CN109789687A - 热塑性复合材料 - Google Patents
热塑性复合材料 Download PDFInfo
- Publication number
- CN109789687A CN109789687A CN201780060852.1A CN201780060852A CN109789687A CN 109789687 A CN109789687 A CN 109789687A CN 201780060852 A CN201780060852 A CN 201780060852A CN 109789687 A CN109789687 A CN 109789687A
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- CN
- China
- Prior art keywords
- band
- filament
- layer
- fluoropolymer
- polymer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
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- 239000002131 composite material Substances 0.000 title claims description 72
- 229920001169 thermoplastic Polymers 0.000 title claims description 37
- 239000004416 thermosoftening plastic Substances 0.000 title claims description 37
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 60
- 239000004917 carbon fiber Substances 0.000 claims abstract description 60
- 229920000642 polymer Polymers 0.000 claims abstract description 52
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 43
- 238000000034 method Methods 0.000 claims abstract description 36
- 238000002156 mixing Methods 0.000 claims abstract description 9
- 239000010410 layer Substances 0.000 claims description 99
- 229920002313 fluoropolymer Polymers 0.000 claims description 36
- 239000004811 fluoropolymer Substances 0.000 claims description 36
- 239000000463 material Substances 0.000 claims description 27
- 238000004519 manufacturing process Methods 0.000 claims description 13
- 239000011241 protective layer Substances 0.000 claims description 12
- 239000002033 PVDF binder Substances 0.000 claims description 10
- 229920002981 polyvinylidene fluoride Polymers 0.000 claims description 10
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims description 9
- 239000004810 polytetrafluoroethylene Substances 0.000 claims description 9
- 239000000203 mixture Substances 0.000 claims description 8
- 229920005594 polymer fiber Polymers 0.000 claims description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 6
- 239000004812 Fluorinated ethylene propylene Substances 0.000 claims description 6
