Helical Composite Pipe Reinforcement for Fast Low-Stress Winding
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Solution Overview
Problem
Conventional methods for manufacturing flexible pipes with composite structures face challenges such as slow production speed and residual stresses, which can lead to pipe failure, especially when using composite materials that behave elastically and cannot be plastically deformed.
Innovation Solution
A pultrusion process is employed to manufacture composite bodies with an innate helical shape, allowing for quicker production and reduced residual stresses by varying parameters like the pulling force location, temperature distribution, and fiber orientation to create composite wires that can be helically wound around an underlying layer, eliminating stresses and strains in the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite structures are used to replace metallic reinforcement wires, then weight is reduced and corrosion resistance is improved, but manufacturing speed decreases and residual stresses increase leading to pipe failure
Solution Approach 1:
The patent applies parameter changes by modifying the pultrusion process parameters including temperature distribution along the die, pulling speed, and resin injection timing. These parameter changes enable composite bodies to be manufactured with controlled helical shapes that can be directly wound, thereby maintaining productivity while using composite materials.
Solution Approach 2:
The patent implements preliminary action by pre-forming the composite bodies with innate helical shapes during the pultrusion manufacturing process itself, rather than forming them after manufacturing. This preliminary shaping eliminates subsequent winding operations and associated residual stresses, thereby maintaining high manufacturing speed.
2Ease of manufacture
If composite structures are molded in situ to achieve suitable shapes, then manufacturing flexibility is improved, but production speed decreases significantly
Solution Approach 1:
The patent applies preliminary action by incorporating the helical shape formation into the pultrusion manufacturing process itself. The composite bodies are pre-formed with the required helical geometry during continuous production, eliminating the need for subsequent in-situ molding operations while maintaining manufacturing flexibility through parameter control.
Solution Approach 2:
The patent uses parameter changes in the pultrusion process, specifically varying temperature distribution and pulling conditions, to enable the composite material to adopt helical shapes during manufacturing. This allows flexible shape control without sacrificing production speed.
3Strength
If pre-consolidated thin tapes are stacked and bonded to create wire arrangements, then composite structure formation is achieved, but residual stresses remain and production speed is inhibited
Solution Approach 1:
The patent implements continuity of useful action by using a continuous pultrusion process to manufacture composite bodies, replacing the discontinuous process of stacking and bonding pre-consolidated tapes. This continuous manufacturing approach eliminates the bonding steps that cause residual stresses and slow production, while maintaining composite structure integrity through continuous fiber reinforcement.
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 significantly increases the manufacturing rate of composite bodies for flexible pipes, reduces specific weight, and allows for the use of composite reinforcement elements, resulting in a flexible pipe with reduced bending strains and improved load-bearing capacity compared to traditional pultrusions.
Implementation Method 1
a pultrusion process which can be utilised to manufacture composite bodies having an innate helical shape
Implementation Method 2
varying parameters like the pulling force location, temperature distribution, and fiber orientation
Data Source
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AI summary
A method and an apparatus of manufacturing flexible pipe body (100) is disclosed. The method includes the step of winding at least one composite body having a substantially helical innate shape around an underlining pipe layer.