater than 5 mm, in particular greater than 10 mm, for example between 15 mm and 25 mm. This length corresponds to the length of the joint 62 on the composite strip 2 obtained after welding.

[0114] Preferably, the length H of each front region 66A, 66B is between 1 / 3 of the width L of the rear region 72A, 72B and the width L of the rear region 72A, 72B.

[0115] In particular, the length H is between 5 mm and 15 mm, in particular between 8 mm and 12 mm.

[0116] The width L is advantageously between 10 mm and 30 mm, in particular 12 mm, 18 mm, 22 mm or 25 mm.

[0117] Thus, each joint 62 has minimal excess thickness while maintaining sufficient tensile strength and curvature during installation.

[0118] As will be seen below, this configuration allows the energy of the laser beam intended to assemble the reinforced tubular structure 4 to remain substantially constant despite the presence of local excess thickness.

[0119] This unexpectedly avoids changes in the laser beam energy following changes in the thickness of the strip 2, thereby avoiding changes in the heating temperature of the strip 2 which could repeatedly reach 550°C.

[0120] Problems associated with overheating or underheating are thus largely avoided. As is well known, the slightest overheating can cause flashing or, conversely, the slightest underheating can lead to insufficient melting of the tape (non-consolidation or non-gluing, resulting in delamination or blistering).

[0121] Another surprising advantage of stacking the end regions 64A, 64B with convex front regions 66A, 66B is that the reinforcing fibers 42 are bonded over sufficient length to withstand stress. The excess matrix 40 fills and impregnates the shorter fibers 42 along the width at a distance from the center, just like there is no joint. Surprisingly, the microscopic cross section of the joint 62 does not show any singularity.

[0122] Each front region 66A, 66B projects from a respective rear region 72A, 72B. The front region is delimited by two side edges 68, 70, each of which has at least one point, in particular at least one section, located spaced from a respective extension of each side edge 74, 76 of the rear region 72A, 72B.

[0123] Thus, the width of the front zone 66A, 66B at its free end is strictly smaller than the width of the rear zone 72A, 72B. Advantageously, the width of the front zone 66A, 66B decreases continuously from the rear zone 72A, 72B towards the free end.

[0124] Advantageously, each front region 66A, 66B comprises an inclined edge 68 and an additional inclined edge 70 extending on both sides of the longitudinal axis F-F'. In this example, the inclined edge 68 and the additional inclined edge 70 intersect on the strip 60A, 60B and together define an end point 78 of the strip 60A, 60B. Thus, the front region 66A, 66B has a triangular shape with the end point 68 as a vertex.

[0125] The inclination angle θ of the inclined edge 68 relative to the longitudinal axis FF′ is, for example, between 20° and 80°, in particular between 30° and 60°, even more particularly between 35° and 55°.

[0126] Advantageously, the additional inclined edge 70 has an inclination angle −θ that is opposite to the inclination angle θ of the inclined edge 68 .

[0127] The inclination angle -θ of the additional inclined edge 70 is, for example, between -20° and -80°, in particular between -30° and -60°, even more particularly between -35° and -55°.

[0128] The length H of the front zone 66A, 66B measured along the axis FF' between the projection of the intersection of the inclined edges 68, 70 with the corresponding side edges 74, 76 on the axis FF' and the end point 78 is equal to the length of the rear zone 72A, 72B, which is intended to receive the front zone 66B, 66A of the other belt portion 60B, 60A.

[0129] The method for manufacturing the belt 2 is Figure 3 embodied in a manufacturing apparatus schematically represented in FIG.

[0130] The device advantageously comprises a supply or manufacturing station 82 for supplying or manufacturing the strips 60A, 60B, which station optionally comprises cutting means 84 for cutting out each inclined edge 68, 70. The device comprises a welding station 86 intended to weld together the end regions 64A, 64B thus formed.

