CA2620221C - Reinforced elongated elements, such as tubes, method and device for producing same and use thereof - Google Patents

Abstract

The invention relates to a reinforced elongated element, its method and apparatus for its manufacture. The reinforced elongated member (12) comprises an elongated core (22) covered with at least one layer (33) of composite material comprising a plurality of ribbons (32) wound at an adjustable winding angle around said core, each of the ribbons (32) being made using son or fibers (35) of glass or carbon embedded in a matrix (34) of thermoplastic resin. This elongated element can be in the form of tubes of great length that can be used off-shore.

Description

Field of the Invention The invention relates to the technical field of manufacture elongate elements, such as tubes, for example off-shore tubes.
State of the art So far, it has been realized the manufacture of steel tubes very heavy, which have corrosion problems in the marine environment, and which are also difficult to weld.
Document FR-A-2,031,719 (Glass Company is known from Textile) filed on February 5, 1969, a method and device for obtaining products composed of fibers agglomerated with resins synthetic materials, in particular thermoplastic resins.
The method and device described in this document allow to directly prepare solid or tubular profiles whatever be their section.
Sekisui JP HEI 2-40408 of February 20, 1990 = JP-A-03 / 243,333 discloses the manufacture of small diameter PVC pipes having an internal diameter of 23 mm and a wall thickness of 3 mm. The coating of the inner or central part of the tube is carried out with thermoplastic composite tapes or ribbons having a thickness of 0.5 mm and a width of about 20 mm, and consisting of spun fiberglass woven impregnated with a specific PVC resin country having a critical content of 62% chlorine. The amount of fiber is % by volume in the band or composite tape. It also appears that the winding angle of the tape or ribbon on the inner part 25 Central tube is fixed or constant for the entire procedure of deposition of the tape or ribbon over the full length of the tube.
The patent document Debalme US 6,605,171 Bi is based on a technology requiring a rotation of the tube a fixed length and the deposit of a thread or cord with overlapping layers, see Figure 1A
30 and 2A thereof.
The document Isocell EP-0,122,884 and a document of the art previous technological background similar.
GOALS OF THE INVENTION
The new technical problem to be solved is to be able to manufacture elongated objects, including tubes, of very large length, usually limited only by the size of the plant or possibly transport.
Regarding the invention, it is possible to manufacture elements lengthened, in particular tubes longer than 30 meters (m) and up to 100 meters or more.
The invention is not limited to the manufacture of elongated elements, in particular tubes, of circular section but can be used for manufacture other sections such as sections of flat or square section, boat masts, wind turbine blades.
The invention still makes it possible to manufacture elongated elements, including tubes, in a way freed from the geometry of the section. This geometry can be of any shape.
Another technical problem that the invention aims to solve is the manufacture of an elongated element, in particular a tube using resin thermoplastic and not thermosetting, and in particular the manufacture of off-shore tubes, including submerged tubes or tubes submerged in the sea, as well as wind turbine blades.
The invention thus aims to replace the very heavy steel tubes which have corrosion problems and are also difficult to weld.
In the offshore structure of metal type, beyond a certain length as for example 1500 m deep, the weight is so important that these structures do not stand up to their own weight.
The invention also solves this problem.
The invention is still aimed at solving the new problem elongated element manufacturing technique, including tubes and in particular particular off-shore tubes or blades or turbine blades or wind turbine with variable tensile strength and / or resistance variable pressure, especially in the longitudinal direction of the elongated element.
Description of the invention According to a first aspect, the present invention covers, as a new product, a reinforced elongated element comprising a core of elongate shape, covered with at least one layer of composite material comprising a plurality of ribbons wrapped around said core, each tapes being made using reinforcing threads or fibers, for example example of son or fiberglass or carbon, embedded in a matrix

2 r .s-in thermoplastic resin, the ribbons being wrapped around the core at a predetermined winding angle adjustable relative to the axis length of the elongated element, and depending on the resistance mechanics desired for the intended application. This winding angle will be able to vary in the same layer along the longitudinal axis of the elongated element. This variation of the angle can naturally be performed for one or more, or for all, layers composites.
These son or reinforcing fibers are preferably continuous.
Thus, the son or fibers are advantageously of great length in generally corresponding to the length of the ribbons.
In the context of the invention, the thermoplastic resin itself The same is commercially available in the form of granules.
Also, with regard to the manufacture of the ribbon used according to the invention, the method and apparatus as described in the document FR-A-2,031,719 cited above. Naturally, others Ribbon manufacturing techniques of this type can be used.
Regarding the use of thermoplastic resin, the mechanical strength is much higher especially in the resistance shock, compared to the use of thermosetting resin.
The use of thermoplastic resin also allows a more great ease of production of elongated elements of complex shapes, especially with cavities or cavities, such as tubes.
Since the invention produces elongated elements, such as tubes or tubular elements, with a thermoplastic resin, their use should be limited in places where the temperature should not be exceed 100 C, ie either in the ground or at sea where an application interesting is off-shore especially for oil installations.
In the case of the production of elongated elements, in particular tubes that can reach a length of 100 m or more, these are then connected to each other by connector devices which can they be metallic so as to ensure a tightness perfect, devices of this type being commercially available particularly with the company Freyssinet International domiciled in France.

