Pipe support

Abstract

A pipe support (100) for supporting a pipe (10) adjacent to a body (20) comprises a composite material (110). The composite material (110) includes a cyanate ester resin. A method of manufacturing the pipe support is also provided.

Description

[0001] PIPE SUPPORT

[0002] The present application relates to a pipe support, a pipe wrap, and a method of manufacturing a pipe support. More specifically, the present application relates to a pipe support and a pipe wrap for thermally isolating and / or insulating a pipe.

[0003] Pipe supports are conventionally used to support a pipe adjacent to a body (e.g. a surface or a structure). Such pipes can be used in a variety of contexts to transport a fluid between two locations. The fluid within the pipes has a certain temperature that will influence the external temperature of the pipe which, in turn, will influence the temperature of the surrounding environment and of the body.

[0004] In some examples, such as the transportation of liquid natural gas (LNG), the liquid is transported at an extreme temperature. In the case of LNG, the fluid is transported at cryogenic temperatures (e.g. below -150°C) such that the LNG is transported in a liquid state. If the cryogenic temperatures are not maintained, the LNG will heat and convert to a gaseous state. This reduces the efficiency of transportation, since the volume of the LNG is larger in the gaseous state. It is therefore common for pipes that carry LNG to be thermally insulated in order to maintain the LNG at cryogenic temperatures. As part of this, any pipe supports that are supporting these pipes may also contain some degree of thermal insulation. That is, thermal insulation may be used on pipe supports to protect the surrounding environment and the body from the extreme temperature of the pipe, as well as to protect the pipe from the temperature of the environment. Preferably, the thermal insulation may be provided along the entire length of the pipe line through which the LNG travels.

[0005] However, existing materials used for such insulation, such as high-density polyurethane foam (HD-PUF), have adequate performance at low (e.g. cryogenic) temperatures, but poor performance at high temperatures (e.g. above 140°C). Therefore, in circumstances where the pipe may be exposed to both high and low temperatures (for example, during the steam cleaning of an LNG pipe), existing insulation materials used in the insulation of pipes are prone to failure or deterioration. Similar issues may be seen in pipe wraps that are made of conventional materials. Furthermore, existing insulation materials do not have high mechanical strength and therefore are not well-suited for long-term use in a pipe support, which may have to provide load-bearing support to the pipe. This leads to further failure or deterioration of the pipe support. Additionally, some existing insulation materials used for pipe supports are brittle, and can easily be damaged during installation.

[0006] There is, therefore, a need to provide an improved pipe support and pipe wrap that mitigates the aforementioned problems.

[0007] In accordance with a first aspect of the present disclosure, there is provided a pipe support for supporting a pipe adjacent to a body, as defined in claim 1 . The pipe support comprises a composite material. The composite material includes a cyanate ester resin.

[0008] As used herein, the term ‘pipe support’ is used to refer to any apparatus for supporting a pipe adjacent to a body. By ‘adjacent’ it is meant that, in relative terms, the pipe is positioned near to, but not in contact with, the body when the pipe is supported by the pipe support. A ‘body’ may refer to a surface (e.g. the ground, a floor, a wall, a ceiling), a structure (e.g. a building, scaffolding, a rig), another pipe and / or another pipe support, or any other body or object adjacent to which a pipe may be supported.

[0009] Alternatively or in addition, the pipe support may be for providing structural support to the pipe, so as to prevent the pipe from moving relative to the body. Alternatively or in addition, the pipe support may be for thermally isolating the pipe from the body. By ‘thermally isolating’ it is meant that the pipe support at least partially inhibits the transfer of heat energy between the pipe and the body. It is not necessary for the pipe support and / or the composite material to completely prevent the transfer of heat between the pipe and the body in order to be considered thermally isolating.

[0010] The cyanate ester resin (CER) may comprise a thermosetting resin. The CER may be semi-solid or solid at room temperature. The CER may have a viscosity of at least 20 mPa.s (millipascal-second), at least 25 mPa.s or at least 30 mPa.s at a temperature of SO . In some embodiments, the CER may have a viscosity of at least 200, 250, 300, 350 or 400 mPa.s at a temperature of 80°C. The CER may have a viscosity less than 1 ,000, less than 900, less than 800, less than 700, less than 600, or less than 500 mPa.s at a temperature of 80°C. In some embodiments, the CER may have a viscosity between 50 mPa.s and 5,000 mPa.s at a temperature of 60°C. The CER may have a viscosity of at least 50, at least 60, at least 70, or at least 80 mPa.s, or at least 85 mPa.s at a temperature of 60°C. The CER may have a viscosity less than 5,000, less than 4,500, less than 4,000, less than 3,500, less than 3,000, or less than 2,500 mPa.s at a temperature of 60°C.

[0011] The CER may have a glass transition temperature of at least 250°C, at least 300°C, at least 320cC, at least 325’C, at least 350GC, at least 375°C, or at least 40CTC. The CER may have a glass transition temperature of less than 600°C, less than 550°C, less than 500°C, less than 450°C, less than 400°C, or less than 350°C. The glass transition temperature may be measured after mould curing of 10 minutes at a temperature of 165,:,C to 185,:,C.

[0012] The CER may have a high temperature resistance. The CER may be non-combustible (e.g. such as according to the test procedure in ASTM E136-11 ). The CER may be able to withstand heating to 750°C for at least 30 minutes. For example, the CER may be selected to withstand temperatures of at least 100°C, at least 150°C, at least 200°C, at least 25CCC. at least 300°C, or at least 350°C. The CER may have a high resistance to extremely low temperatures. The CER may be able to withstand temperatures below - 50 °C, below -100°C, below -150cC, or below "175°C. For example, in some embodiments, the CER may be configured to withstand temperatures between -200°C and 400°C.

[0013] The CER may have a high char yield. As would be understood, the char yield is the remaining mass after completely degrading the resin. In some embodiments the char yield may be at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, or at least 85%. The char yield may be measured according to ASTM D 7309. The CER may have excellent fire, smoke and toxicity ratings. The CER may be compliant with the plastics flammability standard UL 94 (Underwriters Laboratories) and may have a rating of V-0. The CER may have a Limited Oxygen Index (LOI) rating of at least 35%, at least 40%, or more preferably, at least 45%. The LOI determines the minimum concentration of oxygen in a mixture of oxygen and nitrogen flowing upward in a test column that will just support combustion. The CER may have a gel time between 100 and 2500 minutes, more preferably between 250 and 2000 minutes, or 500 and 1500 minutes.

