Semi-consolidated Reinforced Thermoplastic Pipe with Commingled Fibers
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Solution Overview
Problem
Reinforced thermoplastic pipes (RTP) have low pressure resistance and large bending radius, while thermoplastic composite pipes (TCP) with fully consolidated intermediate layers are expensive and have undesirable large bend radius, limiting their field applications.
Innovation Solution
A semi-consolidated reinforced thermoplastic pipe (SC-RTP) is developed with a hollow inner liner, a core layer of commingled thermoplastic and reinforcing fibers wound at a designated angle, and a heat shrinkable wrap outer layer, achieving improved pressure resistance without the large bend radius of TCP.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fully consolidated core layer with unidirectional tape is used (TCP technology), then pressure resistance is improved, but flexibility deteriorates and bending radius increases
Solution Approach 1:
The patent applies local quality by creating a semi-consolidated core layer where only certain regions are consolidated with thermoplastic matrix while other regions remain less consolidated. This localized consolidation approach provides sufficient pressure resistance in critical areas while maintaining flexibility in other regions, resolving the contradiction between strength and ease of operation
Solution Approach 2:
The patent changes the consolidation parameter from full consolidation (TCP) to semi-consolidation (SC-RTP). By controlling the degree of consolidation rather than using complete consolidation, the invention achieves adequate pressure resistance while preserving flexibility and reducing bending radius, thus resolving the technical contradiction
2Ease of operation
If a dry fiber reinforced core layer is used (RTP technology), then flexibility is improved, but pressure resistance deteriorates
Solution Approach 1:
The semi-consolidated core layer applies local quality by selectively consolidating fibers in regions where pressure resistance is needed while leaving other regions less consolidated to maintain flexibility. This localized approach resolves the contradiction between strength and ease of operation
Solution Approach 2:
The patent uses composite materials by combining thermoplastic fibers with reinforcing fibers (such as aramid, glass, or carbon fibers) in a semi-consolidated structure. This composite approach provides both the flexibility of thermoplastic materials and the strength of reinforcing fibers, resolving the contradiction between ease of operation and strength
3Strength
If thermoplastic composite pipe (TCP) with fully consolidated structure is used, then pressure resistance is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies partial action by using semi-consolidation instead of full consolidation. This partial consolidation provides sufficient pressure resistance for the application while reducing material usage and manufacturing complexity, thereby lowering costs while maintaining adequate strength
Solution Approach 2:
The patent changes the consolidation parameter from complete (TCP) to semi-consolidation (SC-RTP). This parameter change reduces manufacturing complexity and material requirements while maintaining sufficient pressure resistance, resolving the contradiction between strength and ease of manufacture
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
SC-RTP can withstand pressures up to 2900 psig with a reduced bending radius compared to RTP and TCP, offering a cost-effective solution between the two.
Implementation Method 1
covering the core layer in a heat shrinkable wrap, and heating one or more of the hollow inner liner layer, the core layer, and the heat shrinkable wrap at least one time
Implementation Method 2
heating one or more of the hollow inner liner layer, the core layer, and the heat shrinkable wrap at least one time to produce a semi-consolidated core layer with a thermoplastic polymer matrix organized along the at least one reinforcement fiber
Data Source
AI summary
A thermoplastic pipe and a method for producing it are described. The thermoplastic pipe includes a hollow inner liner layer, a semi-consolidated core comprising commingled fibers, and a shrink wrap outer layer. The commingled fibers comprise at least one thermoplastic fiber and at least one reinforcing fiber. The semi-consolidated core layer comprises a thermoplastic polymer matrix that is organized along the at least one reinforcing fiber. The method includes winding commingled fibers over the hollow inner liner layer at a designated angle to produce a core layer, covering the core layer in a heat shrinkable wrap, and heating to produce a semi-consolidated core layer. The semi-consolidated core layer comprises a thermoplastic polymer matrix that is organized along the at least one reinforcing fiber.