Composite tape

Abstract

A composite tape can include a fiber reinforced tape and a metallic barrier layer adhered to a major surface of the fiber reinforced tape. The fiber reinforced tape can have a thermoplastic matrix; and a plurality of unidirectional continuous fibers embedded in the thermoplastic matrix. Advantageously, such a composite tape can both reinforce and minimize gas permeability when applied to piping and storage containers such as piping and storage containers for hydrogen or other permeable gases.

Description

COMPOSITE TAPECLAIM OF PRIORITY

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 605,089 bearing Attorney Docket Number 1202331 and filed on December 1, 2023, which is hereby incorporated by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure is directed to a composite tape which includes a fiber reinforced tape and a metallic barrier layer. Such a composite tape can be used to reinforce and add a gas impermeable barrier to piping and storage containers.BACKGROUND

[0003] Fiber-reinforced tapes find use in many applications including reinforcing pipe. Conventional pipes have been made from metals, thermoset composites, and thermoplastic composites. Each combination of materials offers a unique set of positive attributes. However, a continuing need exists for developing fiber-reinforced tape to balance strength, flexibility among other characteristics.SUMMARY OF THE DISCLOSURE

[0004] Advantages of the present disclosure include a composite tape with both fiber reinforcement and gas barrier characteristics in a single structure. The composite tape includes one or more fiber reinforced tapes in which a metallic barrier layer is bonded to a major surface of the fiber reinforced tape. The fiber reinforced tape has a thermoplastic matrix and a plurality of unidirectional continuous fibers embedded in the thermoplastic matrix.

[0005] In certain aspects, the thermoplastic matrix of the fiber reinforced tape can include, without limitation, a polyolefin, such as a polyethylene (PE), a poly (ethylene-vinyl acetate) (PVA), a modified polyolefin such as a maleic anhydride polyolefin, a polyester such as amorphous polyethylene terephthalate (aPET), a polyamide (PA), a polyvinyl chloride (PVC), a polyurethane (PU), thermoplastic vulcanisate, a polyketoneether (PKE), a polyetheretherketone (PEEK), a polyetherimide (PEI), a polyphenylene sulfide (PPS), a polyacrylate such as polymethylmethacrylate (PMMA), or a copolymer or a blend or combination thereof. The fiber reinforced tape can have 20 wt% to 60 wt% of the thermoplastic matrix based on the total weight of the fiber reinforced tape. Advantageously, the thermoplastic matrix allows the tape to be reprocessed by heat for reshaping and / or bonding the fiber reinforced tape to the metallic barrier layer and / or other surfaces.

[0006] In other aspects, the plurality of unidirectional continuous fibers can be composed of glass fibers, aramid fibers, basalt fibers, carbon fibers, polymeric fibers, or a combination thereof. The fiber reinforced tape can have 80 wt% to 40 wt% of the plurality of unidirectional continuous fibers based on the total weight of the fiber reinforced tape. Such fibers can be embedded in the thermoplastic matrix.

[0007] In still further aspects, the metallic barrier layer can be composed of a metal such as aluminum, steel, copper, tin, metal alloy, or a combination thereof, and / or a metalized polymeric substrate, e.g., metal deposited or coated on a polymeric substrate. In some aspects, the metallic barrier layer can have a thickness up to about 0.5 mm, e.g., in the range of from about 0.01 mm to about 0.5 mm and values therebetween.

[0008] In further implementations, one or more composite tapes of the present disclosure can form a reinforcing and barrier layer of a pipe or storage container. For example, one or more layers of composite tape can be wrapped around an outer surface of a pipe to form a reinforcing-barrier layer. Such a pipe can further include an outer jacket on the composite tape or layers of composite tape.

[0009] Another implementation includes a method of reinforcing a pipe such as by completely covering an outer surface of a pipe with the composite tape of the present disclosure, and heating the composite tape and / or the pipe to adhere the composite tape to the pipe.

[0010] Additional advantages of the present disclosure will become readily apparent to those skilled in this art from the following detailed description, wherein only certain embodiment are shown and described, simply by way of illustration of carrying out certain subject matter. As will be realized, the invention is capable of other and different embodiments, and its several details arecapable of modifications in various respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Reference is made to the attached drawings, wherein elements having the same reference numeral designations represent similar elements throughout and wherein:

[0012] FIG. 1 illustrates a composite tape construction including a fiber reinforced tape and a metallic barrier layer thereon according to an implementation of the present disclosure.

[0013] FIG. 2 schematically illustrates a ply of four layers of the composite tape exemplified in FIG. 1 on a pipe liner.

[0014] FIG. 3A, FIG. 3B and FIG. 3C illustrate perspective views of composite tapes with multiple layers of fiber reinforced tape having different relative orientations of fibers in various layers of the fiber reinforced tape.

[0015] FIG. 4A and FIG. 4B illustrate composite tape in multiple layers in which an outer layer overlaps a seam formed by an underlying tape layer.

[0016] FIG. 5A, FIG. 5B and FIG. 5C are schematic cross-sectional illustrations of pipe constructions including multiple layers of composite tapes according to certain implementations of the present disclosure.

[0017] FIG. 6 illustrates a chart showing an average and maximum peel strength of composite tape samples.

[0018] FIG. 7A illustrates dimensions and testing direction of samples for testing tear strength.

