CN118188892A - A non-metallic non-bonded fiber-reinforced composite flexible pipe and a manufacturing method thereof - Google Patents
A non-metallic non-bonded fiber-reinforced composite flexible pipe and a manufacturing method thereof Download PDFInfo
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- CN118188892A CN118188892A CN202410614315.9A CN202410614315A CN118188892A CN 118188892 A CN118188892 A CN 118188892A CN 202410614315 A CN202410614315 A CN 202410614315A CN 118188892 A CN118188892 A CN 118188892A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D23/00—Producing tubular articles
- B29D23/001—Pipes; Pipe joints
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L11/00—Hoses, i.e. flexible pipes
- F16L11/02—Hoses, i.e. flexible pipes made of fibres or threads, e.g. of textile
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L11/00—Hoses, i.e. flexible pipes
- F16L11/04—Hoses, i.e. flexible pipes made of rubber or flexible plastics
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L57/00—Protection of pipes or objects of similar shape against external or internal damage or wear
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L57/00—Protection of pipes or objects of similar shape against external or internal damage or wear
- F16L57/06—Protection of pipes or objects of similar shape against external or internal damage or wear against wear
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L58/00—Protection of pipes or pipe fittings against corrosion or incrustation
- F16L58/02—Protection of pipes or pipe fittings against corrosion or incrustation by means of internal or external coatings
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Rigid Pipes And Flexible Pipes (AREA)
- Laminated Bodies (AREA)
Abstract
本发明提供了一种非金属非粘结型纤维增强复合柔性管及其制造方法；该非金属非粘结型纤维增强复合柔性管由内至外依次设有：内衬层、第一抗内压增强层、第一抗磨层、第二抗内压增强层、第二抗磨层、抗外压增强层、防渗层、第一抗拉增强层、第三抗磨层、第二抗拉增强层和外护层，并在第一抗内压增强层内设有凯夫拉混合光纤缆，所有结构层均为非金属材料，且各个相邻层之间均为非粘结接触。本发明提供的非金属非粘结型纤维增强复合柔性管，不仅轻量化、柔性好、耐腐蚀、耐渗透、加工制作方便，而且具有较好的抗内压和抗外压能力，同时可实现柔性管工作状态实时监测，能够适应恶劣的海洋环境以及复杂的荷载工况，可用作海底油气管道以及动态海洋立管。
The present invention provides a non-metallic non-bonded fiber-reinforced composite flexible pipe and a manufacturing method thereof; the non-metallic non-bonded fiber-reinforced composite flexible pipe is provided with: an inner lining layer, a first internal pressure resistance reinforcement layer, a first anti-wear layer, a second internal pressure resistance reinforcement layer, a second anti-wear layer, an external pressure resistance reinforcement layer, an anti-seepage layer, a first tensile reinforcement layer, a third anti-wear layer, a second tensile reinforcement layer and an outer sheath from the inside to the outside, and a Kevlar hybrid optical fiber cable is provided in the first internal pressure resistance reinforcement layer, all structural layers are non-metallic materials, and each adjacent layer is in non-bonded contact. The non-metallic non-bonded fiber-reinforced composite flexible pipe provided by the present invention is not only lightweight, flexible, corrosion-resistant, permeation-resistant, and easy to process and manufacture, but also has good internal and external pressure resistance capabilities, and can realize real-time monitoring of the working status of the flexible pipe, can adapt to harsh marine environments and complex load conditions, and can be used as submarine oil and gas pipelines and dynamic marine risers.
Description
Technical Field
The invention relates to a non-metal non-bonding fiber reinforced composite flexible pipe and a manufacturing method thereof, in particular to a multifunctional non-metal non-bonding fiber reinforced composite flexible pipe for a submarine oil gas pipeline, a dynamic marine riser connected with a floating production facility and the like and a manufacturing process thereof.
Background
Submarine pipelines play an important role in ocean oil and gas energy development engineering and are known as 'lifelines' of oil and gas production systems. The method has the advantages of low operation cost, good continuity, high safety, large transportation capacity and the like, and is widely used in the marine oil and gas industry. However, submarine pipelines are subjected to severe tests during service, and the combined actions of high temperature inside the pipelines, high pressure outside the pipelines, internal and external corrosion and the like can easily cause material performance to be reduced, so that structural failure is caused. In contrast, the service conditions of the dynamic marine riser are more severe, and besides the factors, the dynamic marine riser is subjected to combined actions of high hydrostatic pressure, axial tension, bending, ocean currents and the like, so that the service safety of the deep-sea oil and gas pipeline faces great challenges under the influence of complex conveying media and severe marine environments.
