Braided Composite Armour Layer for Flexible Pipe Weight Reduction
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Solution Overview
Problem
Existing flexible pipe designs for deep and ultra-deep water environments face challenges with high tension loads and weight increase due to thicker materials needed for strength, which can lead to pipe failure and increased costs, while composite materials like thermoset composites introduce manufacturing difficulties and residual strain during winding.
Innovation Solution
A method involving composite filaments bundled into a braided structure, helically wrapped around a pipe layer, and cured in situ to minimize residual strain and weight, using a braid element to hold the filaments in place and provide strength without significant tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thicker and stronger materials are used in armour layers to improve load response and performance, then strength increases, but weight increases
Solution Approach 1:
The patent applies composite materials consisting of a polymer matrix and discrete reinforcing fibres (such as aramid, carbon, or glass fibres) to create armour layers that provide high strength-to-weight ratio. The composite structure allows the flexible pipe to withstand high tension and pressure loads while maintaining reduced weight compared to traditional solid metallic armour layers.
2Strength
If thicker materials are used to increase strength, then performance improves, but material costs increase
Solution Approach 1:
The composite armour layers use discrete reinforcing fibres embedded in a polymer matrix, which provides high strength with reduced material quantity compared to solid metallic layers. This composite approach allows achieving the required strength performance while significantly reducing the total material quantity and associated costs.
3Weight of moving object
If thermoset composite materials are used to reduce weight, then weight decreases, but manufacturing difficulty increases due to residual strain during winding
Solution Approach 1:
The patent employs thermoset composite materials for the armour layers, utilizing their high strength-to-weight ratio. The manufacturing process involves winding the composite materials in a controlled manner and curing them to minimize residual strains. The parameter changes in material selection and processing conditions are optimized to achieve reduced weight while managing manufacturing complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The braided composite armour layer reduces weight and enhances performance by minimizing residual strain and maintaining high strength, making it suitable for deep and ultra-deep water applications with improved flexibility and resistance to damage.
Implementation Method 1
curing the one or more composite filament
Data Source
AI summary
A flexible pipe body and method of producing a flexible pipe body are disclosed. The method includes providing one or more composite filament (302) as a filament bundle (310); applying a braid element (304) around the filament bundle as a braided bundle (310); helically wrapping the braided bundle (310) around a flexible pipe layer (502); and then curing (510) the one or more composite filament (302).