[0019] FIG. 7B and FIG. 7C are plots showing tear resistance and maximum strength, respectively, for a composite tape relative to an aluminum foil.

[0020] FIG. 8 illustrates a diagram for a gas permeability testing unit.

[0021] FIG. 9 illustrates a diagram for a sample configuration for approximating gas permeability of a seam.

[0022] FIG. 10 is a plot of gas transmission rate versus seam length for a simulated seam.DETAILED DESCRIPTION OF THE DISCLOSURE

[0023] The disclosure may be more fully appreciated by reference to the following description, including the following definitions and examples. Certain features of the disclosed compositions and methods which are described herein in the context of separate aspects, may also be provided in combination in a single aspect. Alternatively, various features of the disclosed compositions and methods that are, for brevity, described in the context of a single aspect, may also be provided separately or in any sub-combination.

[0024] Unless otherwise defined herein, scientific and technical terms used in connection with the present application shall have the meanings that are commonly understood by those of ordinary skill in the art. Further, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular.

[0025] As employed above and throughout the disclosure, the following terms and abbreviations, unless otherwise indicated, shall be understood to have the following meanings.

[0026] As used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise.

[0027] As used in the specification including the appended claims, when a range of values is expressed, such range includes from the one particular value and / or to the other particular value. All ranges are inclusive and combinable. Further, reference to values stated in ranges includes each and every value within that range. The term “about” as used herein when referring to a measurable value such as an amount, a temporal duration, and the like, is meant to encompass reasonable variations of the value.

[0028] The present disclosure is directed to a composite tape. As used herein, a tape is a continuous narrow strip and the term can be used interchangeably with a belt, or a ribbon.

[0029] Composite tapes of the present disclosure include a fiber-reinforced tape and a metallic barrier layer, e.g., an aluminum foil layer, on one or more major surfaces of the fiber-reinforced tape. As such, a composite tape of the present disclosure can have both reinforcement and gas barrier characteristics in a single structure. In certain aspects, a composite tape of the present disclosure can have a tensile strength (GPa) of from about 0.1 to about 10 and / or a modulus (chord) (GPa) of from about 5 to about 900 and / or an ultimate tensile strain (%) of from about 0.1 to about 5. In some aspects, the composite tape of the present disclosure can have a permeability coefficient to a gas that is comparable to the barrier layer, i.e., comparable to a metal layer of the same thickness of the barrier layer having the same composition. For example, the composite tape of the present disclosure can have a permeability coefficient to a gas, e.g., hydrogen or helium, of less than about 10'12(cm3*cm) / (cm2*s*cmHg), such as less than about 10'13, or about 10'14(cm3*cm) / (cm2*s*cmHg).

[0030] A composite tape of the present disclosure can be used to reinforce piping and storage containers including piping and storage containers for gases, such as hydrogen gas. Due to its extremely low density and high permeability, hydrogen is challenging to transport and store. Ductile carbon steel has improved hydrogen embrittlement resistance relative to high-strength steel but has relatively lower strength, which limits operating pressure and thus efficiency of ductile steels as a material for transport and storage of hydrogen. Thermoplastics in general are not susceptible to hydrogen embrittlement; however they are more permeable to hydrogen. Advantageously, however, composite tapes of the present disclosure can be used to reinforce existing piping and storage containers for use with hydrogen due to their beneficial characteristics.

[0031] For example, fiber reinforced pipe (FRP) is currently employed in the oil & gas industry and the industry is repurposing existing distribution infrastructure to transport hydrogen. Composite tapes of the present disclosure can act as both a reinforcement and as a hydrogen barrier for such FRP.

[0032] In addition, a composite tape of the present disclosure can be used in newly constructed piping and storage containers. While piping can be constructed with a barrier layer such as an aluminum layer, such aluminum barrier layers typically need to be treated with adhesives, tie layers, or surface modifications during a composite pipe construction to ensure good bonding between aluminum and other composite pipe components, such as a pipe liner or reinforcement layer, which is time consuming. However, composite tapes of the present disclosure can be used with new pipe and storage constructs and can be used without the need for adhesives. Moreover, since the composite tapes of the present disclosure include a combination of a fiber reinforced tape and metallic barrier layer, the composite tapes have higher tear strengths than typical metallic barrier layers. Such higher tear strengths advantageously allow the composite tapes of the present disclosure to be used to construct piping at higher line speeds.

[0033] In an implementation, a composite tape includes a fiber reinforced tape having a first major surface and an opposing second major surface. The fiber reinforced tape itself includes a thermoplastic matrix and a plurality of unidirectional continuous fibers embedded in the thermoplastic matrix. The thermoplastic matrix can compose from about 20 wt% to about 60 wt% of the total weight of the fiber reinforced tape. The plurality of unidirectional continuous fibers can compose from about 80 wt% to about 40 wt% of the total weight of the fiber reinforced tape.

