Composite Pipe Intermediate Lamina for Bonding Dissimilar Polymers
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Solution Overview
Problem
Existing thermoplastic composite pipes face challenges in achieving adequate bonding between fibre-rich tape laminas and the inner liner, especially under high stresses and corrosive conditions in offshore applications, and the production of multilayer pipes with large diameters is hindered by limited extrusion systems and incompatible polymer combinations.
Innovation Solution
A process involving the application of a film with a polymer A surface bonded to the liner and a polymer B surface bonded to the tape, followed by heating to achieve strong adhesion, allowing for the use of different thermoplastic polymers and enabling the production of thermoplastic composite pipes with high material freedom and robust layer boundaries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different thermoplastic polymers are used for the inner liner and tape matrix, then material versatility is improved, but bonding strength between layers deteriorates
Solution Approach 1:
A multilayer intermediate lamina is introduced between the inner liner and the fibre-reinforced tape lamina. This intermediate lamina consists of multiple layers with different polymer compositions, where at least one layer contains a polymer compatible with the inner liner and at least one layer contains a polymer compatible with the tape matrix. This intermediate structure acts as a mediator that enables bonding between incompatible polymers, allowing material versatility while maintaining bonding strength.
2Strength
If fibre-rich tape laminas are used for high strength, then mechanical strength is improved, but bonding adequacy deteriorates under stress
Solution Approach 1:
The intermediate lamina is designed with local quality variations, where different layers have different polymer compositions tailored to bond with specific adjacent layers. The first layer bonds with the inner liner, intermediate layers provide transition and bonding support, and the last layer bonds with the fibre-reinforced tape. This localized optimization of material properties ensures reliable bonding at each interface while maintaining the high mechanical strength of the fibre-rich tape laminas.
3Strength
If multilayer intermediate lamina is used to improve bonding, then bonding strength is improved, but production complexity increases
Solution Approach 1:
The multilayer intermediate lamina serves multiple functions simultaneously: it provides bonding interfaces for incompatible polymers, acts as a stress distribution layer, and enables the use of fibre-rich tape laminas for high mechanical strength. By consolidating these multiple functions into a single integrated component with optimized layer structure, the design achieves high bonding strength while managing production complexity through functional integration rather than separate components.
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
This process ensures strong adhesion between the tape and liner, enabling the use of diverse polymer combinations and facilitating the production of thermoplastic composite pipes with improved mechanical properties suitable for offshore applications, while allowing the use of existing extrusion plants without modification.
Implementation Method 1
The film is heated, with melting of the outer surface of the liner and of the contact surface of the film
Implementation Method 2
with melting of the outer surface of the liner and of the contact surface of the film either beforehand, simultaneously or thereafter
Implementation Method 3
where the composite formation of the film and of the tape is effected with application of a contact pressure
Data Source
AI summary
A process for producing a thermoplastic composite pipe, where the process includes:a) providing a tubular liner having a wall containing a thermoplastic polymer A in the region of the outer surface;b) providing a tape containing reinforcing fibres in a matrix containing a thermoplastic polymer B, where polymer A and polymer B are different;c) applying a film or a composite which is produced in d) and is composed of a film and a tape provided in step b) to the tubular liner, with melting of the outer surface of the liner and of the contact surface of the film either beforehand, simultaneously or thereafter,d) applying the tape provided in b) to the outer surface of the film, with melting of the outer surface of the film applied and of the contact surface of the tape either beforehand, simultaneously or thereafter,where the surface of the film which is brought into contact with the liner contains a moulding compound containing polymer A to an extent of at least 30% by weight, and the opposite surface of the film contains a moulding compound containing polymer B to an extent of at least 30% by weight.