[0014] The CER may comprise a novolak cyanate ester. In one series of embodiments, the CER comprises a phenolic novolak cyanate ester resin. For example, the CER may comprise a Primaset™ resin (available from Arxada AG). The Primaset™ resin may comprise Primaset™ PT-30 or Primaset™ PT-15. Primaset™ PT-30 and Primaset™ PT-15 are each an oligo(3-methylene-1 ,5-phenylcyanate) and are desirable as high-performance, thermosetting resins.

[0015] The composite material can comprise a mixture of resins, such as a mixture of CER and epoxy resins. The ratio of CER:Epoxy Resin can be selected according to the temperature range to be covered. Epoxy resins are generally cheaper than cyanate ester resins but are usually not so tolerant of high temperature ranges. However, within certain temperature ranges, mixtures of resins can be determined that provide the required mechanical and temperature behaviour. For example, CER:Epoxy ratios of 50:50 or 75:25 can be used to address applications with an upper temperature of less than 300cC. The use of epoxy resin in the composite material can be useful to manage costs.

[0016] The composite material may further comprise a fibre or fabric. The fibre or fabric may comprise E-glass fibres. In some embodiments, the composite material comprises a glass fabric. The fabric may comprise a woven or non-woven fabric. The fabric may be a non-crimped fabric. The non-crimped fabric may have multiple layers e.g. 2, 3, 4, or greater layers. The layers may be angled relative to one another i.e. the yarns within the fabric layer may be oriented at an angle relative to one or more adjacent layers. The angle may be 22.5° to 67.5°, or 40-50° e.g. 45°. The fabric may be a multiaxial fabric e.g. biaxial, triaxial, or quadraxial. In one series of embodiments, the fabric comprises a quadraxial glass fibre fabric comprising layers of unidirectional fibres, wherein each layer of fibres is oriented at 45° relative to its adjacent layers. Quadraxial fabrics are particularly desirable since they provide high strength in all directions. The fabric may have a density of at least 400gsm, 500gsm, 600gsm, 700 gsm, 750gsm, or 800gsm. The fabric may have a maximum density of 1200gsm, 1100gsm, 1000gsm, 900gsm, 850gsm, or 800gsm. There are several advantages to the use of a cyanate ester resin in a composite material for a pipe support. Firstly, cyanate ester resins are good thermal insulators that enable the pipe support to adequately thermally isolate the pipe from the body. In particular, cyanate ester resins are able to provide sufficient thermal isolation and / or insulation both at low temperatures (e.g. cryogenic temperatures, such as below -150°C) and at high temperatures (e.g. temperatures considerably above the boiling point of water, such as above 200°C). In other words, advantageously, cyanate ester resins have a broad operating temperature range over which they are able to provide thermal isolation without material failure (e.g. melting, fracturing). The operating temperature range of the cyanate ester resin may be, for example, -196°C to 350°C for continuous contact surface temperature exposure. The cyanate ester resin may also be able to operate for short periods of time at temperatures as high as 400°C.

[0017] In contrast, conventional insulating materials used in pipe supports, such as polyurethane foam (PUF), may be capable of providing adequate thermal isolation at cryogenic temperatures (e.g. as low as -180°C), but have a maximum operating temperature that is much lower (e.g. 120°C to 140°C). Therefore, these conventional materials may be suitable for thermally isolating a pipe that operates only at low temperatures (e.g. the pipe carries a fluid or other material that is kept at such low temperatures), but they are not suitable if the pipe periodically operates at high temperatures.

[0018] One such practical example arises in pipes that require regular cleaning. This may be the case in the petrochemical sector for pipes that carry liquid natural gas (LNG).

[0019] For example, during ‘normal’ operation, the pipe may carry a fluid that is kept at a cryogenic temperature. However, the interior of the pipe may require periodic cleaning. During such cleaning, the pipe may be flushed with a high temperature fluid, such as steam. This high temperature fluid may be at a temperature that is between 200-300°C or higher. Conventional pipe support insulation materials are not able to perform at these temperatures and may, in fact, fail (e.g. melt or fracture). Therefore, the conventional materials are prone to deterioration over time when periodically exposed to such high temperatures. This may even require pipes to be removed from the pipe supports and cleaned elsewhere, causing considerable inconvenience and cost to the operator of the pipe. A pipe support as described herein is able to provide thermal isolation at both low temperatures and high temperatures. This means the pipe may be left in contact with the pipe supports during cleaning. This also means that the pipe supports have a longer lifetime because they are less prone to material failure or long-term deterioration due to repeated temperature changes.

[0020] A further advantage of using cyanate ester resins in the composite materials lies in their mechanical strength. Other conventional insulating material used in pipe supports, such as cellular glass insulation materials, are able to provide thermal isolation but are brittle and have low mechanical strength. For example, some cellular glass insulation materials have a compressive strength of around 2000 kPa, whereas composites comprising cyanate ester resins have been shown to have compressive strength of 250 MPa (in a temperature range of 23°C to 350°C). As a further example, some cellular glass insulation materials have a flexural strength of around 450 kPa, whereas composites comprising cyanate ester resins have been shown to have flexural strength of 100 MPa (at a temperature of 23°C).

[0021] Such cellular glass insulation materials are not suitable for pipe supports because their low mechanical strength may lead to material failure, for example, during installation or when a heavy pipe is placed onto the pipe support. Furthermore, such cellular glass materials are also brittle and long-term support of the pipe may therefore lead to material deterioration and failure. Therefore, a compromise exists in current pipe supports between adequate thermal isolation and long-term structural strength and integrity. In contrast, composites comprising cyanate ester resins have both good thermal isolation properties and high mechanical strength, allowing such materials to be used in pipe supports and, in particular, on load-bearing surfaces and / or load-bearing components of the pipe support.