[0034] A wide variety of thermoplastics can be used as the thermoplastic matrix of the fiber reinforced tape of the present disclosure including, for example, a polyolefin, such as a polyethylene (PE), a poly (ethylene-vinyl acetate) (PVA), a modified polyolefin such as a maleic anhydride polyolefin, a polyester such as amorphous polyethylene terephthalate (aPET), a polyamide (PA), a polyvinyl chloride (PVC), a polyurethane (PU), thermoplastic vulcanisate, a polyketoneether (PKE), a polyetheretherketone (PEEK), a polyetherimide (PEI), a polyphenylene sulfide (PPS), a polyacrylate such as polymethyl methacrylate (PMMA), or a copolymer or a blend or combination thereof. Advantageously, many of the polar thermoplastic resins listed herein allow the metallic barrier layer to be directly bonded to the fiber reinforced tape. For example, in certain implementations, a thermoplastic matrix composed of a poly (ethylene-vinyl acetate) (PVA), a modified polyolefin such as a maleic anhydride polyolefin, a polyester such as amorphous polyethylene terephthalate (aPET), a polyamide (PA), a polyvinyl chloride (PVC), apolyurethane (PU), thermoplastic vulcanisate, a polyketoneether (PKE), a polyetheretherketone (PEEK), a polyetherimide (PEI), a polyphenylene sulfide (PPS), a polyacrylate such as polymethyl methacrylate (PMMA), or a copolymer or a blend or combination thereof can be used to directly bond the metallic barrier layer to the fiber reinforced tape without an intermediate layer such as without an adhesive intermediate layer.

[0035] The unidirectional continuous fibers embedded in the 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-benzobisoxazole) fibers, cellulose fibers, rayon fibers, carbon fibers, etc.

[0036] In some aspects, the plurality of unidirectional continuous fibers embedded in the thermoplastic matrix can be in a tow, yam, end, pic, or roving. In some aspects, the plurality of unidirectional continuous fibers can include a sizing composition. The sizing composition both protects the fiber during processing as well as promotes chemical or mechanical bonding between the thermoplastic matrix and the continuous fibers. Sizing is typically applied by the fiber manufacturer. For example, the sizing composition can comprise a film former, a lubricant, a coupling agent, or a combination thereof.

[0037] In further aspects, each of the plurality of unidirectional continuous fibers can have an average diameter from about 1 pm to about 40 pm. In other aspects, a tow, yarn, end, pic, or roving of the plurality of unidirectional continuous fibers can have an average linear mass density from about 100 TEX to about 4400 TEX. (TEX is a unit of measure in grams per 1,000 meters. Also, the ranges above are a generalization of various fiber filament diameters and TEX.)

[0038] In addition to a fiber reinforced tape, the composite tape of the present disclosure includes a metallic barrier layer adhered to a first major surface of the fiber reinforced tape. In certain aspects, the metallic barrier layer is continuous and coextensive with the major surface of the fiber reinforced tape and the metallic barrier layer has a thickness sufficient to minimize permeability of a gas or gases through the composite tape. For example, the metallic barrier layer can have a thickness up to about 0.5 mm, e.g., from about 0.01 mm to about 0.5 mm (about 0.4 mil to about 20 mil) and values therebetween. The metallic barrier layer can be composed of ametal layer such as aluminum, steel, copper, tin, metal alloy layer or a combination thereof, and / or a metalized polymeric substrate, e.g., metal deposited or coated on a polymeric substrate such as a metal coated on an oriented (or bi-oriented) polymeric substrate such as a bi-oriented PET, i.e., metalized Mylar. In an aspect of the present disclosure, the metallic barrier layer is a metal foil, e.g., a foil composed of aluminum or alloy thereof, having a thickness up to about 0.5 mm, e.g., from about 0.01 mm to about 0.5 mm and values therebetween.

[0039] Further, a composite tape of the present disclosure can include two or more layers of the 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 can be oriented in a direction that is different from the orientation of unidirectional continuous fibers in another layer of fiber reinforced tape. In addition, the metallic barrier layer can be adhered to an outer layer or between layers of fiber-reinforced tape.

[0040] In some implementations, a bonding layer can be employed between the fiber reinforced tape and the metallic barrier layer to promote adhesion between the tape and the metallic barrier layer depending on the composition of each. However, for certain materials, an adhesive or bonding layer can be excluded. For example, in some implementations, the composite tape can include a fiber reinforced tape having unidirectionally oriented continuous glass fibers embedded in an amorphous polyethylene terephthalate matrix and an aluminum foil layer as a barrier layer directly bonded to a first major surface of the fiber reinforced tape. Advantageously, amorphous polyethylene terephthalate matrix can directly adhere an aluminum foil and thus an adhesive or bonding layer between the fiber reinforced tape and barrier layer is not needed. In such an implementation, a bonding layer can advantageously be excluded from between the fiber reinforced tape and barrier layer.

[0041] FIG. 1 illustrates a composite tape construction (100) including a fiber reinforced tape (110) that includes a plurality of unidirectional continuous fibers (102) embedded in the thermoplastic matrix (120). A metallic barrier layer (130) is directly bonded to a major surface of the fiber reinforced tape (110a). No bonding layer is used between the fiber reinforced tape (110) and the barrier layer (130) for this exemplified construct of the composite tape.

[0042] As further shown with reference 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 composite tape length can be greater than or similar to its width, but the composite tape thickness is substantially less than either its length or width. For example, the composite tape can have a width in a cross direction in a range of about 6 mm to about 1525 mm (about 0.25 inches (in) to about 60 in), such as from 10 mm, 15 mm, 20 mm, 25 mm, 50 mm, 75 mm, 100 mm, 150 mm, 200 mm, 250 mm to about 1525 mm, 1500 mm, 1400 mm, 1300 mm, 1200 mm, 1000 mm, 900 mm, 500 mm, 200 mm, or any value or range therebetween.