3 According to an alternative embodiment, the elongated core mentioned above is made of a metal or a metal alloy, in particular steel, preferably stainless.
According to another variant embodiment, the core is made in one thermoplastic material, in particular nylon, preferably same nature as the thermoplastic resin used to make the matrix ribbon.
According to yet another variant embodiment, the resin thermoplastic comprises or consists of polyamide 11 or polyamide 12.
According to another advantageous embodiment of the invention, the aforesaid soul has a substantially convex shape.
According to a presently preferred embodiment, the soul of elongate shape is predominantly or essentially shaped tubular hollow tubular type.
According to an advantageous embodiment of the invention, the ribbons are wrapped around the soul at a predetermined angle adjustable with respect to the longitudinal axis of the elongate member, thus vary from one end to the other, in the same layer, for at least a composite layer, according to the desired mechanical strength for the intended application.
For example, this adjustable angle can be between 20 and 85 as measured in relation to the longitudinal axis of the elongated element, and advantageously be modified, in particular progressively, of a first end at a second end of the elongate member in the same layer. For "off-shore" applications, the angle envisaged is currently in the range of 20 to 80 or 20 at 70, measured relative to the longitudinal axis of the elongate member, and can advantageously be modified, in particular progressively, of a first end at a second end of the elongate member in the same layer, in order to vary the mechanical resistance, in particular the tensile strength and / or resistance to pressure, along the axis longitudinal axis of the elongated element.
For "wind turbine blade" applications, the angle envisaged is currently in the range of 20 to 85 measured relative to the longitudinal axis of the elongated element, and may advantageously be modified, in particular progressively, of a

4 first end at a second end of the elongated member, in the same layer.
Unlike filament winding processes which are mainly used for the manufacture of tubes and shapes complexes of the prior art as described in US 6,605,171 B1 and JP
03243,333 or EP-A-0,122,884, the manufacturing method according to the invention, because of the adjustable nature of the winding angle of the ribbon, allows to change the angle of deposition of the composite fiber tape on the tube or complex shape in the same layer. The angle can be changed at the beginning of the production process, as well as during the process as required, in the same layer, especially the resistance needs, vis-à-vis the piece to be made, and of course for one or more or even for all of the composite layers.
It is well known that composites are considered as anisotropic materials and with respect to the goals to be achieved and the objectives to solve the technical problems previously statements of the invention, a variation of the angle during the filing of the same layer is important to adjust the mechanical strength of a ideal way, and required relative to the application for use final. The filament winding process of US 6,605,171 B1 and 31p 03243,333 or EP-A-0,122,884 does not make it possible to modify the resistance due to a variation of the angle as the processes of this prior art work only with fixed angles at least for the same layer. In addition, the filament winding procedure allows only a limited variation such as for example 50 to 55, when a large angle is required, or close to 90 degrees when a low angle is required to obtain the thickness of the composite.
The present invention allows a wide variety of angles from from 0 to 85 or even 90, with the possibility of combining angles different from 0 to 85 during the manufacturing procedure of the same layer according to specific constraints such as resistance to pressure, resistance to bending, tensile strength, relatively for every application like the offshore application, or as a blade wind turbines.
For example, if the offshore application is considered, especially for risers, the head or proximal end of the marine is subject to high mechanical strength

5 since it must support the total weight of the tube. In such a case, the angle winding must be minimal, ie close to the longitudinal axis of the elongated element, here a pipe, for example in a field from about 20 to 25. But on the other hand, that same head or part of the proximal end does not need to have a high resistance to pressure constraints since it is not arranged in the depth from the sea. Conversely, if we consider the bottom or the distal end of the pipeline that is positioned in the deep sea, forces to constraints are inverse and the fund or distal part needs a high resistance to pressure stresses due to depth of the sea especially for a deep offshore application where there is a high risk of collapse of the pipeline, and otherwise only need a low tensile strength since there is no or little weight to bear. In the latter case, the winding angle must be high, for example in an area of about 60-80, or 60-70 relative to the longitudinal axis of the tube.
The same winding angle principle applies for other mechanical objects such as blades or blades of wind turbines or as blades or blades of wind turbines, where torsional forces are maximum at the proximal connection end and the winding angle should be high, for example in the range of 80-85; while the tensile forces are maximum at the free distal end of the blade where the core and the winding angle must therefore be low, for example in the range of 20-25 relative to the longitudinal axis of the elongated element here constituted by a blade or blade of wind turbines or wind turbines.
With all the elongated elements according to the invention, whether they are tubes like offshore riser tubes, where blades or blades of wind turbines or wind turbines, the winding angle can be changed, especially progressively, in the same layer, during the process manufacturing to gradually vary from a low winding angle at a high winding angle or vice versa.
Thus, in the intermediate zone of the elongated element, in particular a tube, the winding angle is intermediate.
According to a particular embodiment of the method or of the apparatus of the invention, thanks to the possibility of variations of the angle winding throughout the manufacturing process for the same layer, the winding angle value is controlled by the ratio of

6 speed between the translational speed of the element length, especially of the pipe, and the speed of rotation of the cassette supporting the ribbons.
The winding angle is in particular given by the formula following mathematical:
a = Arctan (II x D x N / Vt) In which :
a: the winding angle in degree relative to the axis longitudinal of the inner or central part or soul;
D: diameter of the inner or central part or core;
N: rotation speed of the ribbon support cassette Rotations per minute ;
Vt: speed of displacement in translation of the internal part or central or soul in meters / minute.
or Pi = Greek letter or about 3.1416.
Thus, a person skilled in the art understands that the invention makes it possible unexpectedly, to make a single composite part that includes a wide variety of angles, especially a variation of the winding angle in the same layer, and consequently a specific mechanical resistance to forces or stresses, which is useful for specific applications.
Taking into account another example such as blades or blades of wind turbines like wind turbines, the connecting head of blades or blades is subjected to high strength efforts and needs therefore a high or specific tensile strength. Else the free end of the blades or blades has little resistance to support, but needs to be resistant to bending. Therefore, the manufacture of blades or blades in accordance with the technology according to the invention can adjust the tensile strength is to effort to the appropriate places of the blade part or blade and to check the deformation of the blade or blade when it is in operation.
In addition, according to a particular embodiment of the invention, the tension of the ribbon is adjusted according to the value of the winding angle.
According to the invention, it is possible to adjust the tension of the ribbon or the band by the provision of braking means on each cassette