- 239000004952 Polyamide Substances 0.000 claims description 6
- 230000004888 barrier function Effects 0.000 claims description 6
- 229910052799 carbon Inorganic materials 0.000 claims description 6
- 229920009441 perflouroethylene propylene Polymers 0.000 claims description 6
- 229920002647 polyamide Polymers 0.000 claims description 6
- 238000004804 winding Methods 0.000 claims description 6
- 239000004696 Poly ether ether ketone Substances 0.000 claims description 5
- 239000012530 fluid Substances 0.000 claims description 5
- 229920011301 perfluoro alkoxyl alkane Polymers 0.000 claims description 5
- 229920002530 polyetherether ketone Polymers 0.000 claims description 5
- 239000013047 polymeric layer Substances 0.000 claims description 5
- -1 polytetrafluoroethylene Polymers 0.000 claims description 5
- 239000005977 Ethylene Substances 0.000 claims description 4
- 239000000155 melt Substances 0.000 claims description 4
- 210000001520 comb Anatomy 0.000 claims description 3
- 150000001875 compounds Chemical class 0.000 claims description 3
- 229920001577 copolymer Chemical compound 0.000 claims description 3
- HQQADJVZYDDRJT-UHFFFAOYSA-N ethene;prop-1-ene Chemical group C=C.CC=C HQQADJVZYDDRJT-UHFFFAOYSA-N 0.000 claims description 3
- 229920000840 ethylene tetrafluoroethylene copolymer Polymers 0.000 claims description 3
- 239000011159 matrix material Substances 0.000 claims description 3
- 229920000307 polymer substrate Polymers 0.000 claims description 3
- 230000006835 compression Effects 0.000 claims description 2
- 238000007906 compression Methods 0.000 claims description 2
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 claims 2
- 229910052731 fluorine Inorganic materials 0.000 claims 2
- 239000011737 fluorine Substances 0.000 claims 2
- WFLOTYSKFUPZQB-UHFFFAOYSA-N 1,2-difluoroethene Chemical group FC=CF WFLOTYSKFUPZQB-UHFFFAOYSA-N 0.000 claims 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims 1
- PQIOSYKVBBWRRI-UHFFFAOYSA-N methylphosphonyl difluoride Chemical group CP(F)(F)=O PQIOSYKVBBWRRI-UHFFFAOYSA-N 0.000 claims 1
- 239000000835 fiber Substances 0.000 description 8