[0043] The thickness of the composite tape (100) is the sum of the thickness of the fiber reinforced tape (110) and metallic barrier layer (130). For example, the fiber reinforced tape can have a thickness (Y direction) in a range from about 0.1 mm to about 1 mm (about 4 mil to about 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 metallic barrier layer can have a thickness (Y direction) in a range of from about 0.01 mm to about 0.5 mm (about 0.4 mil to about 20 mil), such as in a range 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 certain aspects, the thickness of the composite tape is the sum of the thickness of the fiber reinforced tape and the metallic barrier layer and can range from about 0.1 mm to about 1.5 mm. Further, for the example of FIG. 1, the fiber reinforced tape (110) can have a thickness of about 0.010 inch (about 0.25 mm) and the metallic barrier layer (130) can have a thickness of about 0.002-0.005 inch (about 0.05-0.13 mm) and the composite tape can have a thickness of about 0.012 - 0.015 inch (about 0.3-0.38 mm) (which is the combined thickness of the fiber reinforced tape and metallic barrier layer).

[0044] As exemplified in FIG. 1, the plurality of continuous fibers are each more or less oriented in a first direction, i.e., the Z direction (longitudinal or length direction) or 0° from the Z axis. As further illustrated, the plurality of unidirectional continuous fibers (102) span all or substantially all of the width (X direction) of the thermoplastic matrix (120) and fiber reinforced tape (110).

[0045] In an implementation, a composite tape can be stacked on top of another forming a multi ply of layers of composite tape. FIG. 2 schematically illustrates a ply of four layers of the composite tape (100) exemplified in FIG. 1 on a pipe liner (240), e.g., a polyethylene liner. The ply can be laminated by heating layers of composite tape. It will be appreciated that such a laminate can include more or less layers of the composite tape. For example, a ply can include four to six layers of composite tape (e.g., a quad ply or 6 ply) which can be used to reinforce a pipe and further to act as a barrier to permeation of gases transported through the pipe.

[0046] In addition, the fibers in the various composite tape layers can be oriented in the same or in different directions relative to other fibers in composite tape layers. For example, a ply or laminate can include a first layer of composite tape in which the plurality of unidirectional continuous fibers are oriented in a first direction and a second layer of composite tape in which the plurality of unidirectional continuous fibers are oriented at an angle greater than or equal to 0° and less than or equal to 90° with reference to the plurality of unidirectional continuous fibers in the first layer of composite tape. FIG. 2 illustrates a four ply construction of composite tape (100) in which the fibers in each layer are all oriented in the same direction (Z direction). That is, the plurality of unidirectional continuous fibers are oriented at an angle of about 0° relative to each other.

[0047] In some implementations, the composite tape can include more than one layer of fiber reinforced tape. Further, the orientation of the unidirectional continuous fibers in a fiber reinforced tape can be in the same or in a different orientation relative to the unidirectional continuous fibers in an adjacent fiber reinforced tape in a multilayer construct. For example, in some aspects, the composite tape can include at least two fiber reinforced tape layers, e.g., at least 3, 4, 5, 6, 7, 8, etc. layers of fiber reinforced tape. In addition, the first layer of the fiber reinforced tape can have its plurality of unidirectional continuous fibers oriented in a first direction. An adjacent layer, i.e., a second layer, of the fiber reinforced tape can have its plurality of unidirectional continuous fibers in the second layer oriented at an angle equal to or greater than about 0° and less than or equal to about 90° with reference to the first direction of the plurality of unidirectional continuous fiber in the first layer of fiber-reinforced tape. The angle of the second fibers relative to the first fibers can be at about 0°, 10°, 20°, 30°, 40°, 50°, 60°, 67°, 70°, 80°, 90°, or any value or range therebetween.

[0048] FIGS. 3A-3C illustrate composite tapes with multiple layers of fiber reinforced tape and different relative orientations of fibers in various layers of the fiber reinforced tape. FIG. 3 A illustrates a perspective view of a composite tape (301) including two layers of fiber reinforced tape, e.g., first layer of fiber reinforced tape (310a) and second layer of fiber reinforced tape (310b). For this example, the first layer of the fiber reinforced tape (310a) includes a plurality of unidirectional continuous fibers (302) that are oriented in a first direction, i.e., at 90° degrees from the Z direction (or at a 0° angle from the X direction). As further shown for this example, the second layer of the fiber reinforced tape (310b) includes a plurality of unidirectional continuous fibers (304) that are oriented in a second direction, i.e., at 0° degrees from the Z direction (or at a 90° degree angle from the X direction). Hence, the plurality of unidirectional continuous fibers in the second layer are oriented at an angle of about 90° with reference to the first direction of the plurality of unidirectional continuous fiber in the first layer of fiber-reinforced tape (e.g., the first fiber reinforced tape is rotated 90° from the Z-axis). That is, the fibers in the two adjacent layers are relatively aligned in 9070° orientation. A metallic barrier layer (330), e.g., an aluminum foil, is adhered to a major surface of the second fiber reinforced tape.

[0049] FIG. 3B illustrates a perspective view of a composite tape (303) including two layers of fiber reinforced tape (310c, 3 lOd) in which the fibers in the tape layers are relatively aligned in 0790° orientation. That is, the first layer of the fiber reinforced tape (310c) includes a plurality of unidirectional continuous fibers (306) that are oriented in a first direction, i.e., at 0° degrees from the Z direction (or at a 90° angle from the X direction) and the second layer of the fiber reinforced tape (3 lOd) includes a plurality of unidirectional continuous fibers (308) that are oriented in a second direction, i.e., at 90° degrees from the Z direction (or at a 0° degree angle from the X direction). A metallic barrier layer (330), e.g., an aluminum foil, is adhered to a major surface of the second fiber reinforced tape.