[0131] The supply or manufacturing station 82 is capable of supplying or manufacturing composite tape portions 60A, 60B having a matrix 40 and fibers 42 as described above.

[0132] The maximum length of the strips 60A, 60B formed in the station 82 is, for example, less than 5000 meters. This length is, for example, greater than 350 meters, in particular between 500 meters and 1500 meters.

[0133] In one embodiment, the strips 60A, 60B initially supplied or manufactured by the station 82 are rectangular in profile. Then, the cutting device 84 is able to cut out each inclined edge 68, 70 in the end region 64A, 64B of each strip 60A, 60B. The cutting is performed with a blade and / or laser cutting.

[0134] exist Figure 7 In the example shown, the cutting device 84 comprises a base 200 defining a groove 202 for receiving the belt portion, a cutting wedge 204, and the cutting wedge 204 is movably mounted relative to the base 200 between a position for loading / unloading the belt portions 60A, 60B and a position for cutting the belt portions 60A, 60B. The cutting device 84 advantageously comprises a guide 206 for guiding the movement of the cutting wedge 204.

[0135] The base 200 has a cut end 208 having the same contour as the front region 66A, 66B of each end region 64A, 64B.

[0136] The cutting wedge 204 also has a cutting end 210 having the same contour as the front region 66A, 66B of each end region 64A, 64B. The cutting end 210 is provided with at least one blade 211 extending along the contour of the cutting end 210 toward the base 200.

[0137] The movement guide 206 is formed, for example, by a number of parallel rods 212 protruding from the base 200. Each rod 212 is housed in a complementary through-channel 214 formed through the cutting wedge 204.

[0138] To carry out the cutting, the strip portion 60A, 60B with a rectangular profile, initially supplied or manufactured by the station 82 , is introduced into the groove 202 of the base 200 , the cutting wedge 204 occupying its loading / unloading position.

[0139] The cutting wedge 204 is then transferred to its cutting position adjacent the base 200. The blade 211 at the cutting end 210 cuts the side edges 68, 70 of the front regions 66A, 66B along the contour of the cutting end 208 of the base 200.

[0140] Alternatively, the strip portions 60A, 60B supplied or manufactured by the station 82 have the or each inclined edge 68, 70 in the end region 64A, 64B of each strip portion 60A, 60B. In this case, the apparatus is devoid of the cutting station 84.

[0141] like Figure 3 As shown, the welding station 86 comprises a metal support 88 intended to be heated preferably by induction, advantageously also at least one induction coil 90 intended to be positioned opposite a heating zone 91 of the metal support 88, and at least one movable wedge 92 for applying pressure.

[0142] Alternatively, welding station 86 includes a non-inductive heating device.

[0143] The wedge 92 is movable relative to the metal support 88 between a retracted position for seating the end regions 64A, 64B of the belt portions 60A, 60B and a position for applying pressure to the end regions 64A, 64B of the belt portions 60A, 60B.

[0144] The metal support 88 has an upper surface 94 intended to receive in abutment each strip portion 60A, 60B with the end regions 64A, 64B superimposed on one another in the heating zone 91 opposite the induction coil 90 .

[0145] The metal support 88 is made of, for example, aluminum or tool steel.

[0146] The induction coil 90 can be supplied with a variable current from a source (not shown) to generate an induced current in a heating zone 91 of the metal support 88 opposite the coil 90 capable of heating the metal support 88 by the Joule effect.

[0147] The thickness of the metal support 88 up to the surface 94 measured in the heating region 91 opposite the induction coil 90 is, for example, less than 5 mm, in particular between 1 mm and 3 mm.

[0148] The current induced by the coil 90 in the heating zone 91 is able to raise the temperature of the metal support 88 within the heating zone 91 to a temperature above the melting temperature of the polymer, i.e. 340° C., in particular for a PEEK matrix, to a temperature between 345° C. and 360° C. Heating by induction current preferably allows obtaining a temperature rise gradient greater than 15° C. / s, in particular between 17° C. / s and 25° C. / s.