- 229910052751 metal Inorganic materials 0.000 description 7
- 239000002184 metal Substances 0.000 description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- 238000013461 design Methods 0.000 description 5
- 239000000654 additive Substances 0.000 description 4
- 239000000956 alloy Substances 0.000 description 4
- 229910045601 alloy Inorganic materials 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- 230000000996 additive effect Effects 0.000 description 3
- 238000007596 consolidation process Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 238000000429 assembly Methods 0.000 description 2
- 230000000712 assembly Effects 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 238000007667 floating Methods 0.000 description 2
- 229920001519 homopolymer Polymers 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 229910000975 Carbon steel Inorganic materials 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 239000010962 carbon steel Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000006837 decompression Effects 0.000 description 1
- 238000001739 density measurement Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 230000007717 exclusion Effects 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 description 1
- 239000012802 nanoclay Substances 0.000 description 1
- 238000000399 optical microscopy Methods 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
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- 229920000647 polyepoxide Polymers 0.000 description 1
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- 238000006116 polymerization reaction Methods 0.000 description 1
- 230000004044 response Effects 0.000 description 1
- 239000013535 sea water Substances 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000002411 thermogravimetry Methods 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
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- 239000004634 thermosetting polymer Substances 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
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Abstract
一种制造柔性管层的方法,该方法包括:将聚合物细丝和碳纤维细丝混杂以形成紧密混合物,形成混杂细丝的纱线,将纱线形成带,并将带施加到管体上以形成柔性管层。