[0022] Optionally, the pipe support comprises the composite material disposed in a layer such that a surface of the layer abuts the pipe when the pipe is placed onto the pipe support.

[0023] As used herein, the term ‘abuts’ refers to a direct contact between two objects in which there are no intervening or intermediate components between the two objects. This is in contrast to one object being ‘on’, ‘disposed on’, or ‘disposed at’ another object, which may include any number of intervening or intermediate components between the two objects.

[0024] Advantageously, the layer of composite material causes thermal isolation to exist between the pipe and any other components of the pipe support or the body. That is, the layer of composite material acts as a thermal barrier between the pipe and other components of the pipe support or the body, and there are no intermediate components to compromise the effectiveness of the thermal barrier.

[0025] The layer may be flat or curved. For example, the layer may be curved so as to closely or exactly match the curvature of the pipe that is to be placed onto the pipe support.

[0026] Optionally, the composite material is arranged to provide load-bearing support to the pipe when the pipe is placed onto the pipe support.

[0027] Advantageously, the composite material may be disposed inside in the pipe support such that, when the pipe is placed onto the support, the composite material provides loadbearing support. This allows the composite material to simultaneously serve both purposes of providing thermal isolation and structural integrity. As discussed above, the use of a cyanate ester resin allows such a configuration to exist because composites comprising cyanate ester resins have high mechanical strength compared to conventional insulating materials for use in pipe supports.

[0028] Optionally, the pipe support further comprises a base portion securable to the body. The pipe support may further comprise a support portion coupled to the base portion. The support portion may be configured to receive the pipe and hold the pipe in position relative to the body.

[0029] The base portion may be securable to the body by any suitable means. For example, the base portion may be securable to the body by one or more fasteners (e.g. screws, bolts), one or more clamps, welding, adhesive and / or other known means. This may depend on the body to which the base portion is to be secured. For example, one or more screws or bolts may be used if the body comprises a surface (e.g. the ground). The base portion and the support portion may be separate components that are joined (for example, by one or more fasteners, one or more clamps, welding, adhesive and / or other known means). Alternatively, the base portion and the support portion may be integral with one another. The term ‘base’ in this context does not imply a spatial relationship to the support portion, the pipe support, or the pipe. That is, the base portion does not necessarily need to be (but may be) positioned below the support portion and / or the pipe when in use. The base portion, for example, may be securable to a wall and thus may be horizontally disposed relative to the support portion and / or the pipe when in use.

[0030] Optionally, the pipe support comprises the composite material disposed at an interface between the base portion and the support portion.

[0031] Advantageously, by providing the composite material between the base portion and the support portion, this provides thermal isolation at least between the pipe and base portion (due to thermal isolation between the support portion and the base portion). This may, in turn, allow the material of the base portion to be chosen without consideration of its thermal properties, since the base portion is thermally isolated from the pipe. This allows the material to be chosen based on other considerations, such as cost, weight, or strength. For example, a lightweight, cheaper material may be chosen for the base portion. Furthermore, the composite material disposed at such an interface may be loadbearing, which provides the advantages discussed above.

[0032] Optionally, the support portion comprises the composite material on a contact surface of the support portion that abuts the pipe when the pipe is placed onto the pipe support.

[0033] Advantageously, this provides thermal isolation to the support portion by placing the pipe in direct contact with the composite material on the contact surface. This may, in turn, allow the material of the support portion to be chosen without consideration of its thermal properties, since the support portion is thermally isolated from the pipe. This allows the material to be chosen based on other considerations, such as cost, weight, or strength. For example, a lightweight, cheaper material may be chosen for the support portion. Furthermore, the composite material disposed on the contact surface may be loadbearing, which provides the advantages discussed above. Optionally, the pipe support further comprises a base portion securable to the body. The base portion may comprise the composite material on a contact surface of the base portion that abuts the pipe when the pipe is placed onto the pipe support.

[0034] Optionally, the contact surface is curved relative to a longitudinal axis of the pipe support, the longitudinal axis of the pipe support being coaxial with a longitudinal axis of the pipe when the pipe is placed onto the contact surface.

[0035] Advantageously, a curved contact surface reduces the potential for motion of the pipe relative to the pipe support that might otherwise be caused by the pipe rolling on a flat surface. Furthermore, the curved contact surface may increase the surface area of the contact surface that is in contact with the pipe when the pipe is placed onto the pipe support. Advantageously, this allows the composite material to provide thermal isolation to a larger portion of the surface area of the pipe, which may, for example, reduce heat transfer between the pipe and the surrounding environment. This provides greater thermal insulation to the pipe.

[0036] Optionally, the pipe support further comprises a layer of secondary insulation material. The layer of secondary insulation material may be positioned such that, when the pipe is placed onto the pipe support, the composite material is disposed between the pipe and the layer of secondary insulation material.

[0037] The pipe may be in direct contact with the composite material and the composite material may abut or be disposed on the secondary insulation material. The secondary insulation material may provide further thermal isolation between the pipe support and the body, or between the composite material and other components of the pipe support.

[0038] Advantageously, by placing the composite material between the pipe and the secondary insulation material, the composite material is able to provide the majority of the thermal isolation effects, with the secondary insulation material providing further thermal isolation at less extreme temperatures. The secondary insulation material may have a narrower operating temperature range than the composite material. For example, if the composite material has an operating temperature range of -196°C to 300°C, the secondary insulating material may have an operating temperature range that is narrower than this (e.g. -180°C to 140°C). The secondary insulating material may comprise PUF. Advantageously, this may reduce the cost and / or the weight of the pipe support by allowing an insulation material to be provided that does not comprise a cyanate ester resin, without compromising the thermal performance of the pipe support.

[0039] Optionally, the pipe support further comprises a base portion securable to the body and configured to hold the pipe in position relative to the body, wherein the composite material is disposed at an interface between the base portion and the body.

[0040] Optionally, the pipe support further comprises a securing portion for securing the pipe to the pipe support.

[0041] For example, the securing portion may be securable to the base portion, the support portion, the pipe and / or the body to secure the pipe to the pipe support. The securing portion may be securable by one or more fasteners (e.g. screws, bolts), one or more clamps, welding, adhesive and / or other known means.

