RTP Pipe Coupler Structure for Corrosion-Free Welded Joints
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Solution Overview
Problem
Existing RTP connections face challenges in achieving high mechanical performance, good sealing properties, and corrosion resistance, with metallic connections prone to corrosion, thermoset connections unable to be welded, and thermoplastic couplers having limited mechanical and thermal performance.
Innovation Solution
A connection system utilizing a reinforced thermoset resin (RTR) coupler with thermoplastic tie layers and a mechanical connection system, including wedges and flanges, to securely connect and seal RTP pipes through thermoplastic welding and mechanical interlocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic connections are used for RTP pipes, then mechanical strength and thermal resistance are improved, but corrosion resistance deteriorates due to exposure to hydrocarbons and environmental conditions
Solution Approach 1:
The connection system uses a composite structure combining RTR coupler (thermoset resin with fiber reinforcement) and thermoplastic tie layers. This composite material approach provides both high mechanical strength from the fiber reinforcement and excellent corrosion resistance from the thermoplastic layers that are chemically inert to hydrocarbons and environmental conditions.
Solution Approach 2:
The thermoplastic tie layer acts as an intermediary between the RTR coupler and the RTP pipe. This intermediate layer enables welding to the thermoplastic pipe while the RTR coupler provides structural strength, and together they provide corrosion resistance without requiring metallic components.
2Strength
If fiber reinforced thermoset connections (GRE) are used, then mechanical and thermal performance is improved, but weldability deteriorates because thermoset polymer cannot be welded
Solution Approach 1:
The connection system is segmented into distinct functional layers: the RTR coupler body provides structural strength, while separate thermoplastic tie layers are applied on the connection surfaces. This segmentation allows the thermoset core to provide strength while the thermoplastic segments enable welding capability.
Solution Approach 2:
The RTR coupler with thermoplastic tie layers creates a composite structure where the thermoset resin with fiber reinforcement provides mechanical strength and thermal resistance, while the thermoplastic tie layers provide weldability to connect with RTP pipes through thermal welding processes.
3Ease of manufacture
If thermoplastic couplers are used, then weldability is improved allowing direct welding to RTP pipe, but mechanical and thermal performance deteriorates limiting system pressure rating
Solution Approach 1:
The connection system uses a composite structure where the RTR coupler (thermoset resin with fiber reinforcement) provides high mechanical strength and thermal resistance to support higher pressure ratings, while the thermoplastic tie layers maintain weldability for direct connection to RTP pipes.
4Productivity
If connections are used to join RTP pipes, then transportability of long seamless pipe is improved by reducing connection needs, but reliability deteriorates because connections remain the weak link with higher leakage probability
Solution Approach 1:
The thermoplastic tie layer acts as an intermediary that creates a seamless welded bond between the RTR coupler and the RTP pipe. This welded connection eliminates gaps and interfaces that could lead to leakage, making the connection as reliable as the pipe itself while still enabling modular assembly for transportability.
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 provides a corrosion-free, mechanically robust, and optimally sealed connection system for RTP pipes, capable of withstanding axial and hoop stresses while preventing fluid ingress and reducing maintenance costs.
Implementation Method 1
a first thermoplastic tie layer provided between the first socket extension and the first end of the first pipe
Implementation Method 2
applying heat to the fitted first end to thermoplastic weld the inner surface of the first end to the first thermoplastic material of the first socket extension
Implementation Method 3
a first set of wedges positioned circumferentially around an outer surface of the first end of the first pipe, and a first flange fitted around the first set of wedges, wherein the first set of wedges is wedged between the first end and the first flange
Data Source
AI summary
A connection system for reinforced thermoplastic polymer (RTP) pipe includes a first pipe with a first end and a reinforced thermoset resin (RTR) coupler positioned adjacent to the first end of the first pipe. The RTR coupler has an annular body with a first socket extension extending into the first end of the first pipe and a first thermoplastic tie layer provided between the first socket extension and the first end of the first pipe. A first set of wedges is positioned around an outer surface of the first end of the first pipe, and a first flange is fitted around the first set of wedges, wherein the first set of wedges is wedged between the first end and the first flange.