Flexible Composite Pipe Spiral Reinforcement for High Pressure
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Solution Overview
Problem
Existing methods for producing flexible thermoplastic composite pipes do not adequately address the need for improved structural and functional performance, particularly in terms of high-pressure resistance and long-distance transportation of media.
Innovation Solution
A method involving the production of a flexible thermoplastic composite pipe using a multi-ply reinforcing layer applied through a spiral winding process, followed by thermal consolidation to fuse the reinforcing layers with the thermoplastic pipe, enhancing the pipe's structural integrity and pressure resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a multi-ply reinforcing layer is applied through spiral winding process, then the pipe's pressure resistance and structural integrity are improved, but the manufacturing complexity and process time increase
Solution Approach 1:
The thermoplastic pipe is pre-heated before the reinforcing layers are applied, preparing the base material in advance to facilitate subsequent bonding. This preliminary heating action enables the reinforcing layers to be firmly bonded when they are later consolidated, improving pressure resistance without requiring complex real-time heating systems during the winding process.
Solution Approach 2:
The patent utilizes temperature parameter changes to control the bonding process. The thermoplastic pipe and reinforcing layers are heated to specific temperatures to enable fusion bonding, then cooled to set the structure. This parameter-based approach simplifies the manufacturing process by using thermal cycles rather than complex mechanical bonding systems.
2Stability of the object's composition
If multiple reinforcing plies are consolidated through thermal processing, then the structural integrity is enhanced, but the production time and energy consumption increase
Solution Approach 1:
Multiple reinforcing plies are wound and consolidated in a continuous sequence without interruption. The spiral winding process applies multiple layers in one continuous operation, and the thermal consolidation follows immediately, merging the winding and bonding operations into an integrated process that reduces total production time while maintaining structural integrity.
Solution Approach 2:
The patent maintains continuous heating and winding operations throughout the manufacturing process. The thermoplastic pipe remains in a heated, bondable state throughout the entire reinforcing layer application, eliminating idle time between layers. This continuous action ensures structural integrity while minimizing production time by avoiding repeated heating cycles.
3Strength
If the reinforcing layers are firmly bonded to the thermoplastic pipe, then the high-pressure resistance is improved, but the flexibility and pliability of the pipe are reduced
Solution Approach 1:
The reinforcing layers are applied in a spiral pattern rather than as complete circumferential wraps, creating localized reinforcement zones. This allows the pipe to maintain flexibility in areas between the spiral windings while still achieving high pressure resistance at the reinforced locations. The local application of strength provides both pressure resistance and retained flexibility.
Solution Approach 2:
The spiral winding pattern creates a curved, helical reinforcement structure that naturally accommodates pipe bending and flexing. Unlike rigid circumferential hoops, the spiral configuration allows the reinforcing layers to follow the pipe's curvature during flexing, maintaining both firm bonding for pressure resistance and the pipe's overall flexibility for installation adaptability.
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 results in a thermoplastic composite pipe that is both flexible and robust, capable of withstanding high pressures and transporting media over long distances while maintaining its pliability.
Implementation Method 1
The plastics pipe may be or will be produced by means of an extrusion process or pultrusion process
Implementation Method 2
followed by thermal consolidation to fuse the reinforcing layers with the thermoplastic pipe
Data Source
AI summary
A method for producing a flexible thermoplastic composite pipe, wherein the method comprises the following steps: applying a first ply of a reinforcing layer onto a plastics pipe; consolidating the first ply of the reinforcing layer with the plastics pipe, wherein at least the first ply of the reinforcing layer is brought to a first temperature which leads to at least partial melting of the first ply of the reinforcing layer, such that the first ply of the reinforcing layer and the plastics pipe are rigidly interconnected, in particular in a fused manner; applying a second ply of the reinforcing layer onto the first ply of the reinforcing layer; consolidating the second ply of the reinforcing layer with at least the first ply of the reinforcing layer, wherein at least the second ply of the reinforcing layer is brought to a second temperature which leads to at least partial melting of the second ply of the reinforcing layer, such that the second ply of the reinforcing layer and the first ply of the reinforcing layer are rigidly interconnected, in particular in a fused manner; applying at least a third ply of the reinforcing layer onto the second ply of the reinforcing layer; consolidating the at least one third ply of the reinforcing layer with at least the second ply of the reinforcing layer, wherein at least the third ply of the reinforcing layer is brought to a third temperature which leads to at least partial melting of the third ply of the reinforcing layer, such that the third ply of the reinforcing layer and the second ply of the reinforcing layer are rigidly interconnected, in particular in a fused manner, and thermoplastic composite pipe and the use of a thermoplastic composite pipe.