7 supporting or storing the tape or tape, being wound on it.
One skilled in the art understands that by varying the braking force from the cassette, the ribbon tension can be set to the desired value.
In addition, the method allows a progressive evolution of a angle at a different angle in the same layer throughout the process.
For example, for an angle of about 200, the ribbon tension may be especially about 15 DecaNewton; and for an angle of about 700, the ribbon tension can be about 5 DecaNewton.
In an advantageous embodiment, it is possible to provide at least one and preferably a plurality of layers composite materials of the same structure or composition or of structures / compositions, in particular ribbons which are different or arranged at different winding angles.
In another particular embodiment, it is possible to provide at least one layer made of composite material comprising a thermoplastic resin and using cords or fibers, by example of cords or glass or carbon fibers, as reinforcement, by making it possible to wind up said cords or fibers according to predetermined winding angles that can vary along the axis longitudinal axis of the elongated element, in particular a tube or blade or blade, the same layer, around the previous layer.
According to another advantageous embodiment, provision is made for to make the outermost layer of the elongate element made of composite comprising a plurality of ribbons also wrapped around of the preceding layer, said ribbon comprising a resin matrix thermoplastic and reinforcement in the form of cords or fibers, for example cords or fiberglass or carbon.
Thanks to the invention, it is no longer necessary to have a layer protection to protect the elongated element, the layer of material composite made of plastic material constituting in itself a layer of protection because of its mechanical resistance, particularly its impact resistance.
In testing the impact resistance, it was found that the resins Thermosetting epoxy type, the energy needed to achieve the break is usually 1/5 of the energy required for the break thermoplastic resins. This demonstrates the advantage of being able to

8 to produce elongated elements with thermoplastic resins according to the invention.
According to a second aspect, the present invention also a method of manufacturing reinforced elongated elements, characterized in that it comprises:
at. Prediction of a support element of a soul of form elongated, having means for effecting motion translating said elongated core;
b. The prediction of at least one cassette and advantageously several cassettes for storing ribbons made of composite material comprising a thermoplastic resin matrix in which are embedded in the reinforcement yarns or fibers, for example yarns or fibers of glass or carbon;
vs. The forecast of means of rotation of each cassette;
d. the provision of means for adjusting the winding angle to adjust the winding angle of each ribbon relative to the axis longitudinal, around said soul;
e. The forecast means of synchronization means of displacement in translation of the elongate core and means of rotating each tape cassette;
f. The prediction of at least one heating device at a temperature above the melting temperature of the resin thermoplastic for a period of time sufficient to achieve the complete melting of the thermoplastic resin and the bonding of the composite material on said core or on the preceding layer;
boy Wut. In a synchronized manner, the displacement is translation of the elongated core with the synchronized winding at an adjustable predetermined angle of at least one ribbon by rotating at least one tape storage cassette;
h. The formation of at least one layer is carried out either by unwinding a sufficient number of ribbons to form said layer, either by carrying out several passages in translation of said souls to winding said ribbons by varying the angle winding ribbons in the same layer along the axis length of the elongated element and depending on the mechanical strength desired for the intended application;

9 i. It is cooled or allowed to cool, after said heating, in thus obtaining the reinforced elongated element.
Optionally, we can repeat the operation to deposit an additional layer or a plurality of layers with ribbons of different nature.
According to a particular embodiment of the method or of the apparatus of the invention, the value of the winding angle or the value of displacement of the soul is controlled by the speed ratio between the translational speed of the elongated element, in particular of the pipe, and the speed of rotation of the cassette supporting or storing the ribbon.
The winding angle is in particular given by the formula following mathematical:
Alpha = tangent arc (pi x D x N / Vt) In which :
Alpha: the winding angle in degree relative to the axis longitudinal of the inner or central part or soul;
D: diameter of the inner or central part or core;
N: rotation speed of the ribbon support cassette Rotations per minute ;
Vt: speed of displacement in translation of the internal part or central or soul in meters / minute;
Pi = Greek letter or about 3.1416.
Taking into account another example such as blades or blades of wind turbines like wind turbines, the connecting head of blades or blades is subjected to high strength efforts and needs as a result of high or specific tensile strength.
On the other hand, the free end of the blades or blades has little effort to tensile strength to withstand, but needs to be resistant to bending efforts. As a result, the manufacture of blades or blades according to the technology according to the invention makes it possible to regulate resistance to traction and effort to the appropriate places of the part of the blade or blade and control the deformation of the blade or blade when will be in operation.
According to an advantageous embodiment of the method of the invention, provision is made successive devices of cassette holders of said ribbons so as to to realize in a single translational movement of the soul or the element of elongated shape, the deposition of several layers of composite material.
According to an advantageous embodiment of the invention, performs the winding of each ribbon with a predetermined tension, for example a tensile force of about one DecaNewton per ribbon, in such a way that when the thermoplastic resin is melted, realizes an auto-effect of displacement towards the center thus towards the soul of threads or fibers embedded in the resin of each ribbon, by an effect of internal tension, resulting in a plating effect on the core or layer previous.
According to the invention, according to a particular embodiment, the Ribbon tension is set according to the winding angle value. In in addition, the method allows a gradual change from an angle to an angle different throughout the process. For example, for an angle of about 200, the ribbon tension will preferably be about 15 DecaNewton; and for an angle of about 70, the ribbon tension will preferably be about 5 DecaNewton.
Ribbon tension can be set to such low values than 1 DecaNewton for ordinary applications.
According to a particular embodiment of the invention, the tension ribbon is provided by a braking action to slow down the speed of rotation of each cassette on which is wound the ribbon.
Also, one skilled in the art understands that with the invention, by such a braking action, the tension is easily adjustable to a value precise and can vary to follow the value of the winding angle, and this for the same coating layer, along the longitudinal axis of the elongated element.
According to the invention, the resin heating device thermoplastic is provided with an adjustable orientation so as to avoid to overheat the central part or soul, or the previous layer, of way to avoid degrading it. This is obtained according to the invention now the adjustable flow direction of the hot fluid flow, preferably a flow of hot air, the heating device in a direction substantially perpendicular to the ribbon regardless of its effective winding angle. Those skilled in the art understand that fluids other than air are usable as inert gases although they are usually more expensive.