The flexible pipe is a light high-strength pipeline compounded by metal or nonmetal materials and polymers through an advanced processing and forming process, and the mechanical properties and interlayer interactions of the materials of each layer are fully exerted, so that the pipeline has excellent compounding performance. The flexible pipe is easy to lay, corrosion-resistant and recyclable, can bear larger bending deformation, can work well together with the upper floating platform, and becomes the best or the only choice in the sea area under certain severe sea conditions. The flexible pipe may be classified into a metal flexible pipe and a non-metal flexible pipe according to the type of material, and may be classified into a bonded flexible pipe and a non-bonded flexible pipe according to the processing process.
The metal bonding type flexible pipe has the characteristics of high axial strength, good compression resistance, convenient transportation and installation and the like, for example, the steel-plastic composite pipe disclosed in CN116045088A comprises an inner layer pipe, a steel belt layer, an outer layer pipe, an adhesive layer and a bonding layer. The inner layer is random copolymer polypropylene added with ceramic, the steel belt layer is aluminized steel belt, the outer layer is heat-resistant polyethylene with polytetrafluoroethylene coating coated on the outer surface, and the adhesive used by the adhesive layer is anaerobic adhesive with bonding, sealing and plugging functions. The metal bonding type composite flexible pipe has relatively poor fatigue resistance and corrosion resistance, is not suitable for being applied to deep sea environment and severe sea conditions, and is commonly used for short-distance oil and gas resource transportation.
The metal non-bonding type flexible pipe has the characteristics of good flexibility, high pressure resistance, good flexibility and the like, is a most favored structural form in the field of international oil and gas resource development at present, and comprises a framework layer, an inner liner layer, a compression armor layer, a middle protection sleeve layer, a cable hole layer, a first tensile armor layer, a second tensile armor layer and an outer protection sleeve layer, wherein the metal non-bonding type flexible pipe is disclosed in CN 208735050U. A first wear-resistant layer is arranged between the cable hole layer and the first tensile armour layer, and a second wear-resistant layer is arranged between the first tensile armour layer and the second tensile armour layer; the cable hole layer is spirally wound on the middle protective sleeve layer; the framework layer is made of stainless steel, nickel alloy steel or molybdenum alloy steel; the compression-resistant armor layer is made of carbon steel; the lining layer is made of high-density polyethylene, crosslinked polyethylene, nylon or polyvinylidene fluoride; the material of the outer protective sleeve layer is high-density polyethylene. When the metal armor layer is applied in the deep sea field, the armor layer is usually required to be large in wall thickness, so that the top tension is large, and in addition, the metal armor layer and the framework layer still have the risk of being corroded by seawater, so that the long-term service performance is influenced.
The nonmetal bonding type flexible pipe has the characteristics of light weight, good air tightness, corrosion resistance and the like, for example, a thermoplastic composite material long conveying pipe disclosed by CN107081922A is sequentially provided with an inner liner layer, a fiber reinforced layer and an outer protective layer from inside to outside. The inner liner layer and the outer protective layer are both thermoplastic composite materials; the fiber reinforced layer is formed by 3D printing and compounding of high-strength fibers and thermoplastic polymers. But the flexibility and fatigue resistance are relatively poor due to their cohesive structural configuration. In addition, when the composite structure works in deep water and ultra-deep water environment, the composite structure cannot meet the working requirements of high water pressure and high top tension, and the pipeline is easy to fail.
The non-metal non-bonding flexible pipe has the advantages of light weight, corrosion resistance, high flexibility and the like, but is still less concerned, CN117146071A discloses a non-metal non-bonding flexible mixed transportation pipe for deep sea mining, an inner liner layer, an anti-internal pressure reinforcing layer, a first wear-resisting layer, a first compensation reinforcing layer, a second wear-resisting layer, a second compensation reinforcing layer, a third wear-resisting layer, a framework layer, an isolation layer, a first tensile reinforcing layer, a fourth wear-resisting layer, a second tensile reinforcing layer and an outer coating are sequentially arranged from inside to outside, and a non-bonding connection mode is adopted between adjacent layers. The flexible pipe adopts fiber bundles and resin to manufacture a fiber reinforced layer by on-site processing, has complex operation and influences the processing progress. In addition, because the number of layers is more and the internal pressure resistance enhancement layer is of a cylindrical structure, the flexibility and the toughness of the internal pressure resistance enhancement layer are greatly limited, the working requirements of the dynamic vertical pipe cannot be met, and potential safety hazards are brought.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides the nonmetal non-bonding type fiber reinforced composite flexible pipe and the manufacturing method thereof, and the flexible pipe has the advantages of light weight, corrosion resistance, permeation resistance, good flexibility, convenient processing, good heat preservation, heat insulation and high pressure resistance, can realize the real-time monitoring of the working state of the flexible pipe, can adapt to the severe environment in the ocean, and has wide application prospect in the field of deep water and ultra-deep oil gas resource development.