[0149] This temperature is sufficient to cause at least partial melting of the polymer matrix 40 of the end regions 64A, 64B.

[0150] The wedge 92 defines internally a recess 96 as a parallelepiped space, the width of which corresponds to the width of the strip 2 measured between the parallel side edges 74 , 76 .

[0151] The wedge 92 is movable relative to an upper surface 94 of the metal support 88 between a retracted position and a position applied to the metal support 88 .

[0152] When applied to the surface 94 , the wedge 92 applies pressure to the overlapping end regions 64A, 64B, thereby ensuring intermixing between the polymer matrix 40 and the reinforcing fibers 42 of each end region 64 , 64B to produce the joint 62 after cooling.

[0153] The method of manufacturing the composite strip 2 in the apparatus will now be described.

[0154] Initially, the belt portions 60A, 60B are manufactured separately from each other and / or supplied to a supply and / or manufacturing station 82 .

[0155] In the case where the strip portions 60A, 60B initially have a rectangular profile, the end regions 64A, 64B are fed into a cutting device 84 to be cut therein and form the beveled edge 68 and the additional beveled edge 70 with the bevel angles θ or −θ as described above.

[0156] Once this operation is completed, the belt portions 60A, 60B are arranged on the upper surface 94 of the metal support 88 .

[0157] In the heating region 91 , the front region 66A of the end region 64A of the first belt portion 60A is arranged in contact with and above the rear region 72B of the end region 64B of the second belt portion 60B.

[0158] Thus, the front region 66B of the end region 64B of the second belt portion 60B is arranged below the rear region 72A of the end region 64A of the first belt portion 60A.

[0159] Once completed, the welding station 86 is activated to form the joint 62. To this end, an alternating current is supplied to the induction coil 90, thereby generating an induced current in the metal support 88 and heating the upper surface 94 by the Joule effect.

[0160] This heating causes the polymer matrix 40 of the end regions 64A, 64B to at least partially melt.

[0161] The movable wedge 92 is then moved from its retracted position to a position in which it is applied to the end regions 64A, 64B of the belt portions 60A, 60B. The polymer matrix 40 of the end regions 64A, 64B mixes and forms the joint 62.

[0162] Then, the power supplied to coil 90 is turned off, and polymer matrix 40 in the area of ​​joint 62 cools and solidifies to form joint 62 .

[0163] It should be noted that, even after welding, the trajectory of the inclined edge 68 , 70 of each end zone 64A, 64B is advantageously still visible on the outer surface of the strip 2 .

[0164] The tape 2 is then wound onto a reel for use in Figure 4 The flexible pipe 10 is used in an apparatus 98 for manufacturing the flexible pipe 10 shown schematically in FIG.

[0165] The apparatus 98 comprises a station 100 for supplying the sheath 20 , a possible pre-compacting station 102 , a shaping station 104 for forming the tubular structure 4 , and a possible post-compacting station 106 .

[0166] The apparatus 98 advantageously comprises a winding station 108 for winding the armor layers 24 , 25 and a sheath 30 forming station 110 .

[0167] The station 100 for supplying the sheath 20 is capable of manufacturing and / or deploying the sheath 20 along the longitudinal axis AA' so as to introduce it into the successive stations 102, 104, 106. The sheath 20 thus defines a cylindrical outer surface 112 (see Figure 5 ), a tubular structure 4 is formed on the cylindrical outer surface.

[0168] Figure 5 The forming station 104 is schematically shown in FIG. The forming station comprises a frame 120 defining a central passage 122 for passage of the sheath 20 along the central axis AA', a winding device 124 for winding a plurality of strips 2 in parallel onto the outer surface 112 defined here by the sheath 20, and at least one heating device 126 for heating the strip 2.

[0169] The forming station 104 also includes a compacting device 128 .

