Thermoplastic Composite Pipe Intermediate Lamina Adhesion
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Solution Overview
Problem
Existing thermoplastic composite pipes face challenges in achieving strong adhesion between different polymer layers, particularly in offshore applications where they are subjected to high stresses and corrosive conditions, leading to potential detachment and layer separation.
Innovation Solution
A process involving the bonding of tape laminas based on different polymers to produce a film with specific surface compositions, followed by heat application to enhance adhesion between the film and the composite layers, allowing for the use of diverse material combinations while ensuring strong bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different polymer materials are used for inner liner and composite layers, then material versatility and cost optimization are improved, but adhesion between layers deteriorates
Solution Approach 1:
The patent introduces an intermediate lamina composed of polymer C that is compatible with both polymer B (inner liner) and polymer D (outer composite layer). This intermediate layer acts as a mediator that bonds to both different polymers, enabling adhesion between incompatible materials while maintaining material selection freedom for cost optimization and performance tuning.
Solution Approach 2:
The patent employs a multilayer composite structure where each layer is made of different thermoplastic polymers (A, B, C, D) with specific functions. The composite structure combines the advantages of each material while the intermediate lamina ensures interlayer bonding, achieving both material versatility and structural reliability.
2Strength
If steel armour layers are used in unbonded flexible pipes, then structural strength is improved, but weight and corrosion resistance deteriorate
Solution Approach 1:
The patent replaces permanent, heavy steel armour layers with thermoplastic composite layers that provide sufficient strength for the application. The composite structure, while lighter and corrosion-resistant, achieves the necessary mechanical performance through optimized fibre reinforcement and multilayer construction, eliminating the need for heavy metal armour.
Solution Approach 2:
The patent changes the material parameter from metallic (steel) to polymeric (thermoplastic composites), fundamentally altering the weight-to-strength ratio. The composite layers maintain structural integrity through high-strength fibres embedded in thermoplastic matrices, achieving comparable strength with significantly reduced weight and improved corrosion resistance.
3Ease of operation
If unbonded flexible pipe structure is used, then flexibility and rollability are improved, but layer detachment under stress deteriorates
Solution Approach 1:
The patent segments the pipe structure into multiple functional layers (inner liner, intermediate lamina, composite layers, outer coating) with distinct properties. The unbonded flexible pipe structure allows relative movement between these segments under normal conditions for flexibility, while the intermediate lamina provides bonding capability when stress requires layer integration, preventing detachment.
Solution Approach 2:
The patent creates a dynamic bonding system where the intermediate lamina provides adhesion when needed (under stress, during installation) but allows flexibility during normal operation. The thermoplastic nature of the intermediate layer enables it to bond under compression or tension while maintaining overall pipe flexibility, adapting its bonding characteristics to operational conditions.
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 achieves high degrees of freedom in material selection and provides excellent adhesion at critical layer boundaries, enhancing the structural integrity and durability of the composite pipe, particularly in harsh offshore environments.
Implementation Method 1
with melting of the outer surface of the first composite layer and of the contact surface of the film either beforehand, simultaneously or thereafter
Data Source
AI summary
A process for producing a thermoplastic composite pipe is provided. The thermoplastic composite pipe thus produced contains a liner, two or more composite layers composed of tape laminas, and a single- or multilayer intermediate lamina arranged between different composite layers. Composite formation between identical polymers in the process achieves improved adhesion. The thermoplastic composite pipe is especially suitable for offshore applications in oil or gas production.