, μ
According to an advantageous embodiment of the invention, the heating is carried out using nozzles diffusing a hot fluid, warm air at a minimum temperature that is not less than the melting temperature of the thermoplastic resin used.
The invention therefore makes it possible to use only hot air nature less aggressive towards the matrix than a flame used in the prior art and is also safer compared to other fluids.
According to an advantageous embodiment of the invention, uses an elongated element of tubular form of any section polygonal or circular, advantageously hollow so as to form tubes or pipes for the transport of material, in particular fluid, especially oil or liquid gas or not.
The invention is not limited by any particular form of the elongated element because, thanks to the use of ribbons, these embrace all geometric shape. The invention is however advantageously used to strengthen souls of essentially convex shape, ie having no hollow on their outer surface, hollow on which it is extremely difficult to apply said ribbons.
According to a third aspect, the present invention also covers a apparatus for manufacturing reinforced elongated elements, characterized in that that he understands:
at. Prediction of a support element of a soul of form elongated, having means for effecting motion translating said elongated core;
b. The prediction of at least one cassette and advantageously several ribbons storage cassettes made of material composite comprising a thermoplastic resin matrix in which are embedded in glass or carbon threads or fibers;
vs. The forecast of means of rotation of each cassette;
d. The provision of winding angle adjustment means to adjust the winding angle of each ribbon relative to the axis longitudinal around said soul;
e. The forecast means of synchronization means of displacement in translation of the elongate core and means of rotating each tape cassette;

f. The prediction of at least one heating device at a temperature above the melting temperature of the resin thermoplastic for a period of time sufficient to achieve the complete melting of the thermoplastic resin and the bonding of the composite material on said core or on the preceding layer;
boy Wut. The forecast of control means, so synchronized means for synchronizing the moving means in translation of the elongated core and the means for setting rotation of each tape cassette; these control means being provided to perform the sequence of a sufficient number of ribbons to form at least one layer of composite material comprising a plurality of ribbons wrapped around the elongate core, either for carry out several passages in translation of said soul, to achieve a winding said ribbons by varying the winding angle of ribbons in the same layer along the longitudinal axis of the element elongated and depending on the desired mechanical strength for the intended application;
h. Said control means being provided for controlling each heating device at a temperature above one melting temperature of the thermoplastic resin during a period enough time to complete the complete melting of the resin thermoplastic and the bonding of a layer of composite material on said soul or on the previous layer.
In the case of the apparatus of the invention, to accelerate the cooling of the reinforced elongate member obtained, it can be provided cooling means downstream of the device (s) of heater.
According to an alternative embodiment of the apparatus of the invention, the device can be provided to allow the operation to be repeated for deposit an additional layer or a plurality of layers with ribbons of different nature. In this context, it may be provided at least one second set of at least one cassette and preferably several cassettes for storing ribbons of identical nature or of different nature.
Thus, according to an advantageous embodiment of the apparatus of the invention, provides for several successive cassette support devices of said ribbons, in order to achieve in one movement of translation of an element elongated shape and the deposition of several layers of materials composites.
According to a particular embodiment of the method or of the apparatus of the invention, the value of the winding angle or the core is controlled by the speed ratio between the speed of movement in translation of the elongated element, in particular of the tube, and the speed of rotation of the cassette supporting or storing the ribbon. The angle of winding is in particular given by the mathematical formula next :
a = Arctan x D x N / Vt) In which :
a or alpha: the winding angle in degree relative to the longitudinal axis of the inner or central part or core;
D: diameter of the inner or central part or core;
N: rotation speed of the ribbon support cassette Rotations per minute ;
Vt: speed of displacement in translation of the internal part or central or soul in meters / minute;
FI or Pi = Greek letter fi or about 3.1416.
Thus, those skilled in the art understand that the invention makes it possible to unexpectedly make a composite part that includes a wide variety of winding angles and consequently resistance specific mechanical forces or constraints that are useful for specific applications, as indicated above concerning the process.
All the embodiments given for the process are clearly applicable to the device.
According to another advantageous embodiment of the apparatus according to the invention, provision may be made for voltage adjustment means for adjust or adjust the unwinding tension of each ribbon to a value predetermined voltage, for example by providing that these means of voltage adjustment allow adjustment and ribbon traction, so that when the thermoplastic resin is in fusion, it is realized a self-effect of displacement towards the center therefore to the soul of the threads of fibers embedded in the resin of each ribbon, by an effect of internal tension, hence a plating effect on the soul or the previous layer.

According to another particular embodiment, each means voltage adjustment device comprises braking means capable of to apply a braking action on each cassette on which the ribbon is rolled up.
With the tension adjustment means, in particular comprising the braking means, it is very easy to adjust the voltage of the ribbon according to the winding angle. For example, for an angle of about 200, the ribbon tension will preferably be about 15 DecaNewton; and for an angle of about 70, the ribbon tension will preferably be about 5 DecaNewton.
Ribbon tension can be set to such low values than 1 DecaNewton for ordinary applications.
According to an advantageous embodiment of the invention, the heating device of the thermoplastic resin is provided with Adjustable orientation means for adjusting the orientation of a fluid flow hot to avoid overheating of the central or internal part or the previous layer so as to avoid degrading it.
According to an advantageous embodiment of the invention, the apparatus comprises adjustable orientation holding means for maintain the adjustable orientation of the hot fluid flow of the device heating in a direction substantially perpendicular to the ribbon regardless of its effective winding angle.
According to yet another advantageous embodiment of the apparatus according to the invention, provision may be made for the heating device includes nozzles delivering hot air at a temperature that is not not lower or even at least higher than the temperature of melting of the thermoplastic resin used.
According to a fourth aspect, the present invention still covers the use of the aforementioned reinforced elongated elements, in particular obtained by the process according to the invention or the apparatus for producing the invention, for the manufacture of pipes, in particular so-called risers, buried in the ground or used as shore in particular extending from an offshore platform to the bottom for the manufacture of turbine blades or blades or wind machines or wind turbines.

