PEEK Carbon-Fiber Composite Hose With Lower Bend Radius
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Solution Overview
Problem
Thermoplastic composite pipes (TCPs) and hybrid flexible pipes with PEEK-based reinforcing structures suffer from rigidity issues, leading to high minimum bend radius, which complicates manufacturing and installation, particularly in deep-water applications where flexibility and reduced weight are crucial.
Innovation Solution
A thermoplastic composite pipe design featuring a reinforcing structure with PEEK matrix and carbon fibers, optimized through specific molecular weight distribution, Charpy impact strength, and viscosity, allowing for improved flexural performance and reduced minimum bend radius, enabling larger inner diameters and simplified installation using existing equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If PEEK-based reinforcing structure is used in thermoplastic composite pipes, then structural integrity and pressure resistance are improved, but flexural performance deteriorates leading to high minimum bend radius
Solution Approach 1:
The patent applies parameter changes by modifying the molecular weight distribution of PEEK (number average molecular weight Mn > 38,000 g/mol, peak molecular weight Mp > 70,000 g/mol, polydispersity index PI < 2.3) and controlling Charpy impact strength (≥5.5 KJ/m2) to achieve optimal balance between structural integrity and flexural performance, allowing the pipe to maintain strength while reducing minimum bend radius
Solution Approach 2:
The patent uses composite materials by combining PEEK matrix with carbon fibers in the reinforcing structure, creating a composite that leverages the high strength and stiffness of carbon fibers while the PEEK matrix provides toughness and flexibility, thereby improving both structural integrity and flexural performance simultaneously
2Volume of moving object
If larger inner diameter pipes are manufactured, then fluid transport capacity is improved, but minimum bend radius increases complicating installation
Solution Approach 1:
The patent applies parameter changes by optimizing the PEEK molecular weight distribution and Charpy impact strength parameters, which fundamentally improves the flexural performance and reduces the minimum bend radius. This allows larger inner diameter pipes to be manufactured with bend radii that are manageable during installation, thereby increasing fluid transport capacity without proportionally increasing installation complexity
3Ease of manufacture
If existing equipment is used for installation, then installation costs are reduced, but pipe flexibility requirements become more stringent
Solution Approach 1:
The patent applies parameter changes by precisely controlling the PEEK molecular weight distribution (Mn > 38,000 g/mol, Mp > 70,000 g/mol, PI < 2.3) and Charpy impact strength (≥5.5 KJ/m2), which improves flexural performance and reduces minimum bend radius. This enables the pipe to meet the flexibility requirements of existing installation equipment while maintaining structural integrity, thereby reducing installation costs without compromising adaptability
Data Source
AI summary
A thermoplastic composite pipe intended for transporting fluids that includes, from the inside toward the outside:a tubular internal sheath;a reinforcing composite structure around the tubular sheath and which is bonded to the tubular sheath, the reinforcing composite structure comprising a winding of at least two laminated reinforcing layers, each reinforcing layer being made from a thermoplastic matrix comprising a polyether ether ketone having a specific molecular weight distribution and a Charpy impact strength greater than or equal to 55 kJ/m2, and reinforced with carbon fibers,at least one sealing layer made of a thermoplastic material around the reinforcing composite structure;and a hybrid flexible pipe comprising same.