Pipeline Reinforcement Composite Infiltration for Cold, High-Viscosity Resin
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Solution Overview
Problem
Current methods for on-site defect repair of petroleum and natural gas pipelines, such as resin transfer molding and vacuum infusion, are inefficient due to the need for specialized equipment and are prone to performance issues caused by environmental and human factors, especially when using high viscosity resins and at low temperatures.
Innovation Solution
A device and method utilizing a temperature control stirring unit, infiltration unit, and vacuum unit that allows for multilayer roll infiltration without a mold, enabling the use of high viscosity resins and operating at low temperatures, with a flow-guiding net and vacuum bag film to ensure uniform infiltration and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin transfer molding or vacuum infusion process is used to ensure fiber infiltration and maximize fiber proportion, then composite performance is improved, but specialized equipment and molds are needed leading to inefficient on-site repair
Solution Approach 1:
The patent extracts the essential function of vacuum infusion (resin infiltration) from the complex mold-based system. By removing the mold requirement and using a simplified vacuum bag setup, the system maintains effective resin infiltration while enabling rapid on-site application without specialized equipment.
Solution Approach 2:
The patent changes the operational parameters by eliminating the need for mold-making and specialized vacuum equipment. The simplified system uses standard vacuum bags and basic vacuum pumps, transforming the process from a factory-based operation to an on-site applicable method while maintaining infiltration effectiveness.
2Reliability
If full cure process with pre-produced composite sleeve is used to ensure stable performance, then composite reliability is improved, but high hardness makes it difficult to guarantee full attachment and hollow formation occurs
Solution Approach 1:
The patent transitions from a static pre-produced sleeve to a dynamic multi-layer roll system that can adapt during application. The layers are applied sequentially with resin infiltration, allowing the composite to conform dynamically to the pipeline surface and weld areas, ensuring complete attachment without hollow formation.
Solution Approach 2:
The patent applies different properties to different parts of the composite structure. The multi-layer configuration allows local adaptation to surface irregularities, with each layer contributing to overall attachment quality. The resin infiltration ensures local bonding at critical areas like welds and deformed regions.
3Ease of operation
If wet wrap process is used to allow on-site application with resin coating, then ease of operation is improved, but uncontrollable factors like high resin viscosity at low temperature cause inadequate infiltration and performance loss
Solution Approach 1:
The patent performs preliminary heating of the resin before application. By pre-warming the resin to reduce viscosity, the system ensures proper infiltration occurs even in cold environmental conditions. This preliminary action addresses the temperature-dependent viscosity issue before the actual wrapping and infiltration process begins.
Solution Approach 2:
The patent introduces temperature control as an intermediary factor to mediate between environmental conditions and resin properties. By controlling resin temperature, the system maintains optimal viscosity for infiltration regardless of ambient temperature, ensuring reliable performance across different environmental conditions.
4Reliability
If high viscosity resin is used at low temperature to maintain resin stability, then resin reliability is improved, but infiltration efficiency decreases and installation time increases
Solution Approach 1:
The patent changes the temperature parameter of the resin during the infiltration process. By heating the resin to reduce viscosity, the system achieves both stable resin properties and high infiltration efficiency. The temperature control allows the resin to maintain stability while enabling rapid infiltration, resolving the contradiction between reliability and productivity.
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 solution enhances infiltration efficiency, mechanical properties, and installation time, allowing for effective on-site repair across a broader temperature range and improving the repair effect by 1.5 times in mechanical properties and 2 times in installation efficiency compared to existing methods.
Implementation Method 1
an infiltration unit (2), and a vacuum unit (3)... the temperature control stirring unit, the infiltration unit and the vacuum unit (3) are communicated in sequence
Implementation Method 2
a temperature control stirring unit (1)... allowing to use a resin having a high viscosity as a resin for infiltrating
Implementation Method 3
a flow-guiding net and vacuum bag film to ensure uniform infiltration
Data Source
AI summary
A device for preparation of a composite for on-site pipeline reinforcement includes: a temperature control stirring unit, an infiltration unit, and a vacuum unit, which are communicated in sequence, the infiltration unit includes a spindle, reinforced fiber cloth, a flow-guiding net, and a vacuum bag film sleeved outside the spindle, the reinforced fiber cloth and the flow-guiding net, the spindle is stopped by two baffles, an adhesive feeding joint and an adhesive discharging joint are disposed at two ends of the spindle, respectively, each of the adhesive feeding joint and the adhesive discharging joint includes an inner joint and an outer joint, an outer wall of the inner joint and an outer side of the baffle are covered by a flow-leading net, and the flow-guiding net covered on the outer side of the baffle extends from an edge of the baffle into the adhesive storing compartment of the baffle.