PAEK Pipe Extrusion Pre-Conditioning for Defect-Free Long Lengths
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Solution Overview
Problem
Existing methods for extruding long pipes from polyaryletherketone (PAEK) polymers, such as polyetheretherketone (PEEK), are prone to defects that occur sporadically after a certain length, affecting pipe integrity and suitability for high-quality applications.
Innovation Solution
A pre-conditioning process for PAEK-type polymer feedstock involves exposing it to flowing hot gas at controlled temperatures and durations to reduce organic manufacturing impurities, followed by extrusion using a calibrator device with vacuum and temperature-controlled regions to form defect-free pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If simple drying is used to remove moisture from PAEK pellets, then moisture content is reduced below 0.02%, but organic manufacturing impurities remain and cause defects in long pipe extrusions
Solution Approach 1:
The patent applies preliminary action by implementing a pre-conditioning step before extrusion where PAEK pellets are exposed to flowing hot gas (100-200°C) for extended periods (4-72 hours). This preliminary treatment removes organic manufacturing impurities from the pellet surfaces, preventing defects that would otherwise appear during long pipe extrusion processes.
Solution Approach 2:
The patent changes the parameters of the drying process by using flowing hot gas instead of static air, maintaining temperatures between 100-200°C for extended durations. This parameter change transforms the simple moisture removal process into a comprehensive conditioning treatment that also eliminates organic impurities, thereby improving pipe quality.
2Reliability
If extended pre-conditioning is used to remove organic impurities, then pipe defect-free length increases to 4,120 meters, but processing time increases to 4-72 hours
Solution Approach 1:
The patent employs pneumatic principles by using flowing hot gas through the pellet bed, which enhances mass transfer and removes organic impurities more efficiently than static air. The continuous gas flow carries away volatile organic compounds, achieving superior conditioning results while potentially reducing the required treatment time compared to conventional methods.
3Productivity
If PAEK pellets are extruded without pre-conditioning, then processing is faster, but defects occur sporadically after certain pipe lengths
Solution Approach 1:
The patent implements preliminary action by pre-conditioning PAEK pellets before extrusion. This pre-treatment removes organic manufacturing impurities from pellet surfaces, ensuring that pipes can be extruded for extremely long lengths (up to 4,120 meters) without developing wall defects, thereby maintaining high manufacturing precision throughout the extrusion process.
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 process enables the production of extremely long, defect-free pipes up to 4,120 meters without visible defects, ensuring high-quality standards for applications like oil and aerospace sectors.
Implementation Method 1
contacting said polymer composition with a flowing hot gas for a conditioning period, wherein the temperature T (°C) of the hot gas is a temperature selected in the range from 130°C to 230°C
Implementation Method 2
the conditioning process comprises one or more periods of time totalling at least t hours, wherein t is related to T according to the formula: t=X/(T-120), wherein X is a number selected from the group consisting of 58000, 65000, 70000, 75000, 80000, 90000 and 100000
Implementation Method 3
a calibrator device which includes an elongate opening for receiving a hot extruded pipe, wherein the elongate opening includes a vacuum applying region arranged to apply a vacuum to the outer surface of the pipe within the elongate opening
Implementation Method 4
said device further comprises two or more temperature-controlled regions spaced apart along the length of the calibrator, said temperature controlled regions being arranged to apply a cooling effect to the pipe as it passes through the elongate opening, said calibrator device being in contact with one or more heat transfer fluids so as to assist said cooling effect on the pipe
Data Source
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AI summary
The disclosure relates to a process for making long pipes (e.g. >300m) from certain types of thermoplastic polymer (e.g. a polya ryletherketone polymer) via a single extrusion process without a certain type of visible defect occurring on the wall of the pipe during manufacture. The process involves a pre-conditioning step for the polymer feedstock. Accordingly, the disclosure also relates to the polymer pre-conditioning process, and the conditioned polymer feedstock itself. The disclosure also relates to the long polymer pipes without a certain type of visible defect, formed using the pre- conditioned polymer.