In order to achieve the technical aim, the invention provides a nonmetallic non-bonding type fiber reinforced composite flexible pipe, which is provided with an inner liner layer, a first internal pressure resistant reinforcing layer, a first abrasion resistant layer, a second internal pressure resistant reinforcing layer, a second abrasion resistant layer, an external pressure resistant reinforcing layer, an impermeable layer, a first tensile reinforcing layer, a third abrasion resistant layer, a second tensile reinforcing layer and an outer protective layer from inside to outside, wherein a Kevlar hybrid optical fiber cable is arranged in the first internal pressure resistant reinforcing layer, all structural layer materials are nonmetallic, and adjacent layers are in non-bonding contact;
The inner liner layer, the impermeable layer and the outer protective layer are all thermoplastic polymers and are shaped by melt extrusion to form a cylindrical structure;
The first internal pressure resistant reinforcing layer, the second internal pressure resistant reinforcing layer, the external pressure resistant reinforcing layer, the first tensile reinforcing layer and the second tensile reinforcing layer are all continuous unidirectional fiber prepreg tapes, the cross section of each of the first internal pressure resistant reinforcing layer, the second internal pressure resistant reinforcing layer, the external pressure resistant reinforcing layer and the first tensile reinforcing layer is rectangular, the first tensile reinforcing layer and the second tensile reinforcing layer are made through spiral winding, and the first tensile reinforcing layer, the second tensile reinforcing layer and the second tensile reinforcing layer are formed through heating, cooling and solidifying.
Further, the lining layer is made of high-density polyethylene, polyvinylidene fluoride, crosslinked polyethylene or nylon; the thickness of the lining layer is 2-20mm.
Further, the fibers of the continuous unidirectional fiber prepreg tapes of the first internal pressure resistant reinforcing layer and the second internal pressure resistant reinforcing layer are aramid fibers, carbon fibers or glass fibers, and the resin matrix is epoxy resin or unsaturated polyester resin; the thickness of the unidirectional fiber prepreg tape is 1-10mm, the width is 10-40mm, and the winding angle is 45-75 degrees; the winding angles of the first internal pressure resistant reinforcing layer and the second internal pressure resistant reinforcing layer are the same, but the winding directions are opposite;
The fibers of the continuous unidirectional fiber prepreg tape of the external pressure resistant reinforcing layer are aramid fibers, carbon fibers or glass fibers, and the resin matrix is epoxy resin or unsaturated polyester resin; the thickness of the unidirectional fiber prepreg tape is 5-20mm, the width is 20-50mm, the winding angle is 70-85 degrees, and the stacking number is 1-5;
The fibers of the continuous unidirectional fiber prepreg tapes of the first tensile reinforcement layer and the second tensile reinforcement layer are aramid fibers, carbon fibers or glass fibers, and the resin matrix is epoxy resin or unsaturated polyester resin; the thickness of the unidirectional fiber prepreg tape is 1-10mm, the width is 10-40mm, and the winding angle is 20-40 degrees.
Further, the Kevlar hybrid optical fiber cable or the cable is arranged in the first internal pressure resistance reinforcing layer and is spirally wound together with the unidirectional fiber prepreg tape in parallel, so that the protection of the optical fiber or the cable is realized.
Further, the first abrasion-resistant layer, the second abrasion-resistant layer and the third abrasion-resistant layer are made of polyethylene, polyvinyl chloride or nylon materials, and are wound at 45-80 degrees, so that the last structural layer is completely wrapped.
Further, the material of the impermeable layer and the outer protective layer is high-density polyethylene, polyvinylidene fluoride, crosslinked polyethylene or nylon; wherein, the impermeable layer is formed by adopting thermoplastic polymer material to melt and extrude, and the thickness of the impermeable layer is 1-10mm; the outer sheath is formed by adopting a thermoplastic polymer material through melt extrusion, and the thickness of the outer sheath is 5-20mm.