Description
技术领域
本发明涉及热塑性复合材料和用于形成这种复合材料的方法。特别地,但非排他地,本发明涉及由热塑性复合材料形成的柔性管。本发明还涉及制造柔性管层的方法。
背景技术
传统上,柔性管用于将生产流体如油和/或气体和/或水从一个位置输送到另一个位置。柔性管特别适用于将海底位置(其可以是水下深处)连接到海平面位置。柔性管通常形成为柔性管体和一个或多个端部配件的组件。管体通常形成为形成承压导管的层状材料的组合。管结构允许大的变形量而不会产生弯曲应力,弯曲应力损害管在其寿命期间的功能性。管体通常构建为包括金属和聚合物层的组合结构。
无连接柔性管已用于深水(小于3,300英尺(1,005.84米))和超深水(大于3,300英尺)的开发。正是由于对石油的需求不断增加,导致勘探发生在越来越大的深度,其环境因素更加极端。例如,在这种深水和超深水环境中,海底温度会增加输送流体冷却到可能导致管堵塞的温度的风险。增加的深度也增加了与其中柔性管必须操作的环境相关的压力。
在许多已知的柔性管设计中,管体包括一个或多个压力保护层(pressure armourlayer)。这些层上的主要载荷由径向力形成。压力保护层通常具有特定的横截面轮廓以互锁,以便能够保持和吸收由管上的外部或内部压力产生的径向力。防止管由于压力而坍塌或破裂的绕线的横截面轮廓有时被称为耐压型材。当压力保护层由形成箍组件的螺旋绕线形成时,来自管上的外部或内部压力的径向力导致箍组件膨胀或收缩,从而在线上施加拉伸载荷。
提高载荷响应并因此改善保护层性能的一种方法是由更厚和更坚固且因此更稳健的材料制造层。例如,对于压力保护层,其中层通常由绕线形成,其中相邻的绕组在层互锁中,由较厚的材料制造线导致强度适当地增加。然而,随着使用更多材料,柔性管的重量增加。最终,柔性管的重量可能成为使用柔性管的限制因素。此外,使用越来越厚的材料制造柔性管明显地增加了材料成本,这也可能是一个缺点。
发明内容
本发明人开发了一种可用于在管周围形成保护层的材料。与通常由缠绕的互锁金属线形成的传统保护层不同,新材料基于热塑性复合材料。
根据本发明的第一方面,提供了一种制造柔性管层的方法,该方法包括将聚合物细丝和碳纤维细丝混杂以形成紧密混合物,形成混杂细丝的纱线,将纱线形成带,并将带施加到管体上以形成柔性管层。
根据本发明的另一方面,提供了一种热塑性复合材料,其包括含氟聚合物细丝和碳纤维细丝,其中所述含氟聚合物细丝和所述碳纤维细丝混杂以形成紧密混合物,并且其中所述含氟聚合物具有40至80g/10min范围内的熔体流动指数(230℃/2.16kg)。
上述热塑性复合材料可以形成为带。
根据本发明的另一方面,还提供了一种柔性管,其包括至少一个管层,该管层由如前文描述的复合材料带形成或可由其获得。
本发明还提供一种包括管层的柔性管,其包括由包含聚合物和碳纤维的热塑性复合材料形成的第一区域,其中碳纤维以第一浓度存在,和由(i)包含聚合物和碳纤维的热塑性复合材料,其中碳纤维以第二浓度存在;或(ii)基本上由聚合物组成的聚合物组合物形成的第二区域。
根据本发明的又一方面,提供一种制造如本文描述的热塑性复合材料的方法,其包括将聚合物细丝和碳纤维细丝混杂以形成紧密混合物。
混杂的聚合物细丝和碳纤维细丝可以形成为纱线。几根纱线可以彼此相邻地布置以形成纱线组件(assembly),然后将其压缩以形成带。带可以缠绕在管体上以形成管状管层。然后,可以加热管状管层以熔化碳纤维细丝周围的聚合物细丝以形成含氟聚合物基质。所得结构可以是柔性管层,例如压力保护层。
本发明人发现,通过混合聚合物细丝和碳纤维细丝,可以生产聚合物细丝和碳纤维细丝的紧密混合物。此外,通过选择具有特定熔体流动指数的聚合物,例如熔体流动指数(230℃/2.16kg)在40至80g/10min范围内的含氟聚合物,可以在聚合物和碳纤维之间获得足够的粘合力。通过改善碳纤维在整个聚合物基质中的分散和碳纤维与聚合物之间的粘合性,可以改善所得复合材料的最终机械性能。因此,本发明允许生产热塑性复合材料,其可用于形成压力保护层,该压力保护层具有足够的机械强度以保持和吸收柔性管上的径向或轴向力。同时,例如,当与通常用于形成保护层且特别是现有技术中的压力保护层的金属线相比时,复合材料相对较轻。
如前文的描述,混杂细丝可以形成为纱线。几根纱线可以彼此相邻地布置以形成纱线组件,然后将其压缩以形成带。通过将具有不同碳浓度的纱线布置为彼此相邻,可以生产具有不同碳纤维浓度的区域的带。这种带可缠绕在管体上以形成管状层,然后加热以使聚合物软化或熔化在碳纤维细丝周围。这允许具有包含不同浓度的碳纤维的区域的柔性管层作为整体结构。因此,混杂技术能够根据需要通过设计改变和控制管层的机械性能。设计方面很重要,因为复合材料中的纤维浓度的变化使用常规技术可能是不可避免的,然而这些浓度变化是非预期的或不受控制的,因此不能依赖于设计目的。因此,根据本发明的复合保护层也是复合材料管设计技术的重要改进。
聚合物
