Reinforced Thermoplastic Pipe Consolidation Using Joule-Heated Wires
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Solution Overview
Problem
The existing methods for manufacturing reinforced thermoplastic pipes (RTP) are complex and limit the production rate, particularly for bonded RTP, and do not allow for the separate consolidation of unbonded RTP at a later stage.
Innovation Solution
The method involves using Joule heating or induction heating to heat electrically conductive elements within the RTP body, such as steel wires, to create a viscous state in the thermoplastic material, which is then cooled to consolidate the pipe layers, allowing for partial or full consolidation of the RTP body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If layers of RTP body are bonded or consolidated during the winding phase and/or during final sheath extrusion using conventional heat sources, then bonded RTP body is manufactured, but the process is complex and limits the rate of production
Solution Approach 1:
The patent replaces conventional mechanical heating systems (hot air, radiant heat, laser) with induction heating technology. This substitution allows for rapid, direct heating of the thermoplastic material through electromagnetic fields, eliminating the complexity of conventional heating systems and significantly increasing production rate while maintaining bonded RTP body manufacturing capability
Solution Approach 2:
The patent changes the heating parameters by using induction heating frequency and power control to rapidly heat the thermoplastic material to bonding temperature. This parameter change enables quick heating and cooling cycles, allowing for high-speed production while achieving proper layer consolidation
2Stability of the object's composition
If conventional bonding processes are used during manufacturing, then layers are consolidated, but consolidation cannot be carried out at a later or separate stage
Solution Approach 1:
The patent segments the consolidation process from the manufacturing process. The RTP body can be manufactured with unbonded layers first, then consolidated at a later stage or separate location using induction heating. This segmentation provides flexibility to consolidate only specific sections or the entire pipe body after manufacturing, enabling field-based consolidation operations
Solution Approach 2:
The patent allows for preliminary manufacturing of unbonded RTP body that can be stored and transported, then consolidated when needed. The induction heating system enables this deferred consolidation action without requiring the layers to be bonded during the initial winding and extrusion process
3Productivity
If unbonded RTP body is manufactured, then production is simpler and faster, but the pipe layers remain unbonded requiring later consolidation
Solution Approach 1:
The patent replaces complex conventional consolidation equipment (hot air systems, radiant heaters, lasers) with induction heating technology. This substitution simplifies the consolidation process by providing direct, controlled heating through electromagnetic fields, making the consolidation operation simpler and more efficient while maintaining the advantage of fast unbonded manufacturing
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
This approach enables the separation of consolidation from the manufacturing process, allowing for the field-based consolidation of RTP bodies, improving production efficiency and enabling the use of RTP in various fluid transportation applications.
Implementation Method 1
heating surrounding precursor thermoplastic material via Joule heating of the wire elements
Implementation Method 2
heating the precursor thermoplastic material by induction heating
Data Source
AI summary
A reinforced thermoplastic pipe (RTP), RTP body, and a method of providing RTP body are disclosed. The method of providing RTP body for storage and/or transportation of a fluid, comprises providing a first pipe body layer; providing a further pipe body layer coaxial with the first pipe body layer; providing a plurality of helically wound wire elements disposed between the first pipe body layer and the further pipe body layer; heating surrounding precursor thermoplastic material via Joule heating of the wire elements thereby providing viscous state thermoplastic polymer at least one of a first interface location between the first pipe body layer and the further pipe body layer; and subsequently cooling the viscous state thermoplastic polymer for joint consolidation thereby consolidating RTP body over at least a portion of a whole length of the RTP body.