It is thus understood that the invention makes it possible to solve previously stated technical problems and therefore provides a new and not obvious solution for a man of the art.
Other purposes, features and advantages of the invention will appear clearly in the light of the explanatory description which will follow made with reference to a presently preferred embodiment of an apparatus according to the invention, and making it possible to implement the method according to the invention described above, given simply by way of illustration and therefore can not, in any way, limit the scope of the invention.
The apparatus according to the invention is shown in the figures annexed, and forms an integral part of the invention and therefore feature of this device that will appear new compared to a any state of the art, is claimed as a means general and in its function, as well as its technical equivalents.
In the examples, temperatures are given in degrees Celsius, the pressure is the atmospheric pressure; the atmosphere is the air, unless otherwise stated.
FIG. 1 represents a simplified general side view of a first embodiment of an apparatus according to the invention, given as a illustration;
FIG. 2 represents an enlarged view of a portion of the apparatus produced according to the invention and configuring the means for setting rotation, for example in the form of a wheel or plate, serving as a cassette support comprising the ribbons;
FIG. 3 represents an enlarged view of a portion of the apparatus produced according to the invention with the detail of the removal operation ribbons contained in the cassettes;
Figure 4 shows the detail of a cassette showing clearly storing the ribbon wound on it and unwinding it;
Figure 5 shows the detail of an elongated element obtained according to the invention with a layer formed of a plurality of ribbons 32;
Figure 6 shows a detail view of construction of a ribbon formed by the combination of a thermoplastic matrix and reinforcing yarns or fibers, for example yarns or fibers of glass or carbon, according to the reference VI indicated in Figure 5;

FIG. 7 represents a detail view according to reference VII
of Figure 2 of the cassette showing the presence of adjustment means which according to this particular embodiment comprises braking means;
FIG. 8 represents a second embodiment of a elongated element in the form of an off-shore duct 112 manufactured on the method the apparatus of the invention, a plurality of five pipes or tubes being gathered together to constitute risers of offshore platforms to extract for example natural oil or oil from a well made in the subsoil of a seabed.
Figure 9 shows a cross section of the pipe 112 at the head or proximal position of the riser according to arrow IX of the Figure 8 with the winding angle alpha 1 of the ribbon relative to the axis longitudinal XX of the pipeline 112;
Figure 10 shows a cross section of the channel 112 at the bottom or distal position of the riser according to the arrow X
of Figure 8 with the winding angle alpha 2 of the ribbon relative to the longitudinal axis XX of the pipe 112; and Figure 11 shows another embodiment of an element elongated constituted here by a blade or blade of wind turbines or wind turbine 212, for example for machines for wind energy production, showing the respective winding angles alpha 3, alpha 4, alpha 5 of the proximal connecting end to the free distal end.
With reference to FIGS. 1 to 7, an apparatus according to the invention is represented by the general reference number 10, and is characterized in what he understands:
at. The provision of a support element 20 of a core 22 of elongated shape, comprising means for performing a translational movement T of said elongate core, these means translation are well known to those skilled in the art and therefore are not represented here;
b. The prediction of at least one cassette 30, and advantageously several (here 12) cassettes 30 for storing ribbons 32 made of composite material comprising a resin matrix (34) thermoplastic material in which fibers or yarns of reinforcement (35), for example glass or carbon threads or fibers;

vs. The forecast of means 36 of rotation of each cassette 30, these rotating means 36 comprising, for example, an axis of rotation 37, around which the cassettes 30 are rotating free. In the presently preferred embodiment shown in FIG.
1, the axes of rotation 37 are themselves supported by a plate 38, rotated by conventional rotating means well known to those skilled in the art. All of these elements constitute the means 36 for rotating each cassette 30;
d. The provision of means for adjusting the winding angle constituted here by the combination of the rotating means 36, the turntable 38 and the speed of rotation of the cassettes 30, for adjust the winding angle have each ribbon around the central core, internal or core 22;
e. The prediction of synchronization means (61), conventional well known to those skilled in the art and schematized here to simplify the figure, means 20 for translational movement of the core 22 of shape elongated and means 36 for rotating each cassette 30 of ribbon 32, by the presence of two links 62 and 64, respectively;
f. The provision of at least one heating device 50 to a temperature above the melting temperature of the resin thermoplastic 34 for a period of time sufficient to achieve the complete melting of the thermoplastic resin and the bonding of the layer 33 composite material on said core 22 or on the previous layer;
boy Wut. The provision of control means 60, so synchronized, by a link 68, synchronization means 61, means for translational movement of the elongate core 22 and means 36 for rotating each tape cassette 30 32;
These control means 60 are provided:
- or to realize the course of a number of ribbons 32 sufficient to form at least one layer 33 of composite material comprising a plurality of ribbons wound around the core 22 of shape elongated (as shown in Figure 1 and even more visible in Figures 2 and 3), or to carry out several passages in translation of said soul for winding said ribbons in an equivalent manner and as is understandable to a person skilled in the art.

h. The control means 60 are also provided for control by a link 66 each heating device 50 to a temperature not below or in practice higher than a temperature melting the thermoplastic resin 34 for a period of time sufficient to effect the complete melting of the thermoplastic resin 34 and bonding a composite material layer 33 to said core 22 or on the previous layer.
As clearly shown in FIG. 7, adjustment means or voltage regulation 90 can be provided to add voltage winding each ribbon 32 to a voltage value predetermined, which allows the adjustment to a pulling force desired while the thermoplastic resin is melting, the threads or cords of fibers stuck or included in the resin of each ribbon 32 are automatically moved to the east center as well, towards the central part or the previous layer, adding an effect of internal tensions.
According to a particular mode of relationship of the invention, each means for adjusting the tension comprises braking means, or a brake, 92 capable of exerting a braking action on each cassette 30 on which is wound the ribbon 32.
Naturally, the structure of each brake is of any type that can be used to exert a braking action on the cassette 32.
According to the embodiment of FIG. 7, the brake 92 includes a brake disk 94 which can be braked by disks friction device 98 forming part of the braking activation device electromechanical 96 that can be U-shaped to exert an action braking on both sides of the brake disc 94.
It is apparent that the brake disc 94 is mounted here on a cylinder 95 linked to the cassette 30 to rotate with it. Naturally, the brake disk 94 can be directly mounted on the cassette 30 and be braked laterally as is understandable for a skilled in the art.
It will be well understood by one skilled in the art that with the tension adjusting means 90, in particular comprising the means 92, it is very easy and very effective to adjust a voltage of the ribbon 32 according to the winding angle alpha to any desired value.