[0170] The frame 120 here comprises: a fixed structure fixed to the ground; at least one rotating support element formed by a movable bracket 132, which is rotatably mounted on the fixed structure around a central axis AA'; and a mechanism 134 for driving the movable bracket 132 to rotate relative to the fixed structure.

[0171] The movable bracket 132 includes a roller 136 rotatable about a central axis AA′ and a support member 138 carried by the roller 136 at a distance from the central axis AA′.

[0172] The central passage 122 passes through the drum 136 .

[0173] The winding device 124 is mounted on the support 138 of the movable support 132 to be driven to rotate together with the movable support 32 about the central axis AA′.

[0174] The winding device 124 comprises a plurality of unwinders 142 , and a guide element (not shown) for guiding the strips 2 coming from each unwinder 42 to direct them towards the outer surface 112 while keeping them parallel.

[0175] Each unwinder 142 is respectively capable of unwinding at least one strip 2 intended to form a reinforcement layer.

[0176] Each unwinder 142 includes at least one reel on which at least one tape 2 is wound.

[0177] The guiding element comprises a guide for aligning the belt 2 parallel to each other along axes inclined relative to the central axis A-A' by an angle equal to the helix angle γ, so as to allow the belt 2 from each unwinder 142 to be helically wound onto the outer surface 112 when the movable support 132 rotates about the axis A-A'.

[0178] The heating device 126 is also carried by the support 138 of the movable support 132. The heating device is located opposite the surface 112 in the area where the strip 2 is applied to the outer surface 112. It comprises, for example, a laser, a lamp, in particular a xenon lamp, an infrared lamp, a pulsed lighting device, an ultrasonic welding device and / or a hot air blast device.

[0179] The heating device 126 is able to soften, advantageously melt, the thermoplastic matrix 40 of the strip 2 to allow its complementary application on the outer surface 112 .

[0180] In this example, the compacting device 128 comprises a frame common to the frame 120 of the forming station 104. The compacting device comprises at least one roller system 150 carried by the movable support 132 so as to be driven to rotate together with the movable support 132 about the central axis AA' relative to the outer surface 112. The compacting device 128 also comprises an approach mechanism 152 capable of moving each roller system 150 towards the central axis AA'.

[0181] The compacting device 128 is, for example, of the type described in patent application FR 3 079 162 in the name of the Applicant.

[0182] The method of manufacturing a tubular structure 4 according to the invention in an apparatus 98 will now be described on the example of manufacturing a flexible pipe 10 .

[0183] Initially, the sheath 20 is manufactured and / or supplied in the supply station 100. The sheath is sent to the structure 4 forming station 104 and is translated through the structure 4 forming station 104 along the axis AA' by means of a translation drive.

[0184] Advantageously, before the station 104, the sheath 20 passes through a pre-compacting station 102. The sheath 20 first passes through a heating device 126 to bring its outer surface 112 to a temperature greater than 100°C, in particular between 100°C and 350°C.

[0185] The roller system 150 is driven in rotation around the sheath 20. The rollers are applied to the outer surface 112 so as to make it as cylindrical as possible.

[0186] The sheath 20 is then introduced into the central passage 122 of the forming station 104 .

[0187] In this forming station 104 , a plurality of reinforcement layers are formed from the strip 2 .

[0188] For each reinforcement layer, a plurality of strips 2 are unwound in parallel from the unwinder 142 of the winding device 124. Guide elements keep these strips 2 parallel to each other with a controlled gap.

[0189] The parallel strips 2 pass before a heating device 126 , where they are advantageously heated to a temperature between 150° C. and 450° C., depending on the nature of the thermoplastic polymer constituting the matrix 40 of the strips 2 .