可以使用任何合适的聚合物来形成本发明的热塑性复合材料。在一个实施方式中,聚合物是含氟聚合物。合适的含氟聚合物包括全氟烷氧基烷烃(PFA)、聚(乙烯-共-四氟乙烯)(ETFE)、聚四氟乙烯(PTFE)、氟化乙烯丙烯(FEP)和聚偏二氟乙烯(PVDF),或这些聚合物中的至少两种的合金。优选地,含氟聚合物是PVDF或包含PVDF的合金。本领域技术人员还将认识到,也可以按照本发明的指导使用替代聚合物。例如,非含氟聚合物材料如聚醚醚酮(PEEK)或聚酰胺(例如PA-11或PA-12)也可用作复合材料层的基质材料,设计和制造通过和沿着层具有不同的性质。在一个实施方式中,可以使用至少一种含氟聚合物和至少一种非含氟聚合物的组合。
优选地,聚合物是含氟聚合物,其包含均聚物。优选地,均聚物是PVDF等级。
含氟聚合物可具有40至80g/10min范围内,优选为50至75g/10min范围内的熔体流动速率(230℃/2.16kg)。在一个实施方式中,含氟聚合物具有60至70g/10min范围内的熔体流动指数.熔体流动速率可使用ASTM D1238、ISO 1133测量。
含氟聚合物或含氟聚合物合金可具有1.5-2.1g/cm3范围内的密度。
其它聚合物类型当然具有适合于那些材料的不同熔体流动速率和密度。例如,PEEK可具有1.1-1.5g/cm3的密度。聚酰胺的密度可以在0.9-1.5g/cm3的范围内。
碳纤维
碳纤维可具有3000至12000的丝束尺寸(tow size)。
合适的碳纤维细丝以商标Toray T700或Mitsubishi Grafil 34或HexTow AS4或Tenax HTS 40出售。
热塑性复合材料
热塑性复合材料包括混杂的聚合物细丝和碳纤维细丝。优选地,聚合物细丝可以是含氟聚合物细丝。聚合物细丝可以占复合材料中的聚合物细丝和碳纤维细丝的总重量的30至95wt%,优选为40至65wt%。在一个实施方式中,聚合物细丝占聚合物细丝和碳纤维细丝的总重量的45至60wt%,优选为50至55wt%。
混杂细丝可以通过用压缩气体(多种气体)(例如压缩空气)在细丝水平下搅拌纤维来形成。这可能导致形成紧密混合或混杂纤维的单头粗纱。或者,可以使用布置为混合纤维的一系列梳子来进行混杂。
混杂后,纤维可形成纱线。纱线可以被压缩或挤压(挤出,extruded)(或拉挤)以形成热塑性复合材料的带。带可以缠绕在管体周围以形成管状层。然后,可以加热管状层以产生柔性管层,其可以用作例如柔性管中的压力保护层。
在一个实施方式中,生产具有不同浓度的碳纤维的区域的柔性管层。如果希望改变管的机械性能,例如沿其长度或半径,这可能是有用的。例如,管可以具有一个或多个其中不存在碳纤维的区域。或者,管可以具有一个或多个区域,其中碳纤维浓度高于管的其它区域。
在一个实施方式中,生产具有不同浓度的碳纤维的区域的带。例如,可以通过将具有第一碳纤维浓度的第一纱线区域布置为与具有第二碳纤维浓度的第二纱线区域相邻,并压缩或挤压或拉挤纱线以形成带来生产这种带,由此带具有第一区域和第二区域,第一区域具有第一碳纤维浓度,且第二区域具有第二碳纤维浓度。这种带可以缠绕在管体周围以产生管状层。当加热这种管状层时,聚合物可软化或熔化以产生柔性管层。
在一个实施方式中,纱线的第一区域或第二区域可以不含碳纤维。因此,所得到的带和最终的柔性管层可包含一个或多个没有碳纤维的区域。
在一个实施方式中,当仅部分固结时,包含纤维纱线的带可以缠绕在管体周围,随后在布置在管体上之后,根据需要使用加热和施加的压力固结该层。
在一个实施方式中,在进行任何固结之前,可以将包含纤维纱线的带缠绕在管体周围;根据需要使用热和压力将复合材料的所有固结应用于布置在管体上的混杂纤维。
使用本发明的热塑性复合材料形成的柔性管层可以布置为与管状聚合物层相邻(例如,与其接触)。在一个实施方式中,管状聚合物层存在于使用本发明的热塑性复合材料形成的柔性管层的内侧。管状聚合物层可以是挤压的热塑性阻挡层。热塑性阻挡层可包括例如,含氟聚合物或聚酰胺。用于热塑性阻挡层的含氟聚合物的实例是聚偏二氟乙烯。合适的聚酰胺的实例是11热塑性阻挡层可以用作管体,围绕该管体缠绕由本发明的热塑性复合材料形成的带。
另外地或可替换地,管状聚合物层可包括一种或多种聚合物类型或合金的多个子层,条件是应用热塑性复合材料层的外子层与复合材料层的热塑性聚合物相容或相同。
另外地或可替换地,管状聚合物层可以是与复合材料层的热塑性材料不相容的材料,并且在两者之间需要接头层。该接头层可以包括不同类型的聚合物,例如环氧树脂材料,或者其自身可以包括复合材料,其中具有填料颗粒的基质材料,如WO 2015/118356中所述。
另外地或可替换地,管状聚合物层可以布置在使用本发明的热塑性复合材料形成的柔性管层的外侧。例如,管状聚合物层可以挤压到使用本发明的热塑性复合材料形成的柔性管层的外侧上作为抗磨层。管状聚合物层可以是热塑性层。该层可以由聚酰胺形成,例如,11
拉伸强度层(tensile strength layer)可以缠绕在抗磨层上。合适的拉伸强度层可以由金属线或复合材料形成,例如,根据本发明的复合材料,或者在热固性聚合物基质中包含碳纤维的复合材料。