For example, for the manufacture of an off-shore pipeline can be used as a riser 112 as shown in Figure 8 for the offshore platform 200, the invention makes it possible to vary the angle winding at will by controlling the speed ratio between the displacement speed in translation of the pipe or core or core 22 and the speed of rotation of the cassettes supporting the ribbons 32, as given by the previously stated mathematical formula.
For the zone of riser 112A shown in Figure 9, which is intended to be in a rather riser top position, strong forces of traction are exerted by the weight of the pipes which can have a length usually over 100 meters up to 1000 meters or even more.
In the summit area 112A where the traction forces are the higher, the winding angle can be set to one relatively low, that is, in the range of about 20 to 25 as shown by the alpha value 1 of Figure 9; while in the part of riser bottoms where the pressures are highest because of the deep sea level, the alpha winding angle 2, as shown in FIG. 10 is set to a high value, that is to say here in a range from 60 to 70, for example 65.
Naturally, the winding angle is changed slowly or gradually from the low value to the high value so as to avoid abrupt changes in the winding angle that could cause or promote mechanical deficiencies in the pipeline.
Similarly, in connection with FIG.
a third embodiment of an elongated element here in the form blade or blade of turbine or wind turbine.
The blade of the turbine or wind turbine 212 at one end proximal of 113 which carry connection means 214 for allow attachment to the axis of the turbine and a distal end 215.
As well understandable for one skilled in the art, at the end proximal 213, in the zone 212A, the torsional forces are at the maximum and because of this, it is preferred to have an alpha winding angle 3 also high as possible, close to the perpendicular to the longitudinal axis XX of the blade, that is to say in the range of 80-90, in particular about 85, while at the free end 215, in the zone 212C, the efforts of traction are maximum and it is preferred to have a value of the angle winding, for example in the range of 20-25, referred to as winding angle alpha 5.
As previously indicated for the embodiment relative to the riser, the intermediate zone 212 has an angle of winding alpha 4 which can be in the 45-500 range, while there is progressive modification of the alpha winding angle of the zone proximal 212A with the alpha 3 and the distal 212C
having the winding angle alpha 5.
Consequently, it is easy to understand that the invention allows to adapt the manufacture of an elongated element for any use particular.
In the context of the invention, to accelerate the cooling of the reinforced elongated element obtained, means of cooling downstream of the heating device (s) 50, as this is understandable to one skilled in the art. The means of command 60 are also advantageously provided for controlling the cooling means 70 by an appropriate connection 72.
According to an advantageous variant of embodiment of an apparatus for the invention, the apparatus 10 may be provided to allow starting again the operation to deposit an additional layer or a plurality of layers with ribbons 32 of different nature. In this context, he can at least one second set 38 of at least one cassette and advantageously several cassettes 30 for storing ribbons 32 be of identical nature or of a different nature.
Thus, it will be readily understood that in an advantageous manner of the apparatus of the invention, several devices 38 or trays are provided successive storage media support (s) 30 ribbons 32, so to achieve in one translational movement a member 12 of form elongation and the deposits of several layers of composite material Identical nature, of a different nature.
According to yet another advantageous embodiment of according to the invention, provision may be made for means for adjusting the voltage, such as 80.82, at a predetermined voltage value of winding each ribbon 32, for example by providing that these voltage adjustment means 80, 82 enable adjustment to be made to a tensile force of about one decanewton (one kilogram) per ribbon 32, in such a way that when the thermoplastic resin 34 is melted, realizes an auto-effect of displacement towards the center thus towards the soul of threads or fibers embedded in the resin of each ribbon 32, by an effect of internal tension, resulting in a plating effect on the core or layer previous. The plate 38 may also include a frustoconical portion 46 supporting the means 82, and a disk member 48 supporting means 40 for guiding the ribbons 32, comprising by example of rods 42 and pins 44 (see Figure 3).
According to yet another advantageous embodiment of the invention, each heating device 50 of the thermoplastic resin 34 is provided with adjustable orientation means for maintaining the adjustable orientation of the hot fluid flow of the heating device in a direction substantially perpendicular to the ribbon regardless of its effective winding angle to avoid a overheating of the soul or the previous layer, so as not to degrade.
According to yet another advantageous embodiment of the apparatus according to the invention, provision can be made for each heating 50 comprises nozzles 52 diffusing a hot air to a temperature at least greater than the melting temperature of the thermoplastic resin 34 used. These nozzles 52 can be naturally made orientable to be arranged according to an appropriate angle of orientation to diffuse hot air into the better heating conditions as mentioned before.
Various variants of the elongated element 12, 112, 212 and in particular of the core 22 or ribbons 32 are described in the introductory part of the description.
It is apparent that in the invention, the translation of the part central or core is made substantially parallel to the longitudinal axis of the central part or nucleus. Depending on the shape of the party central or nucleus, another direction of translation could be provided.
It is thus well understood that the invention makes it possible to solve previously stated technical problems and therefore presents a new and not obvious solution for a person skilled in the art.
The invention, as just described for the apparatus, allows well to implement the method of manufacturing the elongated element 12, 112, 212 reinforced by at least one layer 33, previously described in introductory part of the present description.

As previously stated, the invention also covers all means constituting technical equivalents of the means described and represented in the accompanying figures which form an integral part of the invention.

