Composite Tape Splicing for Strong Flexible Pipe Armour Joins
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Solution Overview
Problem
Flexible pipes used for subsea fluid transportation face challenges in deep and ultra-deep water environments due to high tension loads and pressure, leading to potential failure, and existing splicing methods for composite tape do not provide sufficient strength and consistency in joins, affecting the pipe's performance and reliability.
Innovation Solution
A method and apparatus for splicing composite tape by overlapping sections and applying heat and pressure to achieve a lap shear strength of at least 11 MPa, using a splicing apparatus with movable bearing surfaces and controlled heat and pressure application to ensure strong and consistent joins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing splicing methods are used for composite tape, then the manufacturing process is simple, but the join strength and consistency are insufficient
Solution Approach 1:
The splicing process is divided into distinct functional components: heating elements, pressure application mechanisms, and alignment guides. This segmentation allows each component to be optimized independently while maintaining overall system effectiveness, resolving the contradiction between achieving high join strength and managing apparatus complexity
Solution Approach 2:
Traditional mechanical splicing methods are replaced with a thermal-mechanical system that uses controlled heating combined with pressure application. This substitution enables stronger, more consistent joins by utilizing the thermoplastic properties of the composite tape material, while the modular design keeps the apparatus complexity manageable
2Strength
If thicker and stronger materials are used for armour layers, then the load response and performance improve, but the pipe weight increases
Solution Approach 1:
The patent utilizes composite tape materials that combine high-strength fibres with thermoplastic matrices. These composite materials provide superior strength-to-weight ratio compared to traditional solid materials, allowing the armour layers to withstand high tension and pressure loads while minimizing pipe weight
Solution Approach 2:
The splicing process parameters (temperature, pressure, time) are optimized to create strong joins without requiring excessive material thickness. By controlling the thermal-mechanical parameters during splicing, the invention achieves reliable connections that maintain structural integrity while using minimal material, thus reducing overall pipe weight
3Reliability
If discrete lengths of composite tape are joined to form continuous armour layers, then material usage is optimized, but the join strength must be sufficient to withstand deployment forces
Solution Approach 1:
Mechanical joining methods are replaced with thermal bonding through controlled heating and pressure application. This substitution creates molecular-level bonds between tape sections that are as strong as or stronger than the parent material, ensuring deployment reliability while simplifying the manufacturing process through automated heating and pressing mechanisms
Solution Approach 2:
The splicing process exploits the phase transition of the thermoplastic matrix material from solid to molten state during heating, then back to solid upon cooling. This phase transition enables the material to flow and bond seamlessly at the join interface, creating strong, reliable connections that can withstand deployment forces while maintaining ease of manufacture through controlled thermal processing
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 and apparatus improve the strength and consistency of tape joins, enhancing the reliability and performance of flexible pipes by achieving higher lap shear strength and ensuring the tape can withstand the demanding conditions of subsea environments without breaking during deployment.
Implementation Method 1
applying heat and pressure to the overlapping tape section to form a joined overlapping tape section
Implementation Method 2
applying heat and pressure to the overlapping tape section to form a joined overlapping tape section
Data Source
AI summary
A method of manufacturing an armour layer of a flexible pipe for transporting fluid from a subsea location and apparatus are provided. The method comprises winding a first length of composite tape to form a first section of the armour layer and positioning an end region of the first length of composite tape over an end region of a second length of composite tape to form an overlapping tape section. Heat and pressure is applied to the overlapping tape section to form a joined overlapping tape section in which the first length of tape is joined to the second length of tape such that the joined overlapping tape section has a lap shear strength of at least 11 MPa. The joined overlapping tape section and the second length of composite tape are wound to form a second section of the armour layer.