On-Site FRP Pipe Manufacturing via Helical Winding
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Solution Overview
Problem
Traditional pipeline construction methods are costly, environmentally disruptive, and inefficient, particularly in urban areas, due to the need for open trench digging and transportation of pre-manufactured pipe segments, which disrupts traffic and increases project costs.
Innovation Solution
On-site manufacturing of continuous FRP pipes using resin-saturated carbon or glass fabric wrapped around a mandrel, allowing for rapid curing and installation within tunnels or existing pipes, reducing material waste and transportation costs by varying reinforcement layers based on load requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional open trench digging and pre-manufactured pipe segment transportation are used, then pipe installation can be completed, but project costs increase and environmental disruption occurs
Solution Approach 1:
The patent applies preliminary action by manufacturing the pipe directly at the installation site before it is needed, eliminating the need for pre-manufacturing, storage, and transportation of pipe segments. The continuous pipe is formed on-site through winding reinforcement materials and applying resin, then cured in place, so the pipe is ready for installation exactly when and where needed.
Solution Approach 2:
The patent extracts the pipe manufacturing process from traditional centralized factories and relocates it to the installation site. This extraction eliminates the harmful intermediate steps of storage and transportation, and allows the pipe to be manufactured continuously in the exact location where it will be installed, reducing material waste and environmental disruption.
2Productivity
If pre-manufactured pipe segments are transported to the site, then pipe installation can proceed, but transportation costs and traffic disruption increase
Solution Approach 1:
The patent performs the pipe manufacturing action preliminarily at the installation site rather than at a remote factory. By setting up the winding and curing equipment on-site and manufacturing the pipe continuously as it is installed, the process eliminates transportation time entirely while maintaining high installation efficiency through continuous operation.
Solution Approach 2:
The patent merges the pipe manufacturing process with the installation process into a single continuous operation. The pipe is formed, cured, and installed in one continuous sequence without interruption, combining what were traditionally separate processes (manufacturing, transportation, and installation) into a unified on-site operation that eliminates transportation time.
3Ease of manufacture
If uniform reinforcement layers are used throughout the pipe, then manufacturing is simplified, but load requirements cannot be optimized
Solution Approach 1:
The patent applies local quality by varying the reinforcement layer configuration at different locations along the pipe based on specific load requirements. The winding process can adjust the number of layers, fiber orientation, and material type at each section, providing optimized strength where needed while using lighter reinforcement in areas with lower loads, thus achieving both manufacturing efficiency and structural optimization.
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 method significantly reduces project costs by minimizing trench excavation, pipe storage, and transportation, while enabling flexible reinforcement designs to match load conditions, resulting in cost-effective and sustainable pipeline construction.
Implementation Method 1
resin-saturated carbon or glass fabric wrapped around a mandrel, allowing for rapid curing and installation
Data Source
AI summary
Methods and systems are disclosed for laying trenchless pipes under ground. In these methods strips of fabrics saturated with resin are helically or non-helically wrapped around desired shape mandrels that are located near an entrance to an underground tunnel or an old pipe, and the partially cured pipes are lowered into the tunnel or the old pipe and is pulled by chain or cable from the other side of the tunnel or the old pipe to line the tunnel and the old pipe. One or more kinds of sensors or gauges may also be attached to or embedded in the fabrics to monitor various aspects of the pipe or the content of the pipe.