[0050] FIG. 3C illustrates another perspective view of a composite tape (305) including two layers of fiber reinforced tape (310a, 310b) in which the fibers in the tape layers are relatively aligned in 9070° orientation. The orientation of the first and second fiber reinforced tapes are the same as set out in FIG. 3 A. However, in this exemplary construct, the metallic barrier layer (330) is sandwiched between the two layers of fiber reinforced tape. That is, the metallic barrier layer(330) has a first major surface (330a) and an opposing second major surface (330b) in which the first layer of the fiber reinforced tape (310a) is adhered to the first major surface (330a) of the metallic barrier layer (330) and the second layer of fiber reinforced tape (310b) is adhered to the opposing second major surface (330b) of the metallic barrier layer (330). While the constructs in FIG 3 show two layers of fiber reinforced tape, additional layers can be included in the construct. Further, while the constructs in FIG 3 show adjacent layers of fiber reinforced tape having relative orientations of fibers at 90°, the angle of the second fibers relative to the first fibers can be at about 0°, 10°, 20°, 30°, 40°, 50°, 60°, 67°, 70°, 80°, or any value or range therebetween. In addition, each of the layers of fiber reinforced tape illustrated in the figures can be laminated to each other and the metallic barrier layer by the application of heat to form the composite tape with multilayered fiber reinforced tape.

[0051] In certain implementations, the composite tape of the present disclosure can form a reinforcing and barrier layer of a pipe or storage container. For example, the composite tape can be wrapped around a pipe to form a reinforcing and barrier layer for such a pipe. The composite tape can be wrapped as a single layer or as a multilayer ply in which an outer composite tape layer overlaps an underlying composite tape layer. The outer composite tape layer can have its fibers with an offset angle varying from about 0° to about 90° along a longitudinal direction (length direction) relative to the underlying composite tape layer. Different wrap angles of the composite tape can provide different mechanical or chemical advantages. For example, the composite tape can be helically wrapped around an outer surface of pipe along a longitudinal direction of the pipe. In some aspects, the pipe can include another composite tape, a second composite tape, helically wrapped around the first composite tape. The pipe or container can include 2 to 12 layers of the composite tape, such as 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12 layers of composite tape, or any value or range therebetween. The composite tape or layers of composite tape can be laminated to the pipe and / or to each other by the application of heat.

[0052] In addition to, or as an alternative to a composite tape having multiple fiber reinforced tape layers, the composite tape itself can be formed as a ply of multiple composite tape layers. For example, a composite tape of the present disclosure can be applied to a pipe in multiple layers and the various tape layers can be applied such that an outer layer overlaps a seam formed by anunderlying tape layer. FIG. 4A and FIG. 4B illustrate examples in which a liner can have multiple layers of composite tape. FIG. 4A and FIG. 4B show a first composite tape (460a) on liner 440 forming a first tape layer (460) in which an adjacent composite tape (460b) in the tape layer (460) forms a first seam (462). As further shown in the figures, a second composite tape (470a) can be applied on the first composite tape to form a second tape layer (470). Other composite tapes can be applied to the second composite tape layer (470) to form additional tape layers (e.g., 480)). Advantageously, the second composite tape (470a) forming the second tape layer (470) can overlap the seam (462) in the first tape layer 460. The overlap by the second composite tape in the second layer can range from about 10 % to about 50% of a width of the second composite tape. As illustrated in FIG. 4A, the second composite tape (470b) overlaps the seam (462) by about one half of the width of the second composite tape (464). FIG. 4B illustrates that the second composite tape (470b) overlaps the seam (462) by at least about one third of the width of the second composite tape (466).

[0053] While FIG. 4A and FIG. 4B show a first composite tape on a liner, the first composite tape can be wrapped around a longitudinal direction of an outer surface of a pipe with another tape layer thereover to form a reinforcement and barrier layer around the outer surface of the pipe. In such a case, the first composite tape can form the first tape layer in which adjacent composite tape in the tape layer form a first seam. The second composite tape can be wrapped around the first tape layer forming a second tape layer on the first tape layer. Advantageously, the second composite tape can overlap the seam formed by the first composite tape in the first tape layer from about 10 % to about 50% of a width of the second composite tape, e.g., by at least about one third to about one half of the width of the second composite tape. In addition, the orientation of the unidirectional continuous fibers in a composite tape can be in the same or in a different orientation relative to the unidirectional continuous fibers in an adjacent composite tape in a multilayer construct. Further, a reinforcing and barrier layer constructed from overlapping composite tapes of the present disclosure advantageously can reduce the permeability of gases escaping the outer surface of the pipe or liner to that of the composite tape, e.g., a permeability coefficient of helium or hydrogen of less than about 10'12(cm3*cm) / (cm2*s*cmHg), such as less than about 10‘13, or about 10'14(cm3*cm) / (cm2*s*cmHg).