[0190] When the matrix 40 of the strips 2 is made of PEEK (melting point of about 350° C.), the temperature at which the heating device 126 heats the strips 2 is advantageously between 350° C. and 450° C., preferably between 380° C. and 420° C. When the matrix 40 of the strips 2 is made of PVDF (melting point of about 180° C.), the temperature at which the heating device 126 heats the strips 2 is advantageously between 180° C. and 280° C., preferably between 200° C. and 250° C. This advantageously results in at least partial melting of the matrix 40.

[0191] When movable support 132 is driven in rotation about axis AA′ and sheath 20 is translated along axis AA′, band 2 is helically wound on outer surface 112 defined by sheath 20 or by a layer formed around sheath 20 at a helix angle equal to γ.

[0192] Immediately after winding, a roller system 150 driven in rotation co-rotating with the movable support 132 is applied to the belt 2 .

[0193] The tubular structure 4 thus formed then enters the post-compacting station 106. The outer surface 112 of the tubular structure 4 is then softened while passing through a heating device and then compacted again by a rotating roller system 150. The rollers of the roller system 150 roll along the corresponding belt 2 according to a spiral path, thereby ensuring that the degree of disorder of the reinforcement fibers 42 is minimized.

[0194] Advantageously, the operations of pre-compacting (station 102), forming of the tubular structure (station 104) and post-compacting (station 106) are repeated ( Figure 2 A ring 101 on the top) is provided to form a further reinforcement layer with other belts 2 as described above.

[0195] The tubular structure 4 is thus manufactured layer by layer, each pass through the station 104 adding a new outer layer of thickness substantially equal to that of the strip 2. These operations can be repeated several dozen times, in particular when the thickness of the strip 2 is significantly less than the final wall thickness of the tubular structure 4.

[0196] Furthermore, each time a new layer is added, the characteristics and / or laying and / or compacting parameters of the tape 2 can be modified. For example, the helix angle of the tape 2 can be modified, in particular so that the fibers of two superimposed layers cross.

[0197] The tubular structure 4 then passes through a winding station 108 to allow the armouring layers 24 , 25 to be placed.

[0198] The armouring elements 50 of the tensile armour layers 24, 25 are wound around the reinforced tubular structure 3 in a manner that they are not bonded to the reinforced tubular structure 4. Advantageously, a wear resistant layer 26 is interposed between the reinforced tubular structure 4 and the first tensile armour layer 24 and between each pair of tensile armour layers 24, 25.

[0199] Advantageously, a reinforcement tape 28 is then wrapped around the outermost tensile armour layer 25 .

[0200] Then, in the sheath forming station 110 , the sheath 30 is formed around the tensile armor layers 24 , 25 .

[0201] The composite strip 2 manufactured by the method according to the invention is therefore particularly suitable for forming a tubular structure 4 of a flexible pipe 10 in a station 104 comprising a heating device 126 such as a laser.

[0202] For the manufacture of the strip 2, a welding station 86 operated by induction is used in combination with the use of unconnected strip portions 60A, 60B having end regions 64A, 64B having at least one inclined edge 68, 70, which allows a welded joint 62 to be formed between the strip portions 60A and 60B which is strong and durable, has low stiffness and suitable tensile strength, so that it can be unwound from each unwinder 142 and wound onto the outer surface 112.

[0203] The presence of the joint 62, made by welding between the strip portions 60A, 60B using induction heating, avoids the generation of local high temperatures when passing through the station 104, especially when this station comprises a laser heating device 126. No flash or burning effect is observed at the joint 62.

[0204] The joint 62 between the strap portions 60A and 60B remains simple and quick to achieve and does not create holes, debris or areas that exhibit delamination.

[0205] The end regions 64A, 64B of the strip portions 60A, 60B can be easily prepared for welding by simple cutting.

[0206] The application of heat and pressure to weld the end regions 64A, 64B together is performed without applying a film to the surface of each end region 64A, 64B.

[0207] This allows the production of long lengths of continuous strip which are directly used to manufacture tubular structures 4, in particular in flexible pipes 10 for use at great depths.

