Polyurethane Composite Clamp Structure for Creep Resistance
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Solution Overview
Problem
Polymer clamps used in subsea and deepwater oil and gas operations suffer from creep deformation under high stress and temperature, leading to permanent deformation and reduced operational life, which can result in failure to secure tubular members and ancillary equipment.
Innovation Solution
A creep-resistant material comprising a core layer of rigid polyurethane sandwiched between two tensile reinforcement layers, with the reinforcement layers being fibre-reinforced composites or corrosion-resistant metal sheets, applied on both surfaces of the core to reduce flexural stress and prevent deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If polymer clamps are used to reduce weight in deepwater environments, then weight reduction is achieved, but creep deformation occurs under high stress and temperature leading to permanent deformation and reduced operational life
Solution Approach 1:
The clamp is constructed as a composite structure with a polyurethane foam core layer providing lightweight cushioning, sandwiched between two tensile reinforcement layers (such as steel, aluminium, or fibre-reinforced plastic) that provide high strength and creep resistance. This composite design allows the clamp to maintain polymer-like weight advantages while achieving metal-level structural integrity and dimensional stability under subsea operating conditions.
2Reliability
If the size of clamping components is increased to reduce stress levels, then creep tendency is reduced, but component size and weight increase significantly
Solution Approach 1:
The composite structure with tensile reinforcement layers bonded to the foam core enables the clamp to maintain compact dimensions while achieving high creep resistance. The reinforcement layers carry the tensile loads, allowing the clamp to withstand high buoyancy forces without requiring increased component size, thus avoiding the trade-off between creep resistance and volume.
Solution Approach 2:
The tensile reinforcement layers are strategically positioned on the outer surfaces of the foam core, concentrating the high-strength material where tensile stresses are maximum during clamping operation. This local placement of reinforcement optimizes creep resistance without adding unnecessary material volume throughout the entire component.
3Reliability
If metallic materials are used to achieve high creep resistance, then creep performance is improved, but weight and corrosion protection requirements increase
Solution Approach 1:
The hybrid composite structure combines lightweight polyurethane foam with thin tensile reinforcement layers of metal or fibre-reinforced plastic. This allows the clamp to achieve metal-level creep resistance with significantly reduced overall weight compared to solid metallic clamps, as the foam core provides volume and buoyancy while the thin reinforcement layers provide the necessary tensile strength.
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 significantly enhances the creep resistance of clamping components, extending their operational life and maintaining secure connections under extreme conditions without increasing component size or weight, thus addressing the limitations of existing polymer materials.
Implementation Method 1
the reinforcement layers being fibre-reinforced composites or corrosion-resistant metal sheets, applied on both surfaces of the core to reduce flexural stress and prevent deformation
Data Source
AI summary
A creep resistant material comprises a core layer (12) of rigid polyurethane with a first tensile reinforcement layer (17) applied on one surface and a second tensile reinforcement layer (17) applied on the other opposed surface of the core layer, the entire respective first and second tensile reinforcement layers being in contact with the first and second surface of the core layer of the material.