热塑性复合材料的气泡空隙含量可小于5vol%(体积百分数),且优选小于2vol%。这可以使用标准密度测量并将其与热重分析测试相结合来确定。另一种方法是在复合材料的一系列横截面上使用光学显微镜估算纤维的体积分数。ASTM D2734是基于密度测量的另一种替代方法。
热塑性复合材料可含有添加剂。合适的添加剂可包括马来酸酐,其可以在聚合物细丝的制造过程中的各个阶段加入到聚合物基质中。可替换地,可以添加诸如改善材料的抗紫外线性或耐磨性或摩擦特性的那些添加剂,例如炭黑、纳米粘土、氧化钛等。这些添加剂可以在形成带之前或者在加热带以形成管状层之前添加到热塑性复合材料中。或者,这些添加剂可以掺入聚合物细丝中,并且可以在聚合物细丝与碳纤维细丝混合之前存在于聚合物细丝中。
附图说明
下面参考附图进一步描述本发明的实施方式,其中:
图1示出了柔性管体;并且
图2示出了立管、流线和跳线。
在附图中,相同的附图标号表示相同的部件。
具体实施方式
在整个说明书中,将参考柔性管。应当理解,柔性管是管体的一部分和一个或多个端部配件的组件,在其中的每一个中管体的相应端部终止。图1示出了根据本发明实施方式,管体100如何由形成承压导管的层状材料的组合形成。尽管在图1中示出了许多特定层,但是应该理解,本发明可广泛应用于包括由各种可能材料制成的两层或更多层的同轴管体结构。例如,管体可以由聚合物层、金属层、复合材料层或不同材料的组合形成。还应注意,层厚度仅出于说明性目的而示出。
如图1所示,管体包括任选的最内胎体层(innermost carcass layer)101。胎体提供互锁结构,其可用作最内层,以防止由于管减压、外部压力和拉伸保护压力以及机械压碎载荷而导致的内部压力护套102的完全或部分塌陷。胎体层通常是金属层,例如由不锈钢形成。胎体层也可以由复合材料、聚合物或其它材料或材料的组合形成。应当理解,本发明的某些实施方式适用于“滑膛(smooth bore)”操作(即,没有胎体层)以及这种“粗镗(roughbore)”应用(具有胎体层)。
内部压力护套102用作流体保持层并且包括确保内部流体完整性的聚合物层。应该理解,该层自身可以包括许多子层。应当理解,当使用任选的胎体层时,内部压力护套通常被本领域技术人员称为阻挡层。在没有这种胎体的操作中(所谓的滑膛操作),内部压力护套可以被称为衬里。
压力保护层103是结构层,其增加柔性管对内部和外部压力以及机械压碎载荷的抵抗力。该层还在结构上支撑内部压力护套。在优选的实施方式中,压力保护层103由本文所述的热塑性复合材料形成。
柔性管体还包括任选的第一拉伸保护层105和任选的第二拉伸保护层106。每个拉伸保护层用于承受拉伸载荷和内部压力。拉伸保护层通常由多个(例如,金属)线材(以赋予层的强度)形成,所述线材位于内层上方并且沿着管的长度以通常约10°至55°的捻角螺旋缠绕。拉伸保护层通常成对地反向缠绕。拉伸保护层通常是金属层,例如由碳钢形成。拉伸保护层也可以由复合材料、聚合物或其它材料或材料的组合形成。
所示的柔性管体还包括任选的带层104,其有助于包含底层并且在一定程度上防止相邻层之间的磨损,或者实际上作为在可能在使用期间经受磨损的区域中的柔性管的外表面。带层可以是聚合物或复合材料或材料的组合。带层104可以由本文所述的热塑性复合材料形成。
柔性管体通常还包括任选的绝缘层107和外护套(out sheath)108,外护套108包括用于保护管免受海水和其它外部环境渗透、腐蚀、磨损和机械损坏的聚合物层。
每个柔性管包括至少一个部分,有时称为管体100的区段或部分,以及位于柔性管的至少一端的端部配件。端部配件提供机械装置,其形成柔性管体和连接件之间的过渡。例如,如图1所示的不同管层终止于端部配件中,以这种方式使得在柔性管和连接件之间传递载荷。
图2示出了适于将生产流体(如油和/或气和/或水从海底位置201输送到浮动设施的立管组件200。例如,在图2中,海底位置201包括海底流线。柔性流线205包括柔性管,其全部或部分地搁置在海床204上或埋在海床下面并用于静态应用中。浮动设施可以由平台和/或浮标提供,或者如图2所示,由船200提供。立管组件200设置为柔性立管,即将船连接到海底设施的柔性管203。柔性管可以是具有连接端配件的柔性管体的区段。
应当理解,存在不同类型的立管(riser),如本领域技术人员所熟知的。本发明的实施方式可以与任何类型的立管一起使用,例如自由悬挂的(自由的,悬链式立管),约束到一定程度的立管(浮标、链条),完全约束的立管或封闭在管(I或J管)中。
图2还示出了柔性管的部分如何可以用作流动线205或跳线206。
对于本领域技术人员来说显而易见的是,关于上述任何实施方式描述的特征可以在不同实施方式之间互换地应用。上述实施方式是说明本发明的各种特征的实例。
在本说明书的整个说明书和权利要求书中,词语“包括(comprise)”和“包含(contain)”及其变体意味着“包括但不限于”,并且它们不旨在(并且不)排除其它部分、添加剂、组分、整数或步骤。在本说明书的整个说明书和权利要求书中,除非上下文另有要求,否则单数形式包含复数形式。特别地,在使用不定冠词的情况下,除非上下文另有要求,否则说明书应被理解为考虑复数以及奇点。
