FRP Core Pipe Structure for Lightweight Buckling Resistance
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Solution Overview
Problem
Conventional pipes are heavy due to solid walls made from a single material, and existing lightweight solutions like 3D fabric-reinforced pipes face issues with buckling under external loads, necessitating the development of a non-corroding, lightweight, and strong pipe that can be easily manufactured and installed without requiring heavy equipment.
Innovation Solution
The Lightweight Strong Pipe (LSP) is constructed using layers of resin-saturated or resin-fortified Fiber Reinforced Polymer (FRP) fabrics wrapped around a mandrel with optional Core layers for added stiffness and strength, featuring a Core material with distinct A and B regions for optimized resin infusion and distribution, allowing for customizable strength and stiffness in any direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid walls made from a single material are used, then strength is improved, but weight increases
Solution Approach 1:
The pipe is constructed using composite materials consisting of multiple layers including FRP fabric layers saturated with resin, core layers with A and B regions, and optional steel wires or meshes. This composite structure achieves high strength while reducing weight compared to solid single-material pipes.
Solution Approach 2:
The pipe wall is segmented into distinct functional layers: outer FRP layers for strength, core layers with A and B regions for resin distribution and stiffness, and optional reinforcement elements. This segmentation allows each layer to contribute specifically to strength while minimizing overall weight.
2Weight of stationary object
If 3D fabric-reinforced pipes are used to reduce weight, then weight is reduced, but buckling resistance deteriorates under external loads
Solution Approach 1:
The core layer is designed with distinct A and B regions where A regions provide localized support to prevent buckling of fabric columns, while B regions allow resin flow and distribution. This local differentiation provides buckling resistance exactly where needed without adding unnecessary weight throughout the entire pipe structure.
Solution Approach 2:
The core layer acts as an intermediary between the outer FRP layers, providing structural support to prevent buckling while allowing resin to permeate through to saturate the fabric layers. The core's A and B regions mediate between the need for buckling resistance and resin distribution.
3Strength
If multiple layers of FRP fabric and core materials are used, then strength and stiffness are improved, but manufacturing complexity increases
Solution Approach 1:
Multiple functional elements are merged into an integrated manufacturing process: FRP fabric layers, core layers with A and B regions, resin saturation, and optional reinforcement elements are all combined in a sequential wrapping process around a mandrel, simplifying what would otherwise be separate manufacturing steps.
Solution Approach 2:
The core layer with A and B regions serves multiple functions simultaneously: it provides structural support to prevent buckling, acts as a resin distribution network, and contributes to pipe stiffness. This multi-functionality reduces the need for separate components, simplifying manufacturing.
4Ease of manufacture
If uniform resin distribution is used, then manufacturing simplicity is improved, but structural performance deteriorates
Solution Approach 1:
The core layer's A and B regions create localized zones with different resin absorption and flow characteristics. B regions are designed to channel and distribute resin uniformly to surrounding A regions, ensuring adequate resin saturation in areas that would otherwise be difficult to reach, thereby improving structural performance without complicating manufacturing.
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 LSP achieves significant weight reduction and increased strength while being cost-effective, allowing for the construction of pipes of any shape and size with minimal equipment, and can be used for both new pipeline construction and repair, offering enhanced durability and ease of installation.
Implementation Method 1
The wrapped materials are allowed to cure around the mandrel—preferably undisturbed until the resin cures.
Implementation Method 2
Core material with distinct A and B regions for optimized resin infusion and distribution
Data Source
AI summary
Methods and systems are disclosed for manufacturing or reinforcing of any length, shape, size, and any thickness pipe with a plurality of layers comprising at least a first reinforcement sheet, a pre-designed and localized resin-fortified Core, and a second reinforcement sheet. The Core includes “A-regions” which are designed to absorb less resin, and “B-regions” which are designed to absorb more resin. For reinforcing a pipe, a first reinforcement sheet is placed over the inside and/or the outside surface of the pipe. A pre-designed and localized resin-fortified Core is placed over and adhered to the first reinforcement sheet. Subsequently a second reinforcement sheet is placed over the surface of the Core, such that the Core stays between the first and the second reinforcement sheet. Next, the resin-saturated sheets and Core are cured—depending on the type of resin—by partial or complete exposure to ambient temperature, to heat, or to light.