[0208] In an alternative (not shown), at least one of the end regions 64A, 64B has a convex front area 66A, 66B which is not necessarily triangular.

Claims

1. A method for manufacturing a composite material strip (2) intended to form a tubular structure (4), said method comprising the following steps: - butting together the end regions (64A, 64B) of unconnected belt portions (60A, 60B), each belt portion (60A, 60B) being formed from a polymer matrix (40) and fibers (42) or a membrane embedded in the polymer matrix (40), - applying heat and pressure to produce a weld joint (62) between the end regions (64A, 64B), Characterized in that at least one end region (64A, 64B) has a rear region (72A, 72B) and a front region (66A, 66B), in which the side edges (74, 76) of the belt portion (60A, 60B) are parallel to each other, the front region protrudes from the rear region (72A, 72B), the front region (66A, 66B) being delimited by two side edges (68, 70), each side edge of the front region having at least one point, in particular at least one section, which is positioned spaced apart from and between a corresponding extension of each side edge (74, 76) of the rear region (72A, 72B), When the end regions (64A, 64B) of the first and second strap portions are butted together, the front region (66A) of the end region (60A) of the first strap portion (60A) is opposite to the end region (64B) of the second strap portion (60B).

2. The manufacturing method according to claim 1, wherein: Applying heat and pressure includes inductively heating a heating region (91) of the metal support (88) on which the end regions (64A, 64B) of the belt portions (60A, 60B) are arranged.

3. The manufacturing method according to claim 2, wherein: An induction coil (90) is arranged opposite to a heating region (91) of the metal support (88), and a variable current is circulated through the induction coil (90) to generate heat by the Joule effect through the current induced in the heating region (91).

4. The manufacturing method according to claim 3, wherein: The manufacturing method includes moving a wedge (92) for applying pressure on a heated area (91), applying pressure to the end areas (64A, 64B) of the belt portion (60A, 60B) between the metal support (88) and the wedge (92).

5. The manufacturing method according to any one of the preceding claims, wherein: When the end regions (64A, 64B) are butted together, at least one side edge (68, 70) of the front region (66A; 66B) is an inclined side edge, and the inclination angle (θ) of the inclined side edge (68, 70) relative to the longitudinal axis (F-F') of the belt portion (60A, 60B) in the end region (64A, 64B) is between 20° and 80°, in particular between 30° and 60°, and even more particularly between 35° and 55°.

6. A method of manufacturing according to any one of the preceding claims, wherein: When the end regions (64A, 64B) are butted together, the front region (66A; 66B) of the end regions (64A, 64B) comprises an inclined side edge (68) and an additional inclined side edge (70), wherein the additional inclined side edge (70) is inclined at an angle (θ) opposite to the inclination angle (θ) of the inclined side edge (68, 70) relative to the longitudinal axis (F-F') of the belt portion (60A, 60B).

7. The manufacturing method according to claim 6, characterized in that: The additional inclined side edge (70) intersects the inclined side edge (70) at an end point (78) of the belt portion (60A, 60B).

8. A method of production according to any one of the preceding claims, wherein: Each end region (64A, 64B) has a rear region (72A, 72B) in which the side edges (74, 76) of the belt portion (60A, 60B) are parallel to each other, and a front region (66A, 66B) protruding from the rear region (72A, 72B), the front region (66A, 66B) being delimited by two side edges (68, 70), each side edge of the front region having at least one point, in particular at least one section, wherein the at least one point, in particular at least one section Positioned to be spaced apart from and between a respective extension of each side edge (74, 76) of the rear region (72A, 72B), the front region (66A) of the end region (60A) of the first belt portion (60A) is opposed to the rear region (72B) of the end region (64B) of the second belt portion (60B) when the end regions (64A, 64B) are butted together.

9. The manufacturing method according to any one of the preceding claims, wherein: The application of heat and pressure to weld the end regions (64A, 64B) together is performed without applying material, and in particular without applying a film, to the surface of each end region (64A, 64B).