[0054] In certain implementations of the present disclosure, a pipe can include a liner and an outer jacket. The composite tape of the present disclosure can be wrapped around an outer surface of the liner or jacket. Advantageously, composite tapes of the present disclosure are sufficiently flexible to allow for installation of the tape to existing piping in the field thereby allowing rehabilitating and / or repairing existing pipe in the field. The metallic barrier layer of the composite tape can provide a barrier layer to gases transported through such piping.

[0055] FIG. 5A illustrates a cross-sectional view of a pipe construction reinforced with a composite tape of the present disclosure (pipe construction I (500A)). In this example, pipe 500A includes outer jacket 550 and two layers of a composite tape (510a, 510b) each of which is comprised of a fiber-reinforced tape layer (512) and a metallic barrier layer (514). The piper further includes an inner layer or liner (540). In some aspects, the inner layer or liner (540) and outer jacket layer (550) are composed of a thermoplastic, e.g., a polyolefin such as a polyethylene or a blend thereof. As exemplified in this figure, the composite tape layers (510a, 510b) do not require an adhesive layer and are directly bonded to each other and can further be bonded to surfaces of the inner liner and outer jacket of the pipe. Such bonding can be facilitated by heating the composite tape and or layers of the pipe. For example, a composite tape composed of fibers in an aPET matrix and aluminum barrier layer can be directly wrapped around a thermoplastic liner and consolidated by heat without the use of adhesive.

[0056] FIG. 5B illustrates a cross-sectional view of another pipe construction reinforced with a composite tape of the present disclosure (pipe construction II (500B)). In this example, pipe 500B includes outer jacket 550 and two layers of a composite tape (510c, 5 lOd) each of which is comprised of a fiber-reinforced tape layer (512) and a metallic barrier layer (514). For this construction, an adhesive layer (516), e.g., bonding layer, is included between fiber-reinforced tape layer (512) and a metallic barrier layer (514). For this example, fiber-reinforced tape layer (512) can have a polyethylene matrix and a bonding layer (516) to adhere the fiber reinforced tape and metallic barrier layer, e.g., an aluminum foil. An outer layer and inner layer, each composed of a thermoplastic (e.g., a polyethylene), can be consolidated and adhered to such a composite tape with heat.

[0057] FIG. 5C illustrates a cross-sectional view of another pipe construction that can be reinforced with a composite tape of the present disclosure (pipe construction III (500C)). In this example, pipe 500C includes outer jacket 550 and two layers of a composite tape (5 lOe, 51 Of) each of which is comprised of a fiber-reinforced tape layer (512), an adhesive layer (516) and a metallic barrier layer (514). FIG. 5C differs from FIG. 5B in that the metallic barrier layer of first composite tape 51 Of contacts an outer surface of inner layer 540 and an opposing major surface of fiber reinforced tape of composite tape 510e contacts an inner surface of outer jacket layer 550. An outer layer and inner layer, each composed of a thermoplastic (e.g., a polyethylene), can be consolidated and adhered to such a composite tape with heat.EXAMPLES

[0058] The following examples are intended to further illustrate certain aspects of the subject technology and are not limiting in nature. Those skilled in the art will recognize, or be able to ascertain, using no more than routine experimentation, numerous equivalents to the specific substances and procedures described herein.

[0059] Example 1

[0060] A fiber reinforced tape was prepared using E-glass single end roving and amorphous polyethylene terephthalate (aPET) pellets. Yields (i.e., TEX) of the glass rovings for this process ranged between 56 yield and 675 yield. A unidirectional (UD) glass fiber reinforced tape was used comprising the aPET matrix resin reinforced with 58 weight percent of the glass fiber and having an areal weight of 0.0803 lb / ft2and thickness of about 0.0100 inches. Aluminum foil (1100 Series) having an areal weight of 0.028 lb / ft2and thickness of 2.0 mil was used. The UD glass fiber tape and aluminum foil were thermally bonded together using a double belt thermal press. Both the fiber reinforced tape and the metal layer were tensioned and aligned in the length direction before being introduced to the belt press. The fiber reinforced tape and the metal layer were bonded directly due to the characteristics of the aPET matrix. The two layers were heated and cooled under pressure to allow the consolidation process to occur. After consolidation of the aPET onto the aluminum layer, the end product composite tape was coiled under tension after exiting the press.Overall, the laminated composite tape had a combined areal weight of 0.108 lb / ft2with a corresponding thickness of about 0.012 inches.

[0061] The composite tape can be taken to a continuous slitter to cut the composite tape to a desired width and wound.

[0062] Process parameters for the double belt lamination include the following: Process temperatures between 160°C and 260°C; Pressure during heating and consolidation ranges between Ipsi and lOOpsi; Lamination line speed ranges between 0.2 m / min and 10 m / min.

[0063] Example 2

[0064] Another fiber reinforced tape was prepares as described in Example 1 in which a glass fiber unidirectional tape was used comprising an aPET matrix resin reinforced with 58 weight percent glass fiber having an areal weight of 0.0803 lb / ft2and thickness of about 0.0100 inches. Aluminum foil from the 1100 Series having an areal weight of 0.070 lb / ft2and thickness of 5.0 mil was used. The combined UD glass fiber tape and aluminum foil were thermally bonded together using a double belt thermal press as described in Example 1. Overall, the laminated composite tape had a combined areal weight of 0.151 lb / ft2with a corresponding thickness of about 0.015 inches.