In order to achieve the technical aim, the invention also provides a manufacturing method of the nonmetal non-bonding fiber reinforced composite flexible pipe, which comprises the following steps:
(1) The temperature and the pressure are regulated to enable the thermoplastic polymer to reach a molten state, then an extrusion process is utilized for molding, and a lining pipe with preset geometric dimensions is prepared through shaping and cooling and is used as an inner lining layer;
(2) Fixing a continuous unidirectional fiber prepreg strip and a Kevlar mixed fiber cable on a pre-tightening device, winding the fiber prepreg strip and the Kevlar mixed fiber cable on the surface of the inner liner layer at 45-75 degrees through a spiral die, performing high-temperature curing through a heating device, and finally cooling and shaping to form a first internal pressure resistance reinforcing layer;
(3) Mixing thermoplastic polymer raw materials, melting and extruding a banded film, cooling, stretching and drying the banded film, and winding the banded film on the surface of the first internal pressure resistance reinforcing layer at 45-80 degrees to form a first wear-resistant layer;
(4) Repeating the processing technology in the step (2), and winding a unidirectional fiber prepreg tape on the surface of the first wear-resistant layer at an angle of 45-75 degrees to form a second internal pressure-resistant reinforcing layer;
(5) Mixing thermoplastic polymer raw materials, melting and extruding a banded film, cooling, stretching and drying the banded film, and winding the banded film on the surface of the second internal pressure resistance reinforcing layer at 45-80 degrees to form a second wear-resistant layer;
(6) Repeating the processing technology in the step (2), and winding a unidirectional fiber prepreg tape on the surface of the second wear-resistant layer at an angle of 70-85 degrees to form an external pressure resistant reinforcing layer;
(7) Extruding thermoplastic polymer out of the external pressure resistant reinforcing layer, shaping and cooling to form an impermeable layer;
(8) Repeating the processing technology in the step (2), and winding a unidirectional fiber prepreg tape on the surface of the impermeable layer at an angle of 20-40 degrees to form a first tensile reinforcement layer;
(9) Mixing thermoplastic polymer raw materials, melting and extruding a banded film, cooling, stretching and drying, and winding the banded film on the surface of the first tensile enhancement layer at 45-80 degrees to form a third wear-resistant layer;
(10) Repeating the processing technology in the step (2), and winding a unidirectional fiber prepreg tape on the surface of the third wear-resistant layer at an angle of 20-40 degrees to form a second tensile reinforcement layer;
(11) Melt-extruding a thermoplastic polymer outside the second tensile reinforcement layer, and forming an outer protective layer through shaping and cooling; thus obtaining the nonmetal non-bonding fiber reinforced composite flexible pipe.
The beneficial effects of the invention are as follows:
(1) The combination of the multi-layer structure improves the bearing capacity:
According to the flexible pipe, eleven independent structural layers are integrated into a whole, all the structural layers are made of non-metal materials, and adjacent layers are in non-bonding contact, so that the fatigue resistance of the pipe body is effectively improved. The first internal pressure resistant reinforcing layer, the second internal pressure resistant reinforcing layer, the external pressure resistant reinforcing layer, the first tensile reinforcing layer and the second tensile reinforcing layer are main bearing structures and are all fiber composite materials. The external pressure resistant reinforcing layer is mainly used for resisting external high hydrostatic pressure, the tensile reinforcing layer is mainly used for resisting axial tension, and the internal pressure resistant reinforcing layer can simultaneously resist internal pressure and axial tension. Obviously, under the composite structure, the overall bearing performance of the flexible pipe is obviously improved, and the flexible pipe is applicable to complex load working conditions and severe marine environments.
(2) The spiral structure is specially designed, so that the flexibility of the pipe body is improved:
All bearing layers of the nonmetal non-bonding type flexible pipe are made of fiber composite materials, and are different from the nonmetal flexible pipe structure disclosed in the prior art, all fiber reinforcement layers of the nonmetal non-bonding type flexible pipe adopt a spiral winding structure instead of a cylindrical structure, gaps are reserved between fiber belts on the same layer, and strips cannot be mutually extruded when the pipe body is coiled for transportation or forced deformation, so that the pipe body has better flexibility and bending performance. Thus, the flexible pipe of the present invention is of great advantage as a dynamic marine riser.
