Composite Flexible Pipe Layer for High-Strength Low-Weight Armour
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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 weight-related issues, as well as high material costs when using thicker materials to enhance strength.
Innovation Solution
A thermoplastic composite is developed by commingling polymer and carbon fibre filaments to form a tape that can be wound around a pipe body, providing a lightweight yet strong pressure armour layer with varying carbon fibre concentrations to manage radial and axial forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thicker and stronger materials are used to manufacture pressure armour layers, then the load response and strength are improved, but the weight of the flexible pipe increases
Solution Approach 1:
The patent applies composite materials by combining polymer filaments with carbon fibre filaments to create a thermoplastic composite armour layer. This composite structure provides high strength-to-weight ratio, achieving the required load response and strength while maintaining lower weight compared to conventional thicker metal wires. The carbon fibre reinforcement within the polymer matrix enables enhanced mechanical properties without proportionally increasing mass.
Solution Approach 2:
The patent utilizes parameter changes by controlling the melt flow index of the fluoropolymer within a specific range (40-80 g/10 min at 230°C/2.16 kg). This parameter optimization ensures proper flow characteristics during processing while achieving the desired composite structure and mechanical properties, allowing the material to be formed into effective armour layers with optimized strength and weight characteristics.
2Strength
If thicker and stronger materials are used to manufacture pressure armour layers, then the load response is improved, but the material costs increase appreciably
Solution Approach 1:
The composite structure of fluoropolymer and carbon fibre filaments provides an cost-effective solution by utilizing materials with high specific strength. The carbon fibre reinforcement allows for thinner, more efficient armour layers compared to conventional metal wires, reducing the total quantity of expensive materials required while maintaining or improving load response capabilities.
Solution Approach 2:
The thermoplastic composite material offers a cost-effective alternative to traditional metal wire armour layers. The combination of polymer and carbon fibre provides comparable or superior performance at lower material costs, making the flexible pipe more economically viable for deep and ultra-deep water applications.
3Force
If conventional metal wires are used for pressure armour layers, then the radial forces are effectively managed, but the weight and material costs increase
Solution Approach 1:
The patent replaces conventional metal wire armour layers with a composite material consisting of fluoropolymer and carbon fibre filaments. This composite structure effectively manages radial forces through the high strength-to-weight ratio of carbon fibre reinforcement, providing comparable force resistance while significantly reducing the overall weight of the flexible pipe.
Solution Approach 2:
The patent substitutes the mechanical wire-based armour system with a composite material system. The thermoplastic composite combines the structural benefits of fibre reinforcement with the processing advantages of polymer materials, achieving effective radial force management through material composition rather than relying solely on thick metal wire construction.
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 improves mechanical properties and adhesion, allowing for a flexible pipe layer that maintains structural integrity while reducing weight and material costs, enabling reliable operation in extreme environments.
Implementation Method 1
a thermoplastic composite comprising fluoropolymer filaments and carbon fibre filaments, wherein the fluoropolymer filaments and carbon fibre filaments are commingled to form an intimate mixture
Implementation Method 2
The fluoropolymer has a melt flow index (230° C./2.16 kg) in the range of 40 to 80 g/10 min
Data Source
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.