Composite Layer Structure for High-Peel Pipeline Insulation Patches
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Solution Overview
Problem
Subsea pipelines and structures face challenges with insulation due to temperature and pressure changes, leading to issues with fuel viscosity, clogging from waxes and hydrates, and inadequate adhesion of polymer patches, which affects the integrity and efficiency of petroleum fuel transport.
Innovation Solution
A composite article with a low surface energy polymer layer, a poly(meth)acrylate layer formed with an organoborane initiator, an epoxide layer, and a polyurethane elastomer layer, providing increased peel strength and improved adhesion for insulation and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If low surface energy polymers (polyethylene, polypropylene) are used for insulation coating, then insulation performance is improved, but adhesion to polymer patches deteriorates
Solution Approach 1:
The patent introduces an intermediate layer comprising a poly(meth)acrylate formed with an organoborane initiator between the low surface energy polymer insulation layer and the polymer patches. This intermediate layer acts as a mediator that provides both insulation properties and adequate adhesion to the patches, resolving the contradiction between maintaining insulation performance and achieving sufficient adhesion strength.
2Strength
If flame treatment is applied to increase surface energy, then adhesion ability is improved, but peel strength remains insufficient
Solution Approach 1:
The patent changes the chemical parameters of the intermediate layer by using a poly(meth)acrylate formed with an organoborane initiator, which provides superior adhesion properties compared to conventional flame treatment. This parameter change in the chemical composition and formation process achieves both adequate adhesion ability and reliable peel strength (at least 50 pli).
3Productivity
If insulation is applied to maintain fuel temperature, then fuel flow efficiency is improved, but adhesion of insulation patches deteriorates
Solution Approach 1:
The patent creates a composite structure consisting of the low surface energy polymer insulation layer, the poly(meth)acrylate intermediate layer formed with organoborane initiator, and the polymer patches. This composite material system maintains the thermal insulation properties necessary for fuel flow efficiency while the intermediate layer ensures reliable patch adhesion.
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 composite article achieves a 90° peel strength of at least 50 pli, ensuring effective insulation and adhesion, preventing fuel from becoming too viscous and clogging, while maintaining fuel integrity during transport.
Implementation Method 1
the poly(meth)acrylate layer includes a poly(meth)acrylate that includes the reaction product of at least one acrylate polymerized in the presence of an organoborane initiator
Implementation Method 2
the various subsea pipelines and structures be insulated to maintain the relatively high temperature of the petroleum fuels
Data Source
Figure 1~2
Figure 3
AI summary
A composite article has an increased peel strength and includes a first layer including a low surface energy polymer. The composite article also includes a poly(meth)acrylate layer, an epoxide layer, and a polyurethane elastomer layer. The poly(meth)acrylate layer is disposed on and in direct contact with the first layer. Moreover, the poly(meth)acrylate layer includes a poly(meth)acrylate that includes the reaction product of at least one (meth)acrylate that is polymerized in the presence of an organoborane initiator. The epoxide layer is disposed on and in direct contact with the poly(meth)acrylate layer. The polyurethane elastomer layer is disposed on and in direct contact with the epoxide layer. The composite article has a 90° peel strength of at least 50 pli measured using ASTM D6862.