Subsea Umbilical Polymer Composite Sheath Weight Diameter Ratio
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Solution Overview
Problem
Current subsea umbilicals face challenges in achieving a specific weight to diameter ratio while maintaining a compact cross section, as excess steel armour is required to meet mechanical strength and stability requirements, leading to increased costs and complex manufacturing processes.
Innovation Solution
The use of a polymer composite sheath with a high density filler, such as metal-based fillers like chromium or tungsten, to achieve the required weight to diameter ratio without the need for excess steel armour, allowing for a more compact cross section and reduced material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If excess steel armour is applied to achieve higher weight to diameter ratio requirements, then the weight to diameter ratio is improved, but the cross section size increases and manufacturing complexity increases
Solution Approach 1:
The patent applies composite materials by integrating high density filler (such as metal particles or heavy minerals) within the polymer sheath material itself, creating a composite sheath that provides both the required weight and compact dimensions. This eliminates the need for separate steel armour layers while achieving the target weight to diameter ratio.
Solution Approach 2:
The patent merges the functions of the sheath and the weight-providing armour into a single integrated component. The sheath is made from a composite material that combines the protective function with the ballast function, eliminating the need for separate steel armour layers and reducing overall cross section size.
2Weight of moving object
If excess steel armour is applied to achieve higher weight to diameter ratio requirements, then the weight to diameter ratio is improved, but the manufacturing process becomes more complicated
Solution Approach 1:
The patent merges the sheath extrusion and armour application into a single integrated manufacturing step. The composite sheath material is extruded directly in the required configuration, eliminating the need for separate armour winding or attachment processes and significantly simplifying manufacturing.
Solution Approach 2:
By using composite sheath material with integrated high density filler, the patent eliminates the need for separate armouring operations. The filler is incorporated during the extrusion process itself, creating a homogeneous composite structure that requires no additional manufacturing steps.
3Weight of moving object
If traditional outer armouring is used to achieve weight requirements, then the weight to diameter ratio is improved, but the outer diameter increases
Solution Approach 1:
The patent uses composite materials with high density filler embedded within the sheath to achieve the required weight without increasing outer diameter. The filler is distributed throughout the sheath volume, providing ballast while maintaining a compact overall structure.
Solution Approach 2:
The patent embeds the high density filler within the sheath material itself, creating a nested structure where the filler particles are contained within the polymer matrix. This integrated approach provides weight without requiring additional external layers that would increase outer diameter.
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 solution enables a subsea umbilical with a specific weight to diameter ratio while minimizing material costs and manufacturing complexity, allowing for longer delivery lengths and improved mechanical protection without the need for traditional steel armouring.
Implementation Method 1
The sheath is made of a polymer composite comprising a high density filler, the polymer composite having a density in the range of 3 to 11 g/cm3
Data Source
AI summary
An umbilical for subsea applications has at least one longitudinal internal element and a sheath, the sheath is formed by extrusion. The internal element is suitable for communicating fluids, electrical power or signals, or for carrying loads. The sheath is made of a polymer composite having a high density filler, the polymer composite having a density in the range 3 to 11 g/cm3.