结合本发明的特定方面、实施方式或实施例描述的特征、整体、特性、化合物、化学部分或基团应理解为适用于本文描述的任何其它方面、实施方式或实施例,除非与其不相容。本说明书中公开的所有特征(包括任何所附权利要求、摘要和附图)和/或如此公开的任何方法或过程的所有步骤可以任何组合进行组合,除了至少一些这样的特征和/或步骤是互斥的的组合。本发明不限于任何前述实施方式的细节。本发明扩展到本说明书中公开的特征(包括任何所附权利要求、摘要和附图)中的任何新颖的或任何新颖组合,或如此公开的任何方法或过程的步骤的任何新颖的或任何新颖的组合。
读者的注意力针对与关于本申请的本说明书同时或在其之前提交的并且与本说明书一起公开供公众查阅的所有论文和文件,并且所有这些论文和文件的内容通过引用结合于此。
Claims (38)
1.一种制造柔性管层的方法,所述方法包括:
将聚合物细丝和碳纤维细丝混杂以形成紧密混合物,
形成混杂细丝的纱线,
将所述纱线形成带,并且
将所述带施加到管体上以形成柔性管层。
2.根据权利要求1所述的方法,其中所述聚合物细丝包含含氟聚合物,并且其中所述聚合物具有50至80g/10min范围内的熔体流动指数(230℃/2.16kg)。
3.根据权利要求2所述的方法,其中所述含氟聚合物具有60至70g/10min范围内的熔体流动指数(230℃/2.16kg)。
4.根据前述权利要求中任一项所述的方法,其中碳细丝具有3000至12000的丝束尺寸。
5.根据权利要求2至4中任一项所述的方法,其中所述含氟聚合物选自全氟烷氧基烷烃(PFA)、聚(乙烯-共-四氟乙烯)(ETFE)、聚四氟乙烯(PTFE)、氟化乙烯丙烯(FEP)和聚偏二氟乙烯(PVDF)中的至少一种。
6.根据权利要求1所述的方法,其中所述聚合物是聚醚醚酮(PEEK)或聚酰胺(PA-11或PA-12)。
7.根据前述权利要求中任一项所述的复合材料,其中所述聚合物以所述聚合物和碳纤维的总重量的30至70wt%的量存在。
8.根据前述权利要求中任一项所述的方法,其中使用压缩气体或一系列梳子将所述细丝混杂以形成细丝的所述紧密混合物。
9.根据前述权利要求中任一项所述的方法,其中将所述纱线压缩或挤压以形成带。
10.根据前述权利要求中任一项所述的方法,还包括:
将具有第一碳纤维浓度的第一纱线区域布置为与具有第二碳纤维浓度的第二纱线区域相邻,和
压缩或挤压所述第一纱线区域和所述第二纱线区域以形成带,从而所述带具有第一区域和第二区域,所述第一区域具有第一碳纤维浓度,所述第二区域具有第二碳纤维浓度。
11.根据权利要求1至9中任一项所述的方法,还包括:
将含有碳纤维的第一纱线区域布置为与基本上由聚合物组成的第二纱线区域相邻,和
压缩或挤压所述纱线以形成带,从而所述带具有包含碳纤维的第一区域和基本上由聚合物组成的第二区域。
12.根据前述权利要求中任一项所述的方法,包括围绕所述管体缠绕所述带,并加热缠绕的带,使得所述聚合物细丝围绕碳细丝熔化以形成聚合物基质。
13.根据前述权利要求中任一项所述的方法,其中所述管体包括挤压的管状聚合物层。
14.一种热塑性复合材料,包含含氟聚合物细丝和碳纤维细丝,其中所述含氟聚合物细丝和所述碳纤维细丝混杂以形成紧密混合物,并且其中所述含氟聚合物具有50至80g/10min范围内的熔体流动指数(230℃/2.16kg)。
15.根据权利要求14所述的复合材料,其中所述含氟聚合物具有60至70g/10min范围内的熔体流动指数(230℃/2.16kg)。
16.根据权利要求14或15所述的复合材料,其中碳细丝具有3000至12000的丝束尺寸。
17.根据权利要求14至16中任一项所述的复合材料,其中所述含氟聚合物选自全氟烷氧基烷烃(PFA)、聚(乙烯-共-四氟乙烯)(ETFE)、聚四氟乙烯(PTFE)、氟化乙烯丙烯(FEP)和聚偏二氟乙烯(PVDF)中的至少一种。
18.根据权利要求14至17中任一项所述的复合材料,其中所述含氟聚合物是聚偏二氟乙烯(PVDF)。
19.根据权利要求14至18中任一项所述的复合材料,其中所述含氟聚合物以所述含氟聚合物和碳纤维的总重量的30至70wt%的量存在。
20.根据权利要求14至19中任一项所述的复合材料,所述复合材料为纱线形式的复合材料。
21.根据权利要求20所述的复合材料,所述复合材料为由所述复合材料的多根纱线形成的带。
22.根据权利要求21所述的复合材料,其中所述带包括由具有第一碳纤维浓度的所述复合材料的多根纱线形成的第一区域,和由具有第二碳纤维浓度的所述复合材料的多根纱线形成的第二区域,其中第一浓度和第二浓度不同。
23.根据权利要求21或22所述的复合材料,其中所述带包括由所述复合材料的多根纱线形成的区域,以及由基本上由所述含氟聚合物细丝组成的多根纱线形成的不同区域。
24.一种柔性管,包括由权利要求14至23中任一项所述的复合材料的带形成的至少一个管层。
