Continuous Tubular Assembly Wrapping for Long Composite Pipelines
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Solution Overview
Problem
Current methods for constructing long tubular structures, such as pipelines, are limited by the length of mandrels and rolls, making it difficult to create continuous pipes for transportation networks, and the construction process is not cost-effective for large-scale production.
Innovation Solution
A method involving a prefabricated tubular assembly with an inner portion and a flexible outer casing, where the resinous binder is introduced as the outer casing is wrapped around the assembly, allowing for radial expansion to fully impregnate the reinforcement and control expansion to prevent over-expansion and air expulsion, facilitating the construction of longer pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If pipes are constructed using traditional winding methods on mandrels, then the pipe structure can bear hoop and axial stresses, but the length of pipe is limited by the length of the mandrel and cannot form continuous long pipelines
Solution Approach 1:
The pipe construction process is segmented into multiple sequential winding operations. The pipe is built in sections along a continuous mandrel system, where each section is wound and then joined to the next, allowing the overall pipe length to exceed the length of any single mandrel segment. This enables continuous pipe production for long-distance pipelines.
Solution Approach 2:
The winding operation continues uninterrupted along the entire length of the pipeline route. The mandrel system is designed to support continuous winding operations, with sections joined in-situ to maintain structural integrity. This continuous construction approach eliminates the need for separate mandrels for each pipe section, enabling production of very long continuous pipes.
2Ease of manufacture
If pipes are constructed in sections and joined together, then the pipeline can be assembled from manageable segments, but the junctions become areas of weakness in structural integrity
Solution Approach 1:
Adjacent pipe sections are merged together through overlapping winding operations where the fibre reinforcement and resin matrix create a continuous composite structure across the joint. The winding process ensures that fibres continue across section boundaries and the resin bonds the sections together, eliminating weak joints and creating a structurally continuous pipe throughout its length.
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 method enables the construction of longer tubular structures with improved structural integrity and cost-effectiveness by ensuring full impregnation of the reinforcement and preventing air entrapment, thus enhancing the pipeline's hoop and axial stress-bearing properties.
Implementation Method 1
introducing resinous binder into the reinforcement as the strip is being wrapped about the prefabricated tubular assembly
Implementation Method 2
allowing for radial expansion to fully impregnate the reinforcement
Implementation Method 3
Flexible outer casing is installed around the prefabricated tubular assembly to provide the outer portion. Radial expansion of the assembly is then controlled by the outer casing
Data Source
AI summary
A method and apparatus for constructing a tubular assembly 40 comprising an inner portion (24) and a further portion (23) surrounding the inner portion. The inner portion (24) comprises reinforcement (37) and the further portion (23) being formed from a strip (50) of material comprising two opposed longitudinal marginal side portions (53). The apparatus comprises an assembly station (220) comprising a wall (253). The apparatus comprises means for advancing the inner portion (21) along a first path (231) extending passed the wall (253), and means for advancing the strip (50) along a second path (232) and causing the strip to encircle the wall (253) and thereby wrap about and surround the inner portion (21). The apparatus further comprises means (321) for introducing resinous binder into the reinforcement (37) as the strip (50) is being wrapped about the inner portion (21).