(3) The fiber prepreg tape is beneficial to processing and manufacturing:
In the non-metal flexible pipe disclosed previously, the fiber reinforced layer is impregnated and solidified on site by adopting the combination of fiber bundles and resin, the processing method is complex in operation and low in manufacturing speed, and the uniformity of fiber and resin impregnation is difficult to control, so that the overall mechanical property of the fiber reinforced layer is affected. The first internal pressure resistant reinforcing layer, the second internal pressure resistant reinforcing layer, the external pressure resistant reinforcing layer, the first tensile reinforcing layer and the second tensile reinforcing layer are all continuous unidirectional fiber prepreg tapes, on-site impregnation and solidification are not needed, spiral winding construction can be directly carried out, the operation is convenient, the processing progress is faster, and the overall mechanical property of the fiber reinforcing layer is stable and guaranteed.
(4) Convenient real-time supervision, multiple functional usage:
The nonmetal non-adhesive flexible pipe can monitor the working state in real time in the service period, can be used for petroleum, natural gas or mineral resource transportation, is used as a submarine pipeline, a dynamic vertical pipe, an oil outlet pipe, a jumper pipe and the like, has the advantages of light weight, corrosion resistance, permeation resistance, good flexibility, high pressure resistance and the like, can realize the recovery of all or part after the service is finished, and saves the cost.
Drawings
FIG. 1 is a schematic view of the overall structure of a non-metallic non-bonded fiber reinforced composite flexible pipe of the present invention;
fig. 2 is a schematic view of a radial cross-sectional structure of a non-metallic non-bonded fiber reinforced composite flexible pipe of the present invention.
Reference numerals illustrate: an inner liner 1; a first internal pressure-resistant reinforcing layer 2; a first wear layer 3; a second internal pressure-resistant reinforcing layer 4; a second wear layer 5; an external pressure resistant reinforcing layer 6; a barrier layer 7; a first tensile reinforcement layer 8; a third wear layer 9; a second tensile reinforcement layer 10; and an outer sheath 11.
Detailed Description
Example embodiments of the present invention will be described in more detail below by referring to the accompanying drawings. While the drawings show example embodiments of the invention, it is to be understood that the invention may be embodied in various forms and should not be limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
The embodiment provides a nonmetal non-bonding fiber reinforced composite flexible pipe, wherein an inner liner is used for conveying a medium; the internal pressure resistance enhancement layer has the comprehensive properties of internal pressure resistance and tensile strength; the anti-seepage layer can serve as an anti-abrasion layer of the external pressure resistance reinforcing layer and the tensile strength reinforcing layer, and also can serve as an external protection layer to prevent seawater from further immersing when the external protection layer is damaged or fails; the spiral winding structure of the inner pressure resistance reinforcing layer, the outer pressure resistance reinforcing layer and the tensile reinforcing layer can fully ensure the bending performance of the flexible pipe; the inner pressure resistant reinforcing layer, the outer pressure resistant reinforcing layer and the tensile reinforcing layer are all continuous unidirectional fiber prepreg tapes, spirally wound by the pre-tightening device, and then heated, cooled, solidified and formed, so that the inner pressure, the outer pressure and axial tension can be effectively resisted. Therefore, the invention can fully exert the advantages, adapt to severe ocean environment and complex load working conditions and ensure the safety of oil and gas exploitation work.
As shown in fig. 1-2, the non-metal non-bonding fiber reinforced composite flexible pipe provided in this embodiment includes an inner liner layer 1, a first inner pressure resistant reinforcing layer 2, a first abrasion resistant layer 3, a second inner pressure resistant reinforcing layer 4, a second abrasion resistant layer 5, an outer pressure resistant reinforcing layer 6, an impermeable layer 7, a first tensile reinforcing layer 8, a third abrasion resistant layer 9, a second tensile reinforcing layer 10, and an outer protective layer 11, all of which are made of non-metal materials, and non-bonding contact is adopted between adjacent layers.
Wherein, the inner liner layer 1, the impermeable layer 7 and the outer protective layer 11 are all thermoplastic polymers, and are formed into a cylindrical structure through on-site melt extrusion. Preferably, the material of the inner liner 1 is a thermoplastic polymer, including but not limited to high density polyethylene, polyvinylidene fluoride, crosslinked polyethylene, or nylon; the inner diameter of the inner liner 1 is 2-20 inches and the thickness is 2-20mm.