25.根据权利要求24所述的管,其中由所述复合材料的带形成的至少一个管层是压力保护层,所述压力保护层位于邻近管状聚合物层。
26.根据权利要求25所述的管,其中所述管状聚合物层形成在所述压力保护层的内侧作为流体阻挡层。
27.根据权利要求24至26中任一项所述的管,其中通过围绕管体缠绕所述带以形成管层,并加热所述带使得所述含氟聚合物细丝围绕碳细丝熔化以形成含氟聚合物基质可获得所述管层。
28.一种制备权利要求14至27中任一项所述的热塑性复合材料的方法,包括将含氟聚合物细丝和碳纤维细丝混杂以形成紧密混合物。
29.根据权利要求28所述的方法,其中使用压缩气体或一系列梳子将细丝混杂以形成细丝的所述紧密混合物。
30.根据权利要求28或29所述的方法,包括形成混杂细丝的纱线,并且压缩或挤压所述纱线以形成所述热塑性复合材料的带。
31.根据权利要求30所述的方法,包括:
将具有第一碳纤维浓度的第一纱线区域布置为与具有第二碳纤维浓度的第二纱线区域相邻,和
压缩或挤压所述纱线以形成带,从而所述带具有第一区域和第二区域,所述第一区域具有第一碳纤维浓度,所述第二区域具有第二碳纤维浓度。
32.根据权利要求30所述的方法,包括:
将含有碳纤维的第一纱线区域布置为与基本上由含氟聚合物组成的第二纱线区域相邻,和
压缩或挤压所述纱线以形成带,从而所述带具有包含碳纤维的第一区域和基本上由含氟聚合物组成的第二区域。
33.根据权利要求30至32中任一项所述的方法,包括围绕管体缠绕所述带,并加热缠绕的所述带,使得所述含氟聚合物细丝围绕碳细丝熔化以形成含氟聚合物基质。
34.根据权利要求33所述的方法,其中所述管体包括挤压的管状聚合物层。
35.一种柔性管,包括管层,所述管层包括:
由包含聚合物和碳纤维的热塑性复合材料形成的第一区域,其中碳纤维以第一浓度存在;以及
由(i)包含聚合物和碳纤维的热塑性复合材料,其中碳纤维以第二浓度存在,或(ii)基本上由聚合物组成的聚合物组合物形成的第二区域。
36.基本上如以上描述的并参考附图的热塑性复合材料。
37.一种制造热塑性复合材料的方法,基本上如以上描述的并参考附图。
38.基本上如以上描述的并参考附图的柔性管体。
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2017
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- 2017-09-28 WO PCT/GB2017/052918 patent/WO2018060718A2/en active Application Filing
- 2017-09-28 DK DK17780174.3T patent/DK3519187T3/da active
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- 2017-09-28 CN CN202410485775.6A patent/CN118361601A/zh active Pending
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2022
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US11958259B2 (en) | 2024-04-16 |
ES2910175T3 (es) | 2022-05-11 |
BR112019006372B1 (pt) | 2022-11-29 |
BR122020019417B1 (pt) | 2023-01-24 |
BR112019006372A2 (pt) | 2019-08-20 |
CN118361601A (zh) | 2024-07-19 |
EP3519187A2 (en) | 2019-08-07 |
DK3519187T3 (da) | 2022-04-04 |
GB201616706D0 (en) | 2016-11-16 |
EP3519187B1 (en) | 2022-02-23 |
WO2018060718A3 (en) | 2018-05-03 |
WO2018060718A2 (en) | 2018-04-05 |
MY193621A (en) | 2022-10-20 |
US20200031071A1 (en) | 2020-01-30 |
US11529781B2 (en) | 2022-12-20 |
EP3967493A1 (en) | 2022-03-16 |
US20230030995A1 (en) | 2023-02-02 |
BR122020019421B1 (pt) | 2023-01-24 |
CN118361602A (zh) | 2024-07-19 |
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