Composite Pipe Intermediate Lamina for Strong Multilayer Bonding
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Solution Overview
Problem
Existing thermoplastic composite pipes face challenges in achieving adequate bonding between fibre-rich tape laminas and the adjoining surfaces, particularly in offshore applications, where stresses and corrosive conditions are high, 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 surface comprising polymer A from the liner and polymer B from the tape matrix, bonded with heat, followed by application to the liner and subsequent tape laminas, allowing for high material freedom and strong adhesion at critical layer boundaries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fibre-rich tape lamina is bonded to the liner surface, then the composite pipe structure is formed, but the bonding is inadequate to withstand stresses in offshore applications
Solution Approach 1:
An intermediate lamina is introduced between the liner and the fibre-rich tape lamina. This intermediate layer acts as a bonding mediator, with its first surface bonded to the liner and its second surface bonded to the tape lamina, thereby achieving reliable bonding between incompatible materials in offshore applications
Solution Approach 2:
The intermediate lamina is constructed as a composite material system with different polymer compositions on each surface. The first surface uses a polymer compatible with the liner material, while the second surface uses a polymer compatible with the tape matrix, creating a composite structure that bonds both materials effectively
2Strength
If multilayer pipes with large diameters are produced, then the pipe structure is enhanced, but the production is hindered by limited extrusion systems
Solution Approach 1:
The multilayer pipe structure is segmented into distinct functional layers: an inner liner, an intermediate lamina with specific bonding properties, and outer fibre-rich tape laminas. This segmentation allows each layer to be optimized and produced using appropriate methods, making large diameter production feasible
Solution Approach 2:
The invention changes the material parameters of the intermediate lamina, specifying that it comprises at least 30% by weight of a polymer matching the liner material and at least 30% by weight of a polymer matching the tape matrix. This parameter specification enables compatibility with existing extrusion systems while achieving the desired multilayer structure
3Strength
If polymer combinations are optimized for adhesion, then bonding strength is improved, but the adaptability of material selection is reduced
Solution Approach 1:
The intermediate lamina exhibits local quality with different polymer compositions at different surfaces. The first surface is optimized for bonding to the liner material, while the second surface is optimized for bonding to the tape matrix. This local optimization allows strong adhesion without restricting overall material selection freedom
Solution Approach 2:
The intermediate lamina is a composite material containing at least 30% by weight of a polymer compatible with the liner and at least 30% by weight of a polymer compatible with the tape matrix. This composite structure enables the use of different polymer combinations while maintaining strong adhesion at both interfaces
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 enhances the adhesion between the liner and tape laminas, enabling the production of thermoplastic composite pipes with improved strength and flexibility, suitable for offshore oil and gas applications, while allowing the use of existing extrusion plants without modification.
Implementation Method 1
a single- or multi-layer intermediate lamina which is arranged between the inner liner and tape lamina and bonds them
Implementation Method 2
bonded with heat, followed by application to the liner and subsequent tape laminas
Implementation Method 3
the material of the inner liner, the matrix of the tape laminas and the polymers of the intermediate lamina are thermoplastic
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.