Claims (39)

1. Reinforced elongated member (12) defining a longitudinal axis (XX), comprising a core (22) of elongate shape, covered with least one layer (33) of composite material comprising a plurality ribbons (32) wrapped around said core (22), each of the ribbons (32) being made with reinforcing threads or fibers (35), by example of wires or glass or carbon fibers, embedded in a matrix (34) of thermoplastic resin, the ribbons (32) being wound around the core according to a predetermined, adjustable winding angle relative to the longitudinal axis of the elongated element, according to the resistance mechanics desired for the intended application, the winding angle varying from one end to the other in the same layer for at least one composite layer, thus modifying the mechanical strength of a end to end of the elongated element. 2. Elongated element according to claim 1, characterized in that that the winding angle value is controlled by the gear ratio between the speed of displacement in translation of the soul and the speed of rotation of a cassette supporting the ribbon. Elongated element according to claim 1 or 2, characterized in what the winding angle is given by the mathematical formula next :
.alpha. = Arctan (H x D x N / Vt) In which :
.alpha. : the winding angle in degree relative to the axis longitudinal of the inner or central part or soul;
D: diameter of the inner or central part or core;
N: rotation speed of the ribbon support cassette Rotations per minute ;
Vt: speed of displacement in translation of the internal part or central or soul in meters / minute;
.pi. or Pi = Greek letter .pi. or about 3.1416. 4. Elongated element according to one of claims 1 to 3, characterized in that the ribbons are wrapped around the core according to a ribbon tension adjusted according to the value of the winding angle wish. Elongated element according to one of claims 1 to 4, characterized in that the elongate member has two main ends, a first proximal end and a second distal end, the angle winding has been progressively modified since the first end to the second end in one or more, or even in the whole, composite layers. 6. Elongated element according to claim 5, characterized in that that for an angle of about 200, the ribbon tension is set to about 15 DecaNewton, and for an angle of about 70 °, the voltage of the Ribbon is set at around 5 DecaNewton. Elongated element according to one of Claims 1 to 6, characterized in that said elongate core (22) is made of a metal or a metal alloy, made of steel, of stainless steel. 8. Elongated element according to one of claims 1 to 7, characterized in that the core (22) is made of a material thermoplastic, nylon, or of the same kind as resin thermoplastic used to make the matrix (34) of the ribbon (32). 9. Elongate element according to one of claims 1 to 8, characterized in that the thermoplastic resin comprises or is made of polyamide 11 or polyamide 12. Elongated element according to one of Claims 1 to 9, characterized in that the core (22) is substantially shaped convex. 11. Elongate element according to one of claims 1 to 10, characterized in that the winding angle of the ribbon is included in the range from 20 ° to 85 ° and varies progressively along axis length of the elongated element in the same layer, depending on the resistance mechanics desired for the intended application. 12. Elongate element according to one of claims 1 to 11, characterized in that for off-shore applications the elongated element is in the form of an off-shore pipeline, the winding angle is range from 20 ° to 80 ° or from 20 ° to 70 ° and varies progressively along the longitudinal axis of said elongate member in the same layer. Elongated element according to one of claims 1 to 11, characterized in that for turbine or blade type applications wind turbine, the elongate element is in the form of a blade or blade of turbine or wind turbine, the winding angle is included in the range ranging from 20 to 85 ° and varies gradually along the axis longitudinal said elongated element in the same layer. 14. Elongate element according to one of claims 1 to 13, characterized in that at least one and preferably several layers of a composite material of the same nature or nature different, different ribbons or arranged according to angles different winding. 15. Elongated element according to one of claims 1 to 14, characterized in that it is expected that the outermost layer on the elongated element is made of composite material comprising a a plurality of ribbons also wrapped around the previous layer, said tapes comprising a thermoplastic resin matrix and a reinforcing material in the form of yarns or fibers, yarns or fibers of glass or carbon. 16. A method of manufacturing reinforced elongated elements (12), characterized in that it comprises:
at. The provision of a support element (20) for a web (22) of elongated form, comprising displacement means in translation of the soul (22) of elongated form;
b. The provision of at least one cassette (30) and advantageously several cassettes (30) for storing ribbons (32) made of composite material comprising a resin matrix (34) thermoplastic material in which wires or fibers (35), wires or glass or carbon fibers;
vs. The forecasting means (36) of rotation of each cassette (30);
d. the provision of means for adjusting the winding angle to adjust the winding angle of each ribbon around said core;
e. The forecast means of synchronization means of displacement (20) in translation of the elongate core (22) and means (38) for rotating each tape cassette (30) (32);
f. The provision of at least one heating device (50) for temperature above the melting temperature of the resin thermoplastic (34) for a period of time sufficient to perform the complete melting of the thermoplastic resin and gluing the layer (33) of composite material on said core (22) or on the layer previous;
boy Wut. In a synchronized manner, the displacement is translating the elongate core (22) with the winding synchronized at a predetermined adjustable angle of at least one ribbon (32) among the rotation of at least one ribbon storage cassette (30) (32);
h. At least one layer (33) is formed by either the course of a number of ribbons (32) sufficient to form said layer (33), or by carrying out several passages in translation of said core (22) for winding said ribbons (32), by varying the winding angle of the ribbons in the same layer along the axis length of the elongated element and depending on the mechanical strength desired for the intended application;
i. It is cooled or allowed to cool, after said heating, in thereby obtaining the reinforced elongate member (12). 17. The method of claim 16, characterized in that several successive devices (38) of cassette holders are provided (30) said ribbons (32), so as to achieve in a single movement of translation of the elongated element (12), the deposition of several layers (33) of composite material. 18. Method according to one of claims 16 or 17, characterized in that the winding angle value is controlled by the ratio of speed between the translational speed of translation of the soul, and the speed of rotation of the cassette supporting the ribbon. 19. The method of claim 18, characterized in that the winding angle is given by the following mathematical formula:
.alpha. = Arctan (II x D x N / Vt) In which :
.alpha .: the winding angle in degree relative to the axis longitudinal of the inner or central part or soul;
D: diameter of the inner or central part or core;
N: rotation speed of the ribbon support cassette Rotations per minute ;
Vt: speed of displacement in translation of the internal part or central or soul in meters / minute;
He or Pi = Greek letter n or about 3.1416. 20. Method according to one of claims 16 to 19, characterized in that the ribbons are wrapped around the core or the layer previous according to a ribbon tension adjusted according to the value of the angle desired winding. 21. Method according to one of claims 16 to 20, characterized in that said elongated element has two main ends, a first proximal end and a second distal end, the said method comprising progressively modifying said winding angle from said first end to the second end in the same layer. 22. Method according to one of claims 16 to 21, characterized in that at an angle of about 20 °, the ribbon tension is adjusted at about 15 DecaNewton, and for an angle of about 70 °, the voltage of the Ribbon is set at around 5 DecaNewton. 23. Method according to one of claims 16 to 22, comprising the provision of a heating device (50) for heating the resin thermoplastic with adjustable orientation of a hot fluid flow to prevent overheating of the soul or the previous layer so to avoid degrading it. 24. The method of claim 23 including maintaining the orientation of the heater (50) of the resin thermoplastic (34) in a direction substantially perpendicular to the ribbon regardless of its current or actual winding angle. 25. The method of claim 23 or 24, characterized in that the heating is carried out by means of nozzles (52) diffusing a hot air to a temperature at least not below the melting temperature of the thermoplastic resin (34) used. 26. Apparatus for manufacturing reinforced elongate elements (12), characterized in that it comprises:
at. The provision of a support element (20) for a web (22) of elongated form, comprising displacement means in translation of the soul (22) of elongated form;
b. The provision of at least one cassette (30) and advantageously several cassettes (30) for storing ribbons (32) made of composite material comprising a resin matrix (34) thermoplastic material in which fibers or yarns of reinforcement (35), glass or carbon threads or fibers;