Preferably, the first internal pressure resistant reinforcing layer 2, the second internal pressure resistant reinforcing layer 4, the external pressure resistant reinforcing layer 6, the first tensile reinforcing layer 8 and the second tensile reinforcing layer 10 are continuous unidirectional fiber prepreg tapes, the cross sections of which are rectangular, are spirally wound by a pre-tightening device, and are heated, cooled and solidified by a heating device to form the reinforced plastic.
Preferably, the fibers used in the first internal pressure resistant reinforcing layer 2 and the second internal pressure resistant reinforcing layer 4 are aramid fibers, carbon fibers or glass fibers, and the resin matrix used is epoxy resin or unsaturated polyester resin; the thickness of the fiber strip is 1-10mm, the width is 10-40mm, and the winding angle is 45-75 degrees; the first internal pressure resistant reinforcing layer 2 and the second internal pressure resistant reinforcing layer 4 are wound at the same angle but in opposite directions, whereby the torsion effect caused by the tension of the fiber strips can be offset from each other.
Preferably, the fiber used for the continuous unidirectional fiber prepreg tape of the external pressure resistant reinforcing layer 6 is aramid fiber, carbon fiber or glass fiber, and the resin matrix is epoxy resin or unsaturated polyester resin; the thickness of the fiber strips is 5-20mm, the width is 20-50mm, the winding angle of the fiber strips is 70-85 DEG, and the stacking number of the strips is 1-5; therefore, the external pressure resistant reinforcing layer 6 can bear high hydrostatic pressure, and is a guarantee for the safety of the pipe body in deep sea service.
Preferably, the fibers used for the continuous unidirectional fiber prepreg tapes of the first tensile reinforcement layer 8 and the second tensile reinforcement layer 10 are aramid fibers, carbon fibers or glass fibers, and the resin matrix is epoxy resin or unsaturated polyester resin; the thickness of the fiber strip is 1-10mm, the width is 10-40mm, and the winding angle of the fiber strip is 20-40 degrees; the first 8 and second 10 tensile reinforcement layers are wound at the same angle but in opposite directions, whereby the torsion effects of the strips in tension can be counteracted.
Preferably, the kevlar hybrid optical fiber cable or cable can be arranged in the first internal pressure resistant reinforcing layer 2 and is spirally wound together with the unidirectional fiber prepreg tape in parallel, so as to play a role in protecting the optical fiber or cable.
Preferably, the first abrasion-resistant layer 3, the second abrasion-resistant layer 5 and the third abrasion-resistant layer 9 are made of polyethylene, polyvinyl chloride or nylon materials, and the strips are wound at a winding angle of 45-80 degrees and completely wrap the previous layer. Therefore, abrasion among the fiber reinforced layers can be avoided, and the long-term bearing performance of the pipe body is ensured.
Preferably, the materials of the barrier layer 7 and the outer sheath 11 are thermoplastic polymers, including but not limited to high density polyethylene, polyvinylidene fluoride, crosslinked polyethylene, or nylon; the impermeable layer 7 is formed by extrusion of thermoplastic polymer, the thickness is 1-10mm, and the impermeable layer 7 has the functions of wear resistance and seawater isolation; the outer sheath 11 is formed by extrusion of thermoplastic polymer with a thickness of 5-20mm, and the outer sheath 11 mainly serves to isolate seawater.