[0065] Mechanical and Permeability Characteristics of Composite Tapes

[0066] Tensile properties of tape samples were determined on a universal testing machine according to ASTM D3039 (Standard Test Method for Tensile Properties of Polymer Matrix Composite Materials). Samples were conditioned at a temperature of 23.0°C and 50% humidity prior to measurement. A test orientation of 0 degrees was used with a crosshead speed of 50 mm / min. Data for tensile measurements are provided in Table 1 below.Table 1. ASTM D3039 Tensile Test Data on APET / AL in the 0° or parallel to the fibers.| S.D. | 4.97 | 0.89 | 286.35 | 0.86 | 60.93 | 64.18 |Sample dimensions: width of 0.9341 inches (S.D. of 0.0102), thickness of 0.0113 inches (S.D. of 0.0002), area of 0.0105 in2(S.D. of 0.0002).

[0067] Table 2 below provides a comparison between tensile measurements of the fiber reinforced tape alone and with a composite tape including the 2 mil aluminum barrier layer from Example 1.Table 2. D3039 Tensile Test Comparison.

[0068] Peel Strength. The composite tape’s adhesion strength to aluminum foil was determined by performing a T-Peel test on the composite. A fiber reinforced tape was bonded to aluminum foil by using a continuous composite lamination machine operating at 240°C, 85psi, at a speed of 1.0m / s. The fiber reinforced tape and aluminum foil were bonded under uniform heat and pressure to form the composite tape in which the fiber reinforced tape was directly bonded to the aluminum foil, no adhesives were used for the bonding. Samples were prepared for testing by cutting a composite tape into 1 inch strips. The strips had a 5 inch bond length with several inches of nonbonded ends in order to fit into the T-Peel testing apparatus. The T-Peel test was performed in accordance with ASTM D1876 (Standard Test Method for Peel Resistance of Adhesives (T-Peel Test)) and the samples were peeled at a speed of 5 in / min at room temperature. FIG. 6 illustrates an average and maximum peel strength of composite tape samples.

[0069] Tear Strength. Composite tape tear strength was determined by performing a tear test on samples cut using a pre-measured and calibrated cutting die. The die was used to cut samples in accordance with ASTM D624 C (Standard Test Method for Tear Strength of Conventional Vulcanized Rubber and Thermoplastic Elastomers). Specific dimensions of the sample size and testing direction are illustrated in FIG. 7A. As shown in the figure, samples were prepared to measure about 102 mm in length (L), 19 mm in width (W), and to bow outward such that a 90° notch (N) is present in the middle of the sample. Each sample is pulled in opposite directions along the length of the sample at 2 in / min. The fibers in the fiber reinforced tape of the composite tape samples were oriented such that the fibers ran across the length of the sample. FIG. 7B and FIG. 7C are plots showing tear resistance and maximum tear strength, respectively, for a composite tape relative to an aluminum foil.

[0070] Permeability Measurement. Gas permeability of composite tape and other materials were tested using a gas permeability testing unit. FIG. 8 illustrates a diagram of such a testing unit. As shown in the figure, a test sample is used to create a seal between the upper and lower room (chamber). One chamber, i.e., the lower chamber, is evacuated by subjecting it to a vacuum for a specified time, while the other chamber is filled with test gas at a specific pressure. The samples are cut using a calibrated cutting die and are circular and measure about 97 mm in diameter. For each test, vacuum was pulled for 6 hours and Helium test gas was used at 100 kPa at 23°C and 50% relative humidity. The test continued until the pressure in the measurement chamber plateaued. Helium was used for testing permeability since it is safer to handle than hydrogen. Helium permeability was determined as a Permeability Coefficient (P), which is the volume of gas that passes through the sample per unit of thickness. Permeability Coefficients for certain tested samples are provided in Table 3 below.Table 3. Helium Permeability of Samples.

[0071] As provided by Table 3 above, a composite tape having an aluminum foil barrier layer had a gas permeability comparable to an aluminum foil alone. The composite tape also performed better that an unbound aPET film plus aluminum foil, and orders of magnitude better than other materials.

[0072] Patch / Seam Experiment. A seam was simulated by testing samples in the testing chamber shown in FIG. 8. The testing set-up included cutting a hole in the center of an aluminum foil and covering the aluminum foil and hole with a material to be tested such as a composite tape sample. A diagram illustrating sample configuration is provided in FIG. 9. As shown in the figure, the base aluminum foil acts as an impervious layer. When a composite tape sample is placed over the aluminum base, gas flows through the relative higher permeability thermoplastic matrix, e.g., through the aPET matrix of a aPET composite tape, out through the hole in the center of the base aluminum foil. It is believed this experiment simulates a seam can be formed by wrapping a composite tape around a pipe. The hole in the center of the aluminum foil was about one quarter of an inch (0.25 in) in diameter and was cut using a calibrated cutting die. The composite tape samples were 0.56 in, 0.88 in, 1 .0 in, 1.19 in, 1 .38 in, and 1 .75 in in diameter to approximate seam widths of0.31 in, 0.63 in, 0.75 in, 0.94 in, 1.13 in, and 1.50 in. The patches were centered over the hole and heat sealed to the aluminum foil using either a continuous composite laminator or using a platen press at 240°C at l.Om / s or 1 minute cycle time. The patches were tested in the permeability testing unit by pulling vacuum for 6 hours and using Helium test gas at 100 kPa at 23°C and 50% relative humidity. The test continued until the pressure in the measurement chamberplateaued. Results from the patch testing are provided in FIG. 10, which shows gas transmission rate versus seam length for the simulated seam. The gas transmission rate increases with decreasing seam length as expected. However, the gas transmission rate of a composite tape with the smallest seam length is still significantly lower than the gas transmission rate of the samples in Table 3 that did not include a metallic barrier layer.