vs. The forecasting means (36) of rotation of each cassette (30);
d. the provision of means (36, 38) for adjusting the angle to adjust or adjust the winding angle of each ribbon (32) around the soul;
e. Prediction of synchronization means (61) means (20) translational displacement of the elongate core and means (36) for rotating each cassette (30) of tape (32);
f. The provision of at least one heating device (50) for temperature above the melting temperature of the resin thermoplastic (34) for a period of time sufficient to perform the complete melting of the thermoplastic resin and gluing the layer (33) of composite material on said core (22) or on the layer previous;
boy Wut. The provision of control means (60), so synchronized means (61) for synchronizing means of displacement in translation of the elongate core (22) and means (38) for rotating each cassette (30) for storing ribbon; these control means (60) being provided either to realize winding a number of ribbons (32) sufficient to form at least a layer (33) of composite material comprising a plurality of ribbons (32) wound around the elongate core (22), either for performing several passages in translation of said core (22) to achieve winding said ribbons (32), varying the angle winding ribbons in the same layer along the axis length of the elongated element and depending on the mechanical strength desired for the intended application;
h. Said control means (60) being provided for control each heater (50,52) at a temperature greater than a melting temperature of the thermoplastic resin for a period of time sufficient to complete the complete merger thermoplastic resin and bonding a layer of material composite on said core (22) or on the previous layer (33). 27. Apparatus according to claim 26, characterized in that the winding angle value (a) is controlled by the gear ratio between the speed of displacement in translation of the soul, and the speed of rotation of the cassette supporting the ribbon. 28. Apparatus according to claim 26 or 27, characterized in that that the winding angle is given by the mathematical formula next :
.alpha. = Arctan (II x D x N / Vt) In which :
.alpha. : the winding angle in degree relative to the axis longitudinal of the inner or central part or soul;
D: diameter of the inner or central part or core;
N: rotation speed of the ribbon support cassette Rotations per minute;
Vt: speed of displacement in translation of the internal part or central or soul in meters / minute;
He or Pi = Greek letter II or about 3.1416. Apparatus according to one of claims 26 to 28, characterized in that it comprises tension adjustment means for adjusting or set the winding voltage of each ribbon to a voltage value predetermined. Apparatus according to claim 29, characterized in that the tension adjusting means comprise braking means to slow the speed of rotation of each cassette supporting the ribbon. Apparatus according to one of claims 26 to 30, characterized in that said elongated element has two main ends, a first proximal end and a second distal end, the so-called control means gradually modifying said winding angle from said first end to said second end in one or several, or even all, of the composite layers. Apparatus according to claim 30 or 31, characterized in that that for an angle of about 20 °, the ribbon tension is set to about 15 DecaNewton, and for an angle of about 70 °, the voltage of the Ribbon is set at around 5 DecaNewton. Apparatus according to one of claims 26 to 32, characterized in that the apparatus comprises a plurality of successive devices (38) for holding cassettes (30) for storing ribbons (32) or identical nature, of a different nature, in order to achieve, in a single translational movement of a soul (22) or a member (12) of form elongated, the deposition of several layers of composite materials. 34. Apparatus according to one of claims 26 to 33, characterized in that the heating device (50, 52) of the thermoplastic resin includes adjustable orientation means for orienting adjustable a flow of hot fluid so as to avoid overheating of the soul (22) or the previous layer (33), so as not to degrade. Apparatus according to claim 34, characterized in that include means of adjustable orientation to maintain orientation adjustable warmer fluid flow of heater in a direction substantially perpendicular to the tape independent of its angle effective winding. 36. Apparatus according to one of claims 26 to 35, characterized in that the heater (50) comprises nozzles (52) diffusing hot air at a temperature not less than melting temperature of the thermoplastic resin (34) used. 37. Apparatus according to one of claims 26 to 36 characterized in that the support element or core is suitable for manufacture, either of an off-shore pipeline, either a blade or turbine blade or wind turbine. 38. Apparatus according to one of claims 26 to 36, characterized in that a support element or core adapted to the manufacture of an off-shore pipeline, either of a blade or turbine blade or wind turbine. 39. Use of reinforced elongated elements as defined according to any one of claims 1 to 15, obtained by the process according to one of claims 16 to 25 or the manufacturing apparatus according to one of claims 26 to 36, for the manufacture of pipes buried in the ground or used off-shore, in particular deposited on The seabed ; or for the manufacture of blades or blades of turbines or wind machines or wind turbines.