The embodiment also provides a manufacturing method of the nonmetal non-bonding fiber reinforced composite flexible pipe, which comprises the following steps:
(1) A thermoplastic polymer is melt extruded at a proper temperature (180-300 DEG) and pressure (10-100 MPa), and is shaped and cooled to prepare a lining pipe with preset geometric dimensions, which is used as the lining layer 1;
(2) Fixing a continuous unidirectional fiber prepreg tape and a Kevlar mixed fiber cable on a pre-tightening device (such as a winding machine), adjusting the pre-tightening force by using a friction disc of the winding machine, winding the fiber prepreg tape and the Kevlar mixed fiber cable on the surface of the inner liner 1 at a winding angle of 45-75 degrees through a spiral die, performing high-temperature curing by a heating device (such as an electric heating oven), and finally cooling and shaping to form a first internal pressure resistant reinforcing layer 2;
(3) Mixing thermoplastic polymer raw materials, melting and extruding a banded film, cooling, stretching and drying, and winding the banded film on the surface of the first internal pressure resistance reinforcing layer 2 at a winding angle of 45-80 degrees to form a first abrasion-resistant layer 3;
(4) Repeating the processing technology in the step (2), and winding the unidirectional fiber prepreg tape on the surface of the first wear-resistant layer 3 at a winding angle of 45-75 degrees to form a second internal pressure resistance reinforcing layer 4;
(5) Repeating the processing technology in the step (3), mixing and melting thermoplastic polymer raw materials to extrude a strip-shaped film, cooling, stretching and drying the film, and winding the film on the surface of the second internal pressure resistance reinforcing layer 4 at a winding angle of 45-80 degrees to form a second abrasion-resistant layer 5;
(6) Repeating the processing technology in the step (2), and winding the unidirectional fiber prepreg tape on the surface of the second wear-resistant layer 5 at a winding angle of 70-85 degrees to form an external pressure resistant reinforcing layer 6;
(7) Extruding thermoplastic polymer out of the external pressure resistant reinforcing layer 6, shaping and cooling to form an impermeable layer 7;
(8) Repeating the processing technology in the step (2), and winding the unidirectional fiber prepreg tape on the surface of the impermeable layer 7 at a winding angle of 20-40 degrees to form a first tensile reinforcement layer 8;
(9) Repeating the processing technology in the step (3), mixing and melting thermoplastic polymer raw materials to extrude a strip-shaped film, cooling, stretching and drying the film, and winding the film on the surface of the first tensile enhancement layer 8 at a winding angle of 45-80 degrees to form a third wear-resistant layer 9;
(10) Repeating the processing technology in the step (2), and winding the unidirectional fiber prepreg tape on the surface of the third wear-resistant layer 9 at a winding angle of 20-40 degrees to form a second tensile reinforcement layer 10;
(11) Melt-extruding a thermoplastic polymer out of the second tensile reinforcement layer 10, shaping and cooling to form an outer protective layer 11; thus obtaining the nonmetal non-bonding fiber reinforced composite flexible pipe.
The foregoing description is only of the preferred embodiments of the present invention and should not be taken as limiting the scope of the invention, and all equivalent structures or equivalent flow modifications made by the present invention and the accompanying drawings, or direct or indirect application in other relevant technical fields, should be included in the scope of the present invention.
Claims (7)
1. The non-metal non-bonding fiber reinforced composite flexible pipe is characterized in that an inner liner layer, a first internal pressure resistant reinforcing layer, a first abrasion resistant layer, a second internal pressure resistant reinforcing layer, a second abrasion resistant layer, an external pressure resistant reinforcing layer, an impermeable layer, a first tensile reinforcing layer, a third abrasion resistant layer, a second tensile reinforcing layer and an outer protective layer are sequentially arranged from inside to outside, a Kevlar hybrid fiber cable is arranged in the first internal pressure resistant reinforcing layer, all structural layer materials are non-metal, and adjacent layers are in non-bonding contact;
The inner liner layer, the impermeable layer and the outer protective layer are all thermoplastic polymers and are shaped by melt extrusion to form a cylindrical structure;
The first internal pressure resistant reinforcing layer, the second internal pressure resistant reinforcing layer, the external pressure resistant reinforcing layer, the first tensile reinforcing layer and the second tensile reinforcing layer are all continuous unidirectional fiber prepreg tapes, the cross section of each of the first internal pressure resistant reinforcing layer, the second internal pressure resistant reinforcing layer, the external pressure resistant reinforcing layer and the first tensile reinforcing layer is rectangular, the first tensile reinforcing layer and the second tensile reinforcing layer are made through spiral winding, and the first tensile reinforcing layer, the second tensile reinforcing layer and the second tensile reinforcing layer are formed through heating, cooling and solidifying.
2. The non-metallic non-bonded fiber reinforced composite flexible pipe of claim 1, wherein the material of the inner liner is high density polyethylene, polyvinylidene fluoride, crosslinked polyethylene, or nylon; the thickness of the lining layer is 2-20mm.
