Carbon Fiber Thermoplastic Pipe Layer for High-Strength Lightweight Armor
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Solution Overview
Problem
Conventional flexible pipes used in deep and ultra-deep water environments face challenges due to increased pressure and temperature, leading to potential pipe blockage and high material costs associated with using thicker, stronger materials to enhance load response, which also increase weight and material costs.
Innovation Solution
A thermoplastic composite is developed by commingling polymer filaments and carbon fibre filaments to form an intimate mixture, which is then formed into yarns, tapes, and applied to the pipe body to create a flexible pipe layer with varying carbon fibre concentrations, improving mechanical properties and reducing weight compared to metal wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thicker and stronger materials are used to improve load response and performance of armour layers, then strength and load-bearing capacity are improved, but weight of the flexible pipe increases
Solution Approach 1:
The patent applies composite materials by combining polymer matrix with carbon fibre reinforcements to create armour layers that provide high strength-to-weight ratio. The carbon fibre composite armour layers deliver the necessary load-bearing capacity while being significantly lighter than traditional metal wire alternatives, directly resolving the contradiction between strength improvement and weight increase.
2Strength
If thicker and stronger materials are used to manufacture armour layers, then strength and load-bearing capacity are improved, but material costs increase appreciably
Solution Approach 1:
The patent employs carbon fibre composite materials which provide superior strength properties at lower material costs compared to traditional thick metal wires. The composite structure allows achieving the same or better load-bearing capacity with more cost-effective materials, thereby resolving the contradiction between improved strength and increased material costs.
3Reliability
If conventional metal wire armour layers are used in deep and ultra-deep water environments, then structural integrity is maintained, but weight and material costs become limiting factors
Solution Approach 1:
The patent replaces conventional metal wire armour layers with carbon fibre composite armour layers that maintain structural integrity in deep and ultra-deep water environments. The composite material provides equivalent or superior mechanical properties while significantly reducing weight, thereby resolving the contradiction between maintaining reliability and reducing weight limitations.
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 thermoplastic composite provides sufficient mechanical strength to absorb radial and axial forces while being lighter than metal wires, allowing for controlled mechanical properties and reduced material costs, thus enhancing the performance and efficiency of flexible pipes in extreme environments.
Implementation Method 1
The thermoplastic composite comprises fluoropolymer filaments and carbon fibre filaments
Implementation Method 2
forming the yarns into a tape
Data Source
Figure 1
Figure 2
AI summary
A method of making a flexible pipe layer, which method comprises: commingling polymer filaments and carbon fibre filaments to form an intimate mixture, forming yarns of the commingled filaments, forming the yarns into a tape, and applying the tape to a pipe body to form a flexible pipe layer.