Metal-Resin Composite Pipe Coating for Ring Winding Without Deformation
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Solution Overview
Problem
The existing manufacturing methods for metal resin composite pipes face challenges in producing pipes that can be wound in a ring shape without deformation, maintaining circular cross-sectional shape, and achieving high surface quality and density without a sizing process, which affects transportability, constructability, and economic efficiency.
Innovation Solution
A metal resin composite pipe is manufactured with a metal pipe coated by a resin layer and an adhesive layer, where the thickness ratio of the metal pipe to the resin layer is within 5% to 20%, and the resin is extruded under pressure to minimize curvature radius and prevent deformation during winding, using a coating mold unit to ensure proper coating and shape retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a metal pipe is bent to a minimum curvature radius, then the pipe can be wound in a ring shape for improved transportability, but the circular cross-sectional shape deforms or the pipe folds due to material characteristics
Solution Approach 1:
The patent applies composite materials by coating the metal pipe with a resin layer having different mechanical properties. The resin layer has lower elastic modulus and higher ductility compared to the metal pipe, allowing the composite structure to bend to minimum curvature radius without deforming the circular cross-section or folding, thus enabling ring-shaped winding for improved transportability while maintaining shape integrity.
2Reliability
If a thick resin layer is coated on a thin plate metal pipe, then corrosion resistance and cost efficiency improve, but the pipe becomes difficult to wind without deformation
Solution Approach 1:
The patent optimizes the thickness ratio parameter between the metal pipe and resin layer. By controlling the resin layer thickness to be 1.5 to 5 times the metal pipe thickness (within specific ranges), the composite pipe achieves optimal balance: sufficient corrosion resistance from the thick resin layer while maintaining flexibility for winding. This parameter optimization prevents deformation during winding despite the thick coating.
Solution Approach 2:
The composite structure combines metal pipe (for structural integrity) with thick resin layer (for corrosion resistance). The resin layer thickness is optimized to provide protective function while the composite action between metal and resin enables the pipe to be wound without deformation, resolving the contradiction between thick coating and winding processability.
3Ease of operation
If a metal pipe is produced in straight shape with predetermined length, then delivery convenience is improved, but considerable amounts of components, manpower, and time are required for connecting at construction site
Solution Approach 1:
The patent winds the metal resin composite pipe into a ring shape (circular configuration) instead of producing it in straight segments. This curved/ring configuration allows the pipe to be delivered as a continuous long-length product that can be unrolled and installed at the construction site without requiring multiple connection operations, thereby reducing components, manpower, and time while maintaining delivery convenience.
4Ease of manufacture
If extrusion is performed with outer diameter slightly greater than desired outer diameter, then the pipe can be formed during cooling, but a sizing process is required to meet density and surface requirements
Solution Approach 1:
The patent adjusts the extrusion parameters and cooling conditions to achieve the desired outer diameter and density directly during the cooling process. By optimizing the extrusion pressure, temperature, and cooling rate parameters, the pipe attains the correct dimensions and surface quality without requiring an additional sizing process, thereby reducing process complexity while maintaining forming flexibility.
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 method allows for the production of pipes that can be wound in a ring shape with maintained circular cross-section, offering improved transportability, constructability, and economic efficiency, along with high surface quality and proper density without the need for a sizing process.
Implementation Method 1
the resin is extruded under pressure to minimize curvature radius and prevent deformation during winding
Implementation Method 2
a metal resin composite pipe includes a metal pipe, a resin layer formed by coating an outer surface of the metal pipe, and an adhesive layer formed between the metal pipe and the resin layer
Data Source
AI summary
The present invention may manufacture a composite pipe by forming an adhesive layer and a resin layer on an outer surface of a metal pipe, and although the composite pipe is wound in a ring shape after the composite pipe is manufactured, a circular cross sectional shape may be maintained without deformation, and after the composite pipe is straightened for the purpose of construction, separation or buckling may be prevented, resulting in excellent transportability and constructability of a product.