10. The manufacturing method according to any one of the preceding claims, wherein: When the end regions (64A, 64B) are butted together, the overlap between the end region (64A) of the first belt portion (60A) and the end region (64B) of the second belt portion (60B), measured along the longitudinal axis (F-F') of each end region (64A, 64B), is greater than 10 mm, in particular between 15 mm and 30 mm.

11. The manufacturing method according to any one of the preceding claims, wherein: The polymer matrix (40) is made of a polymer selected from the following materials: PEK (polyetherketone), PEEK (polyetheretherketone), PEEKK (polyetheretherketoneketone), PEKK (polyetherketoneketone), PEKEKK (polyetherketoneetherketoneketone), PAI (polyamideimide), PEI (polyetherimide), PSU (polysulfone), PPSU (polyphenylsulfone), PES (polyethersulfone), PAS (polyarylsulfone), PPE (polyphenylene ether), PPS (polyphenylene sulfide), LCP (liquid crystal polymer), PPA (polyphthalamide), their copolymers and / or mixtures; wherein the fibers (42) are selected from carbon fibers, glass fibers, aramid fibers and / or basalt fibers, the fibers advantageously forming a mat, or wherein the membrane is an unfilled polyketone yarn, in particular PEEK (polyetheretherketone) yarn.

12. Use of at least one composite material tape (2) produced according to the manufacturing method of any of the preceding claims for forming, advantageously by winding and heating, a tubular structure (4), in particular a flexible tube (10).

13. A device for manufacturing a composite material strip (2) intended to form a tubular structure (4), comprising: a supply or manufacturing station (82) capable of supplying unconnected belt portions (60A, 60B), each belt portion (60A, 60B) being formed of a polymer matrix (40) and fibers (42) embedded in the polymer matrix (40), A welding station (86) comprising: a support (88) having a heating zone (91) intended to butt-weld the end zones (64A, 64B); and heat and pressure applying means for producing a weld joint (62) between the end zones (64A, 64B), It is characterized in that the supply and manufacturing station (82) comprises a cutting device (84) configured to form at least one end region (64A, 64B), the at least one end region having a rear region (72A, 72B) in which the side edges (74, 76) of the belt portions (60A, 60B) are parallel to each other, and a front region (66A, 66B) protruding from the rear region (72A, 72B), the front region (66A, 66B) being delimited by two side edges (68, 70), each side edge of the front region having at least one point, in particular at least one section, which is positioned to be spaced apart from a corresponding extension of each side edge (74, 76) of the rear region (72A, 72B) and between these corresponding extensions of each side edge (74, 76) of the rear region (72A, 72B).

14. The device according to claim 13, wherein: The support member (88) is a metal support member, and the heat and pressure applying device is capable of inductively heating a heating area (91) of the metal support member (88), and the end area (64A, 64B) of the belt portion (60A, 60B) is arranged on the heating area. The heat and pressure applying device includes an induction coil (90) positioned opposite to the heating area (91) of the metal support member (88), and a variable current source, which is capable of supplying power to the induction coil (90) to generate heat using the Joule effect through the current induced in the heating area (91).

15. The device according to claim 14, wherein: The heat and pressure applying means comprises a movable wedge (92) for applying pressure on the heating area (91), the movable wedge being capable of applying pressure on the end areas (64A, 64B) of the belt portion (60A, 60B) between the metal support (88) and the wedge (92).

16. The apparatus according to any one of claims 13 to 15, wherein: The cutting device (84) comprises: a base (200) defining a groove (202) for receiving the belt portion (60A, 60B); a cutting wedge (204) movably mounted relative to the base (200) between a position for loading / unloading the belt portion (60A, 60B) and a position for cutting the belt portion (60A, 60B), and the cutting device (84) advantageously further comprises a guide member (206) for guiding the movement of the cutting wedge (204).

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