[0042] The securing portion may comprise a securing strap for placement across the pipe to secure the pipe to the pipe support. The securing portion may comprise a clamp arm that clamps across the pipe to secure the pipe to the pipe support. The securing portion may comprise a cover that is secured to the base portion or the support portion to secure the pipe to the pipe support.

[0043] Optionally, the securing portion comprises the composite material disposed on a contact surface of the securing portion that abuts the pipe when the securing portion secures the pipe to the pipe support.

[0044] Advantageously, this provides further insulation to the pipe to prevent heat transfer between the pipe and the environment.

[0045] Alternatively, the securing portion may not comprise any of the composite material. For example, the securing portion may be formed from metal (e.g. the securing portion may be a metal strap). Advantageously, this allows the cost of the pipe support to be reduced in circumstances where insulation of the pipe from the environment is of lesser importance. For example, it may be advantageous to thermally isolate the pipe from the body, to prevent the body being exposed to the extreme temperatures of the pipe, but it may not be necessary to prevent heat exchange between the pipe and the environment.

[0046] Optionally, the pipe support comprises a support portion and / or a base portion, and the composite material is disposed as a first layer on the securing portion and as a second layer on the support portion or the base portion such that, when the securing portion secures the pipe to the pipe support, the first layer and the second layer form a substantially continuous layer that encloses the pipe within the pipe support.

[0047] Advantageously, the substantially continuous layer encloses the pipe and thus thermally isolates the pipe from the environment and the body across a portion of the pipe that is enclosed. The substantially continuous layer may be a cylindrical layer that is concentric and / or coaxial with the pipe.

[0048] In accordance with a second aspect of the present disclosure, there is provided a pipe wrap for insulating an outer surface of a pipe, as defined in claim 16.

[0049] The pipe wrap comprises a composite material. The composite material includes a cyanate ester resin.

[0050] As used herein, the term ‘pipe wrap’ is used to refer to an apparatus for insulating an outer surface of a pipe. In contrast to a pipe support, a pipe wrap typically does not provide structural support or integrity to the pipe and instead serves the primary purpose of insulating the outer surface of the pipe. The pipe wrap may also serve the purpose of protecting against abrasion, wear, and corrosion.

[0051] The pipe wrap may be shaped and / or dimensioned to fit the outer surface of the pipe. For example, the pipe wrap may be shaped to have a curvature that substantially matches the curvature of a pipe that the pipe wrap is intended to insulate.

[0052] The pipe wrap may only partially cover the outer surface of the pipe when in use. The pipe wrap may, therefore, be referred to as a pipe wrap section. For example, the pipe wrap may have an arc length of 90°, 120°, 180°, or 240°, amongst others. The pipe wrap may have a thickness between 4mm and 8mm. In accordance with a third aspect of the present disclosure, there is provided a method of manufacturing a pipe wrap, a pipe support, or a component therefor as defined in claim 17.

[0053] The method comprises heating a cyanate ester resin to form a flowable liquid resin. The method further comprises combining the liquid resin with one or more fibres and / or fabrics to form a pre-impregnated composite material (e.g. a pre-preg). The method further comprises disposing the pre-impregnated composite material into a mould. The method further comprises curing the pre-impregnated composite material to form (at least a portion of) the pipe support or the pipe wrap.

[0054] In some embodiments, heating the cyanate ester resin may comprise heating the cyanate ester resin to 80-100°C, to 85-95°C, or to 90°C. The cyanate ester resin may be held at 90°C until the resin reaches the desired viscosity. The inventors have found that higher temperatures lead to reductions in pot life of the CER.

[0055] The method may comprise adding a catalyst to the flowable liquid resin. The catalyst may comprise 0.5-1 wt% relative to the CER. In some embodiments, the catalyst comprises 0.7-0.8 wt%, or 0.75wt% relative to the CER. The catalyst may comprise a transition metal complex, or an aromatic diamine. The catalyst may be a liquid, and optionally may have a low viscosity. The catalyst may be Lonzacure™ DETDA80 (supplied by Arxada).

[0056] The method may comprise heating the catalyst prior to adding the catalyst to the flowable liquid resin. The method may comprise heating the catalyst to at least 50°C for 10-25, and / or 15-20 minutes.

[0057] The method may comprise mixing the flowable liquid resin and the catalyst until a homogenous mixture or solution is formed e.g. for 2 to 6, or 3 to 5 minutes. The homogenous mixture is maintained at 90-95°C within the oven, preferably for no longer than 10 minutes.

[0058] As is noted above, a mixture of cyanate ester resin and other resins can be used, such as epoxy resin. The times, temperatures, and other components can be adjusted accordingly. In some embodiments, the pre-preg may be formed in the mould. For example, the one or more fibres and / or fabric may be placed in the mould and the liquid resin added thereto.

[0059] In some embodiments, formation of the pre-preg is carried out under vacuum and / or at raised temperatures. For example, forming the pre-preg may comprise heating the mould e.g. to a first temperature. The first temperature may be selected to maintain the liquid state of the resin and ensure effective impregnation of the one or more fibres and / or fabrics without rapidly curing the resin.

[0060] In a series of embodiments, curing the pre-impregnated composite material comprises heating the pre-impregnated composite material. Curing the pre-impregnated composite material may comprise following curing schedule. The curing schedule may comprise one or more ramp up phases, one or more temperature hold phases, and one or more ramp down phases. The curing schedule may comprise ramping up the temperature at a rate of 0.5-2°C / min, 0.75-1 .5°C / min, or 1 °C / min. The ramp up phase may end when the hold phase temperature is reached. The hold phase temperature may comprise 120- 190°C, e.g. 120, 130, 140, 150, 160, 170, 180 or 190°C. The hold phase may comprise 5-20 hours, e.g. 6-18, 7-16, or 8-14 hours. The curing schedule may comprise a second ramp up phase at the rates indicated above. The curing schedule may comprise a second hold phase, higher than the first e.g. 130, 140, 150, 160, 170, 180 or 190°C. The second hold phase may comprise 0.5 to 3 hours, or 1-2 hours. Optionally, the curing schedule may comprise a third ramp up phase at the above noted rates, and optionally a third hold phase higher than the second e.g. 140, 150, 160, 170, 180 or 190°C. The curing schedule may comprise a ramp down phase to ambient or room temperature. The ramp down may be at a rate of 0.5-5°C / min, 0.75-4°C / min, 1-3, or 2°C / min. The curing schedule may be configured depending on the thickness of the composite material being formed.