[0073] Only certain features and aspects of the present disclosure and examples of their versatility are shown and described in the present disclosure. It is to be understood that the technology disclosed herein is capable of use in various other combinations and environments and is capable of changes or modifications. Thus, for example, those skilled in the art will recognize, or be able to ascertain, using no more than routine experimentation, numerous equivalents to the specific substances, procedures and arrangements described herein. Such equivalents are considered to be within the scope of the invention and are covered by the following claims.

Claims

WHAT IS CLAIMED IS:

1. A composite tape comprising: a fiber reinforced tape having a first major surface and an opposing second major surface; the fiber reinforced tape comprising a plurality of unidirectional continuous fibers embedded in a thermoplastic matrix; and a metallic barrier layer bonded to the thermoplastic matrix on the first major surface of the fiber reinforced tape.

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

3. The composite tape of any one of the preceding claims, wherein the metallic barrier layer has a thickness from about 0.01 mm to about 0.5 mm.

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

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

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

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

8. The composite tape of any one of the preceding claims, wherein each of the plurality of unidirectional continuous fibers have an average diameter from about 1 pm to about 40 pm.

9. The composite tape of any one of the preceding claims, wherein the plurality of unidirectional continuous fibers are in a tow, yarn, end, pic, or roving.

10. The composite tape of claim 9, wherein the tow, yarn, end, pic, or roving has an average linear mass density from 100 TEX to 4400 TEX.

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

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

13. The composite tape of any one of the preceding claims, wherein the composite tape comprises a first layer of the fiber reinforced tape in which the plurality of unidirectional continuous fibers are oriented in a first direction and the composite tape further comprises a second layer of the fiber reinforced tape in which the plurality of unidirectional continuous fibers in the second layer are oriented at an angle greater than 0° and less than or equal to 90° with reference to the first direction of the plurality of unidirectional continuous fiber in the first layer of fiber- reinforced tape.

14. The composite tape of any one of the preceding claims, wherein the composite tape comprises a first layer of the fiber reinforced tape in which the plurality of unidirectionalcontinuous fibers are oriented in a first direction and the composite tape further comprises a second layer of the fiber reinforced tape in which the plurality of unidirectional continuous fibers in the second layer are oriented at an angle of about 90° with reference to the first direction of the plurality of unidirectional continuous fiber in the first layer of fiber-reinforced tape.

15. The composite tape layer of claim 13 or 14, wherein the second layer of fiber reinforced tape is adhered to the opposing second major surface of the first fiber reinforced tape.

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

17. The composite tape of any one of the preceding claims, wherein the metallic barrier layer comprises aluminum, steel, copper, tin, metal alloy, or a combination thereof.

18. The composite tape of any one of the preceding claims, wherein the metallic barrier layer is adhered directly to the first major surface of the fiber reinforced tape without an adhesive.

19. The composite tape of any one of the preceding claims, wherein the composite tape has a permeability coefficient of helium of less than about 10‘12(cm3*cm) / (cm2*s*cmHg).

20. A fiber reinforced pipe comprising: an inner surface and an outer surface; and the composite tape of any one of the preceding claims wrapped around the outer surface of the pipe.

21. The fiber reinforced pipe of claim 20, wherein the composite tape is helically wrapped around the outer surface of the pipe along a longitudinal direction of the pipe.

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

23. The fiber reinforced pipe of claim 22, wherein the composite tape is helically wrapped around the first layer along a longitudinal direction of the pipe.

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

25. The fiber reinforced pipe of any one of claims 22-24, wherein the composite tape comprises a first composite tape and a second composite tape helically wrapped around the first composite tape.

26. The fiber reinforced pipe of claim 25, wherein the first composite tape is helically wrapped around the first layer along a longitudinal direction of the pipe and the second composite tape is helically wrapped around the first composite tape in an opposing direction of the first composite tape.

27. The fiber reinforced pipe of any one of claims 22-27 comprising from 2 to 12 layers of the composite tape.

28. A fiber reinforced pipe comprising: an inner surface and an outer surface; and a reinforcement and barrier layer around the outer surface of the pipe, wherein the reinforcement and barrier layer comprises a first composite tape wrapped around a longitudinal direction of the pipe forming a first tape layer in which adjacent composite tape in the tape layer form a first seam and a second composite tape wrapped around the first tape layer forming a second tape layer on the first tape layer in which the second composite tape overlaps the seam by at least one third of a width of the second composite tape; andwherein the first and second composite tape comprise a composite tape of any one of claims 1-19.

29. The fiber reinforced pipe of claim 28, wherein the reinforcement and barrier layer around the outer surface of the pipe has a permeability coefficient of helium of less than about ICT12(cm3* cm) / (cm2* s * cmHg) .

30. A method of preparing a fiber reinforced pipe comprising: completely covering an outer surface of a pipe with the composite tape of any one of claims 1-19; and heating the composite tape and / or the pipe to adhere the composite tape to the pipe.

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

32. The method of claim 30, wherein the composite tape has a permeability coefficient of helium of less than about 10'12(cm3*cm) / (cm2*s*cmHg).

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