3. The non-metallic non-bonded fiber reinforced composite flexible pipe of claim 1, wherein the fibers of the continuous unidirectional fiber prepreg tapes of the first and second internal pressure resistant reinforcing layers are aramid fibers, carbon fibers, or glass fibers, and the resin matrix is an epoxy resin or an unsaturated polyester resin; the thickness of the unidirectional fiber prepreg tape is 1-10mm, the width is 10-40mm, and the winding angle is 45-75 degrees; the winding angles of the first internal pressure resistant reinforcing layer and the second internal pressure resistant reinforcing layer are the same, but the winding directions are opposite;
The fibers of the continuous unidirectional fiber prepreg tape of the external pressure resistant reinforcing layer are aramid fibers, carbon fibers or glass fibers, and the resin matrix is epoxy resin or unsaturated polyester resin; the thickness of the unidirectional fiber prepreg tape is 5-20mm, the width is 20-50mm, the winding angle is 70-85 degrees, and the stacking number is 1-5;
The fibers of the continuous unidirectional fiber prepreg tapes of the first tensile reinforcement layer and the second tensile reinforcement layer are aramid fibers, carbon fibers or glass fibers, and the resin matrix is epoxy resin or unsaturated polyester resin; the thickness of the unidirectional fiber prepreg tape is 1-10mm, the width is 10-40mm, and the winding angle is 20-40 degrees.
4. The non-metallic non-bonded fiber reinforced composite flexible pipe of claim 1, wherein the protection of the optical fiber or cable is achieved by arranging a kevlar hybrid optical fiber cable or cable within the first internal pressure resistant reinforcement layer in parallel co-spiral winding with unidirectional fiber prepreg tape.
5. The non-metallic non-bonded fiber reinforced composite flexible pipe of claim 1, wherein the first, second and third abrasion resistant layers are each made of polyethylene, polyvinyl chloride or nylon material and are wrapped at 45 ° -80 ° to completely encapsulate the last structural layer.
6. The non-metallic non-bonded fiber reinforced composite flexible pipe of claim 1, wherein the barrier layer and outer jacket are made of high density polyethylene, polyvinylidene fluoride, crosslinked polyethylene, or nylon; wherein, the impermeable layer is formed by adopting thermoplastic polymer material to melt and extrude, and the thickness of the impermeable layer is 1-10mm; the outer sheath is formed by adopting a thermoplastic polymer material through melt extrusion, and the thickness of the outer sheath is 5-20mm.
7. A method for manufacturing a nonmetallic non-bonded fiber reinforced composite flexible pipe, comprising the steps of:
(1) The temperature and the pressure are regulated to enable the thermoplastic polymer to reach a molten state, then an extrusion process is utilized for molding, and a lining pipe with preset geometric dimensions is prepared through shaping and cooling and is used as an inner lining layer;
(2) Fixing a continuous unidirectional fiber prepreg strip and a Kevlar mixed fiber cable on a pre-tightening device, winding the fiber prepreg strip and the Kevlar mixed fiber cable on the surface of the inner liner layer at 45-75 degrees through a spiral die, performing high-temperature curing through a heating device, and finally cooling and shaping to form a first internal pressure resistance reinforcing layer;
(3) Mixing thermoplastic polymer raw materials, melting and extruding a banded film, cooling, stretching and drying the banded film, and winding the banded film on the surface of the first internal pressure resistance reinforcing layer at 45-80 degrees to form a first wear-resistant layer;
(4) Repeating the processing technology in the step (2), and winding a unidirectional fiber prepreg tape on the surface of the first wear-resistant layer at an angle of 45-75 degrees to form a second internal pressure-resistant reinforcing layer;
(5) Mixing thermoplastic polymer raw materials, melting and extruding a banded film, cooling, stretching and drying the banded film, and winding the banded film on the surface of the second internal pressure resistance reinforcing layer at 45-80 degrees to form a second wear-resistant layer;
(6) Repeating the processing technology in the step (2), and winding a unidirectional fiber prepreg tape on the surface of the second wear-resistant layer at an angle of 70-85 degrees to form an external pressure resistant reinforcing layer;
(7) Extruding thermoplastic polymer out of the external pressure resistant reinforcing layer, shaping and cooling to form an impermeable layer;
(8) Repeating the processing technology in the step (2), and winding a unidirectional fiber prepreg tape on the surface of the impermeable layer at an angle of 20-40 degrees to form a first tensile reinforcement layer;
(9) Mixing thermoplastic polymer raw materials, melting and extruding a banded film, cooling, stretching and drying, and winding the banded film on the surface of the first tensile enhancement layer at 45-80 degrees to form a third wear-resistant layer;
(10) Repeating the processing technology in the step (2), and winding a unidirectional fiber prepreg tape on the surface of the third wear-resistant layer at an angle of 20-40 degrees to form a second tensile reinforcement layer;
(11) Melt-extruding a thermoplastic polymer outside the second tensile reinforcement layer, and forming an outer protective layer through shaping and cooling; thus obtaining the nonmetal non-bonding fiber reinforced composite flexible pipe.
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