[0061] The method may comprise a post-curing heating step e.g. comprising heating the composite material. The post-curing heating step may comprise a ramp-up phase, hold phase and a ramp down phase. The ramp up phase may be at a rate of 0.25-2°C / min, 0.5-1 .5°C / min, or 1 °C / min. The hold phase may comprise holding the composite material at 200-300°C, 210-290°C, 220-280°C, 230-270°C, 240-260°C, or 250-260°C, for 0.5-2 hours, or 0.75-1 .5 hours, or for 1 hour. The ramp down phase may be to ambient or room temp and may be at a rate of 0.5-5°C / min, 0.75-4°C / min, 1-3, or 2°C / min.

[0062] It will be understood that end points of the ranges may be combined in any manner.

[0063] In some embodiments, the curing step is carried out in the presence of a catalyst. In some embodiments, the curing step is carried out in the absence of a catalyst. The present inventors have found that catalysed curing steps can be highly exothermic and can be detrimental to the formation of the composite material. Preferably, no catalyst is used when the composite material being formed has a thickness greater than 25mm.

[0064] The method may further comprise forming one or more bores in the composite material to facilitate securing the composite material to other components of the pipe support and / or to the body. Forming the one or more bores may comprise drilling one or more bores into the composite material. Alternatively, the one or more bores may be formed as part of the curing process by virtue of the shape of the pipe support mould.

[0065] The method may further comprise securing one or more other components of the pipe support to the composite material. For example, the one or more other components may comprise a base portion, a support portion, and / or a securing portion.

[0066] Optionally, the mould is an open mould. Curing the pre-impregnated composite material may comprise exposing at least a surface of the pre-impregnated composite material to the atmosphere while the pre-impregnated composite material is disposed in the open mould.

[0067] Advantageously, open moulds are cheap, easy to manufacture, and easy to use. The provision of pipe supports may require the provision of a variety of pipe supports that take different forms and that are configured for use with pipes of different shapes and sizes. This means that a manufacturer of pipe supports may need to manufacture a variety of pipe supports having different structures but all comprising the composite material described herein. The use of an open mould during manufacture, including exposing the pre-impregnated composite material to the atmosphere, provides a readily- adaptable means of manufacture that can produce a variety of different shapes and sizes of pipe support (i.e. by producing a variety of open moulds). The features, characteristics, and advantages of each aspect may be combined with any of the other aspects described herein. In particular, the advantages of the pipe support (and, in particular, the cyanate ester resins) apply equivalently to the pipe wrap and the method.

[0068] Examples of the present disclosure will now be described, by way of example only, with reference to the Figures, in which:

[0069] Figure 1 is a front cross-sectional view of a pipe support according to a first example;

[0070] Figure 2 is an aspect view of a pipe support according to a second example;

[0071] Figure 3 is an aspect view of a pipe support according to a third example;

[0072] Figure 4 is an aspect view of a pipe support according to a fourth example;

[0073] Figure 5 is a plan view of a pipe support according to a fifth example;

[0074] Figure 6 is an aspect view of a pipe wrap; and

[0075] Figure 7 is a flowchart showing a method of manufacturing a pipe support.

[0076] Figures 1-5 depict examples of pipe supports according to the present disclosure. Pipe supports may take a variety of forms and may be manufactured either according to standard shapes and dimensions or according to bespoke requirements of an end-user. A pipe support according to the present disclosure could take substantially any form appropriate for the supporting of a pipe adjacent to a body and need not be limited to the specific embodiments described or depicted herein. Moreover, the features, characteristics, and advantages of each depicted example may be combined with any of the other examples described herein, as appropriate.

[0077] Figure 1 shows a front view of a first example of a pipe support 100 for supporting a pipe 10 (depicted in a dash-dot line) adjacent to a body 20. The pipe support 100 comprises a composite material 110, the composite material 110 including a cyanate ester resin. Advantageously, the use of a cyanate ester resin provides the advantages described herein, including improved thermal insulation at high and low temperatures and also improved mechanical strength.

[0078] The pipe support 100 comprises a base portion 120 securable to the body 20. As shown in Figure 1 , the base portion 120 may take the form of a base plate. The pipe support 100 further comprises a support portion 130. As shown in Figure 1 , the support portion 130 may take the form of a block disposed on the base portion 120.

[0079] The support portion 130 is coupled to the base portion 120. In the depicted example, the support portion 130 is coupled to the base portion 120 by virtue of two mechanical fasteners 150a, 150b (in this case, two nuts secured to each of two bolts). The mechanical fasteners 150a, 150b pass through the support portion 130 and extend into the base portion 120. The base portion 120 and / or the support portion 130 may comprise one or more bores (e.g. threaded bores) for receiving the mechanical fasteners 150a, 150b.

[0080] The support portion 130 is configured to receive the pipe 10 and hold the pipe 10 in position relative to the body 20. In the particular depicted example, the support portion

[0081] 130 is so configured by virtue of a contact surface 131 that is curved relative to a longitudinal axis of the pipe support 100. The longitudinal axis of the pipe support 100 is coaxial with a longitudinal axis of the pipe 10 when the pipe 10 is placed onto the contact surface 131. It will be understood that any other suitable feature may be used to receive and hold the pipe 10.

[0082] The support portion 130 comprises the composite material 110 on the contact surface

[0083] 131 of the support portion 130 that abuts the pipe 10 when the pipe 10 is placed onto the pipe support 100. In the depicted example, the support portion 130 comprises the composite material 110 substantially throughout the entirety of the support portion 130. That is, the support portion 130 is made of the composite material 110. In this way, the support portion 130 may take the form of a substantially uniform, unitary block.

[0084] Alternatively to the unitary arrangement, the composite material 110 may be disposed in one or more layers. For example, the composite material 110 may be disposed in a layer such that a surface of the layer abuts the pipe 10 when the pipe 10 is placed onto the pipe support 110. Alternatively or in addition, the composite material 110 may be disposed at an interface between the base portion 120 and the support portion 130.

[0085] It will be appreciated that the arrangement shown in Figure 1 is an example of a pipe support 100 in which the composite material 110 is arranged to provide load-bearing support to the pipe 10 when the pipe 10 is placed onto the pipe support 100. The pipe support 100 of Figure 1 further comprises a securing portion 140 for securing the pipe 10 to the pipe support 100. In this example, the securing portion 140 comprises a securing strap for securing across the pipe 10 to secure the pipe 10 to the pipe support 100. In particular, the securing strap may be a metal strap. The securing portion 140 may comprise one or more bores for receiving one or more mechanical fasteners 150a, 150b for securing the securing portion 140 to the base portion 120 and / or the support portion 130. In this case, the mechanical fasteners pass through the securing portion 140 and the support portion 130 to secure to the base portion 120, thereby securing these three components to one another.

[0086] Although not depicted in this example, the securing portion 140 may comprise the composite material 110 disposed on a contact surface of the securing portion 140 that abuts the pipe when the securing portion 140 secures the pipe 10 to the pipe support 100.

[0087] Figure 2 shows an aspect view of a second example of a pipe support 200 for supporting a pipe 10 adjacent to a body 20. The pipe support 200 comprises a composite material 210, the composite material 210 including a cyanate ester resin.

[0088] Like pipe support 100, the pipe support 200 comprises a base portion 220 securable to the body 20. In this example, the base portion 220 takes the form of an elongate bar. The pipe support 200 further comprises a securing portion 240 for securing the pipe 10 to the pipe support 200. In this example, the securing portion 140 takes the form of a bar with an approximately semi-circular cross-section.

[0089] In the depicted example, the base portion 210 comprises the composite material 210. The securing portion 240 also comprises the composite material 210. The base portion 210 and / or the securing portion 240 may be substantially entirely made of the composite material 210. Alternatively, the base portion 210 and / or the securing portion 240 may comprise a layer of the composite material 210. For example, the base portion 210 and / or the securing portion may comprise a core made from a different material (e.g. metal), the core being coated with a layer of the composite material 210. The base portion 130 is coupled to the body 20 by virtue of one or mechanical fasteners 250, but other means of coupling the base portion 130 to the body 20 may be used. In contrast to Figure 1 , in the example of Figure 2, the pipe 10 is placed directly onto the base portion 220 and is secured by the securing portion 240.

[0090] Figure 3 shows an aspect view of a third example of a pipe support 300 for supporting a pipe 10 adjacent to a body 20. The pipe support 300 comprises a composite material 310, the composite material 310 including a cyanate ester resin.

[0091] The pipe support 300 is structurally similar to the pipe support 200 depicted in Figure 2. However, the pipe support 300 comprises two base portions 320a, 320b. Each base portion 320a, 320b takes the form of an elongate bar, similarly to the base portion 20 of Figure 2.

[0092] The base portions 320a, 320b are largely identical and are each securable to the body 20. Advantageously, by using two base portions 320a, 320b separated by a gap, the pipe 10 may be stably supported by base portions 320a, 320b that are narrow compared to the length of the pipe 10 to be supported. This reduces the required width of the base portions 320a, 320b, thereby reducing the cost of the pipe support 300.

[0093] Each base portion 320a, 320b comprises the composite material 310. Like pipe support 200, each base portion 320a, 320b may be substantially entirely made of the composite material 310 or may comprise a layer of the composite material 310 surrounding a core of a different material (e.g. metal). Each base portion 320a, 320b is securable to the body 20 by mechanical fasteners 350a, 350b.

[0094] The pipe support 300 does not comprise a securing portion. However, it will be appreciated that the pipe support 300 could comprise one or more securing portions, for example, each securing portion being similar to the securing portion 240 depicted in Figure 2.

[0095] Figure 4 shows an aspect view of a fourth example of a pipe support 400 for supporting a pipe 10 adjacent to a body 20. The pipe support 400 comprises a composite material 410, the composite material 410 including a cyanate ester resin. The pipe support 400 comprises a base portion 420 securable to the body 20. In this example, the base portion 420 takes the form of an I-beam (i.e. a beam having an I- shaped cross-section). It will be understood that an I-beam refers to a beam having two parallel flanges that are joined by a web extending orthogonally to and between the flanges. The web bisects each flange. Beams with other cross-sectional shapes may also be used.

[0096] The pipe support 400 further comprises a support portion 430. The support portion 420 comprises a contact surface 431 that is curved relative to a longitudinal axis of the pipe support 400. The longitudinal axis of the pipe support 400 is coaxial with a longitudinal axis of the pipe 10 when the pipe 10 is placed onto the contact surface 431.

[0097] The pipe support 400 comprises the composite material 410 at an interface between the base portion 420 and the support portion 430. Advantageously, this arrangement provides thermal isolation between the pipe 10 and the base portion 420, allowing the material of the base portion 420 to be chosen without consideration of its thermal properties. For example, the material of the base portion 420 could be chosen to reduce the cost, reduce the weight, or increase the strength of the pipe support 400. The composite material 410 disposed at such an interface may also be load-bearing, having the advantages described herein.

[0098] The support portion 430 is coupled to the base portion 420. In the depicted example, the support portion 430 is coupled to the base portion 420 by virtue of a plurality (in this case ten, of which only five are visible in Figure 4) of mechanical fasteners 450. The mechanical fasteners 450, in this example, comprise nuts and bolts. The mechanical fasteners 450 extend through a flange of the support portion 420 and through one of the flanges of the I-beam that forms the base portion 420. The mechanical fasteners 450 extend via the composite material 410 that is disposed at the interface between the base portion 420 and the support portion 430. The base portion 420, the support portion 430, and / or the composite material may comprise one or more bores (e.g. threaded bores) for receiving the mechanical fasteners 450.

[0099] Figure 5 shows an aspect view of a fifth example of a pipe support 500 for supporting a pipe 10 adjacent to a body 20. The pipe support 500 comprises a composite material 510a, 510b, the composite material 510a, 510b including a cyanate ester resin. The pipe support 500 comprises a base portion 520 securable to the body 20. In this example, the base portion 520 takes the form of two posts 520a, 520b coupled to a base plate 520c. The base portion 520 may be securable to the body 20 via the base plate 520c, for example, by mechanical fasteners. It will be appreciated that the base portion 520 may comprise any number of posts 520a, 520b coupled to the base plate 520c.

[0100] The pipe support 500 further comprises a support portion 530. The support portion 530 takes the form of a cradle. In this example, the support portion 530 is integral with the base portion 520. However, it will be appreciated that the base portion 520 and the support portion 530 may be separate components that are connected to one another, for example, by mechanical fasteners.

[0101] The pipe support 500 further comprises a securing portion 540. The securing portion 540 comprises a securing strap for securing across the pipe 10 to secure the pipe to the pipe support 500. In the depicted example, the securing portion 540 is securable to the support portion 530 (and, in this case, specifically to the cradle) by way of mechanical fasteners 550a, 550b. The mechanical fasteners 550a, 550b comprise bolts that pass through one or more flanges of the securing portion 540 and one or more corresponding flanges of the support portion 530. It will be appreciated that other means may be used to secure the securing portion 540 to the pipe support 500. It is further contemplated that the securing portion 540 may take forms other than a securing strap. For example, the securing portion 540 may comprise a securing clamp having a hinge allowing the securing clamp to be opened and closed freely to allow a pipe to be inserted / removed and secured.

[0102] The pipe support 500 comprises the composite material in a first layer 510a and a second layer 510a. That is, the composite material 510a, 510b is disposed as a first layer 510a on the securing portion 540 and as a secondary layer 510b on the support portion 530. The first layer 510a and the second layer 510b are collectively arranged such that, when the securing portion 540 secures the pipe 10 to the pipe support 500, the first layer 510a and the second layer 510b form a substantially continuous layer that encloses the pipe 10 within the pipe support 500. As can be seen in Figure 5, the first layer 510a and the second layer 510b collectively form a substantially continuous layer having an annular cross-section. It will be appreciated that the second layer 510b could, alternatively or additionally, be disposed on the base portion 520 (for example, in examples where the base portion 520 and the support portion 530 are not integral).

[0103] Although not depicted, any of the aforementioned examples depicted in Figures 1-5 may further comprise a layer of secondary insulation material positioned such that, when the pipe 10 is placed onto the pipe support, the composite material is disposed between the pipe 10 and the layer of secondary insulation material.

[0104] For example, in the example of Figure 1 , the layer of secondary insulation material may be disposed between the support portion 130 and the base portion 120, and / or as a layer within the support portion 130 that is below a layer of the composite material 110.

[0105] In the example of Figure 2, the layer of secondary insulation material may be disposed between the base portion 220 and the body 20. Alternatively or additionally, the layer of secondary insulation material may be provided as a concentric layer that encloses the core of the base portion 220 and / or the securing portion 240 and is enclosed by the layer of composite material 210 in said portion.

[0106] In the example of Figure 3, the layer of secondary insulation material may be disposed between each base portion 320a, 320b and the body 20. Alternatively or additionally, the layer of secondary insulation material may be provided as a concentric layer that encloses the core of each base portion 320a, 320b and is enclosed by the layer of composite material 310 in each base portion 320a, 320b.

[0107] In the example of Figure 4, the layer of secondary insulation material may be disposed at the interface between the base portion 420 and the support portion 430 and, more specifically, between the composite material 410 and the base portion 420. Alternatively or additionally, the composite material 410 may be disposed between the base portion 420 and the body 20.

[0108] In the example of Figure 5, a first layer of secondary insulation material may be disposed between the first layer 510a of the composite material and the securing portion 540. Alternatively or additionally, a second layer of secondary insulation material may be disposed between the second layer 510b of the composite material and the support portion 530. In examples which comprise a first layer of secondary insulation material and a second layer of insulation material, it will be appreciated that the first layer of secondary insulation material and the second layer of insulation material may be collectively arranged such that, when the securing portion 540 secures the pipe 10 to the pipe support 500, the first layer and the second layer of secondary insulation material form a substantially continuous layer that encloses the pipe 10 within the pipe support 500. In other words, the substantially continuous layer of secondary insulation material may be provided as a concentric layer that encloses the substantially continuous layer of composite material.

[0109] Figure 6 shows an aspect view of three pipe wraps 600a, 600b, 600c for insulating an outer surface of a pipe 10 (not shown in Figure 6). Each pipe wrap 600a, 600b, 600c comprises a composite material 610, the composite material 610 including a cyanate ester resin.

[0110] Each pipe wrap 600a, 600b, 600c may substantially consist of the composite material 610 cured to form the shape of the pipe wrap. Alternatively, each pipe wrap 600a, 600b, 600c may comprise a core made from a different material (e.g. metal) and shaped to form the pipe wrap, the core being coated in a layer of the composite material 610.

[0111] Each pipe wrap 600a, 600b, 600c is shaped and dimensioned to fit the outer surface of a given pipe. For example, each pipe wrap 600a, 600b, 600c may be shaped to have a curvature that substantially matches the curvature of the pipe that the pipe wrap is intended to insulate.

[0112] Each pipe wrap 600a, 600b, 600c may only partially cover the outer surface of the pipe when in use. For example, as can be seen in Figure 6, the pipe wrap 600a is shaped and dimensioned to cover the majority of the outer surface of a pipe (e.g. the pipe wrap 600a having an arc length of around 270°), whereas pipe wrap 600b is shaped and dimensioned to cover less of the outer surface (e.g. the pipe wrap 600a having an arc length of around 180°), and the pipe wrap 600c is shaped and dimensioned to cover even less (e.g. the pipe wrap 600a having an arc length of around 90°). It will be appreciated that other pipe wraps having different curvatures and arc length may be provided, depending on the type of pipe to be insulated. Figure 7 depicts a method 700 of manufacturing a pipe support or a pipe wrap. The method 700 comprises heating 702 a cyanate ester resin to form a liquid resin. The method 700 further comprises combining 704 the liquid resin with one or more fibre and / or fabrics to form a pre-impregnated composite material. The method 700 further comprises disposing 706 the pre-impregnated composite material into a mould. In some embodiments (not shown), step 704 is carried out in situ in the mould by disposing the fibres and / or fabrics into the mould and applying the liquid resin. The method 700 further comprises curing 708 the pre-impregnated composite material to form the pipe support or the pipe wrap.

[0113] The mould may be an open mould. In such a case, curing 708 the pre-impregnated composite material may comprise exposing at least a surface of the pre-impregnated composite material to the atmosphere while the pre-impregnated composite material is disposed in the open mould. material formation

[0114] 1 kg of a cyanate ester resin (CER) was weighed out into an ovenproof vessel and placed in an oven at 90-95°C for 1 hour until all of the resin had reached 90°C. The CER selected was Primaset™ PT-30 supplied by Arxada. Separately, an 8mm deep mould was prepared by placing a laminate fabric comprising e-glass fibres into the mould and placing the mould inside an oven at 90-95°C.

[0115] Subsequently, 0.75wt% of catalyst (DETDA80) was heated to 50°C for 15 minutes, and then mixed with the CER for 4 minutes to produce a homogenous solution. Within a few minutes, the solution was added to the mould containing the laminate fabric and held at 90°C and allowed to infuse to form a pre-preg. Once infused, the curing schedule was carried out by heating the mould containing the pre-preg to 130° at a ramp-up rate of 1 °C per minute. The mould was then held at 130°C for 8 hours and then ramped down to ambient temperature to produce a cured composite material.

[0116] Subsequently, a post-curing process was carried out by heating the cured composite material to 260°C at a rate of 0.5°C per minute. The composite material was held at 260°C for 1 hour and then the temperature ramped down to form the final composite material with a thickness of 8mm. material formation

[0117] The process of Example 1 was repeated using 5kg of cyanate ester resin and a mould with a depth of 40mm. The cyanate ester resin was heated to 90°C for 2.5 hours to ensure it was a consistent temperature throughout. 0.75wt% of the catalyst was added, and the mixture added to the mould comprising the fabric. The curing schedule comprised a ramp up to 150°C at a rate of 1 °C per minute, and a hold at 150°C for 14 hours. Subsequently, the temperature was ramped up to 180°C at 1 °C per minute and held for 1 hour before ramping down to ambient. The same post-curing process was used to produce a final composite material with a thickness of 40mm. material formation

[0118] The process of Example 2 was repeated, omitting the catalyst from the pre-preg. The curing schedule comprised a ramp up to 150°C at a rate of 1 °C per minute, and a hold at 150°C for 14 hours. The temperature was then ramped up to 180°C at a rate of 1 °C per minute, and held for 1 hour. A further ramp up to 200°C was carried out at a rate of 1 °C per minute, held for one hour and then ramped down to ambient. The same postcuring process was used to produce a final composite material with a thickness of 40mm.

Claims

CLAIMS:

1. A pipe support for supporting a pipe adjacent to a body, the pipe support comprising a composite material, the composite material including a cyanate ester resin.

2. The pipe support according to claim 1 , wherein the pipe support comprises the composite material disposed in a layer such that a surface of the layer abuts the pipe when the pipe is placed onto the pipe support.

3. The pipe support according to claim 1 or claim 2, wherein the composite material is arranged to provide load-bearing support to the pipe when the pipe is placed onto the pipe support.

4. The pipe support according to any preceding claim, further comprising: a base portion securable to the body; and a support portion coupled to the base portion and configured to receive the pipe and hold the pipe in position relative to the body.

5. The pipe support according to claim 4, wherein the pipe support comprises the composite material disposed at an interface between the base portion and the support portion.

6. The pipe support according to claim 4 or claim 5, wherein the support portion comprises the composite material on a contact surface of the support portion that abuts the pipe when the pipe is placed onto the pipe support.

7. The pipe support according to any of clams 1 -3, further comprising a base portion securable to the body, wherein the base portion comprises the composite material on a contact surface of the base portion that abuts the pipe when the pipe is placed onto the pipe support.

8. The pipe support according to claim 6 or claim 7, wherein the contact surface is curved relative to a longitudinal axis of the pipe support, the longitudinal axis of the pipe support being coaxial with a longitudinal axis of the pipe when the pipe is placed onto the contact surface.

9. The pipe support according to any preceding claim, wherein the pipe support further comprises a layer of secondary insulation material positioned such that, when the pipe is placed onto the pipe support, the composite material is disposed between the pipe and the layer of secondary insulation material.

10. The pipe support according to any of claims 1 -3, further comprising a base portion securable to the body and configured to hold the pipe in position relative to the body, wherein the composite material is disposed at an interface between the base portion and the body.11 . The pipe support according to any preceding claim, further comprising a securing portion for securing the pipe to the pipe support.

12. The pipe support according to claim 11 , wherein the securing portion comprises the composite material disposed on a contact surface of the securing portion that abuts the pipe when the securing portion secures the pipe to the pipe support.

13. The pipe support according to claim 12, wherein the pipe support comprises a support portion and / or a base portion, and wherein the composite material is disposed as a first layer on the securing portion and as a second layer on the support portion or the base portion such that, when the securing portion secures the pipe to the pipe support, the first layer and the second layer form a substantially continuous layer that encloses the pipe within the pipe support.

14. The pipe support according to any preceding claim, wherein the composite material comprises a mixture of cyanate ester resin and epoxy resin.

15. The pipe support according to claim 14, wherein the ratio of cyanate ester resin to epoxy resin is 75:25 to 50:50.

16. A pipe wrap for insulating an outer surface of a pipe, wherein the pipe wrap comprises a composite material, the composite material including a cyanate ester resin.

17. A method of manufacturing a pipe wrap, a pipe support, or a component therefor, the method comprising: heating a cyanate ester resin to form a flowable liquid resin; combining the flowable liquid resin with one or more fibres and / or fabrics to form a pre-impregnated composite material; disposing the pre-impregnated composite material into a mould; and curing the pre-impregnated composite material to form the pipe support or the pipe wrap.

18. The method according to claim 17, wherein the mould is an open mould, and wherein curing the pre-impregnated composite material comprises exposing at least a surface of the pre-impregnated composite material to the atmosphere while the preimpregnated composite material is disposed in the open mould.

Images