RU2151059C1 - Method and device for manufacture of elastically flexible band spiral of composite materials (modifications) - Google Patents

Abstract

FIELD: applicable in repair of mainlines. SUBSTANCE: the method provides for penetration of polymeric binder at speed of material towards the mandrel within 0.006 to 0.03 m/s and tension in glass cloth canvases within 250 to 700 kgf at temperatures of the heating and prepressing rolls with an after-hardening of binder by blank heat treatment. The device has platforms, carrying the tempering mechanisms with bobbin carriers inclined towards the mandrel. EFFECT: enhanced quality of manufacture of band spiral, etc strength. 10 cl, 32 dwg, 3 tbl

Description

 The invention relates to a method for manufacturing an elastic flexible tape spiral from composite materials and to a device for its manufacture, used, in particular, in the repair of trunk pipelines having wall defects in the form of cracks and damage from the external surface from corrosion, in the form of bonded brace belts bonded by turns and piping with adhesive composition.

 Elastic flexible tape spirals made of composite materials are subject to increased requirements for increasing the strength and reliability of repairing pipelines to be protected by damage belts in the form of bandages made of them. When solving issues of reliable protection of pipelines, there is a danger of their premature destruction, despite the measures taken according to the principle scheme of amplification, quality and reliability of repairs. Therefore, reinforcing systems of fibers passing along the spiral of the tape are introduced into tape spirals from composite materials, providing them with a “shape memory effect”, however, methods for manufacturing such spirals are complex and time-consuming, especially at the stage of their forming. The tendency to obtain a tape spiral from a composite material of the greatest possible strength in the circumferential direction of the retaining belt has led to the fact that shrink stresses are actively manifested in the tape spirals, which lead to cracking of the tape spiral, which weakens the axial direction of the repair section of the pipeline and reduces its reliability. The introduction of intersecting fibers in relation to spiral fibers did not solve the problem of providing increased strength of the tape itself and the repaired section of the pipeline due to the weakness and low bond strength between them, determined only by the strength of the adhesive composition. Existing equipment is not suitable for the manufacture of an elastic flexible tape spiral made of composite materials.

A known method of manufacturing an elastic flexible tape spiral from composite materials, which consists in winding on a mandrel a reinforcing filler of filament systems impregnated with a polymeric binder, laying flexible elastic material with anti-adhesive properties between the turns of the tape. (USSR Author's Certificate N 280821, ³ B 29 D 23/12, 1970).

A known method of manufacturing elastic flexible spirals from composite materials by winding impregnated fibers with a binder on a mandrel in the form of glass strands, followed by crimping. (USSR Author's Certificate N 154662, ³ B 29 D 23/12, 1963).

A known method of manufacturing such layered products by winding on a mandrel fiberglass previously impregnated with a binder, and one-sided heating using hot shafts. (USSR author's certificate N 168169, ³ B 29 D 23/00, 1965).

 A known method and device for the manufacture of an elastic flexible tape spiral made of composite materials with impregnation of threads immediately before winding on the mandrel. (U.S. Patent No. 4,700,752; NKI 138-172; 138-178, 1987).

A device for the manufacture of an elastic flexible tape spiral made of composite materials, containing a mandrel connected to a drive of its rotation, the main heated shaft, shaft shafts and tempering mechanisms with belt-mounted bobbin holders mounted on the base. (USSR author's certificate N 226134, ³ B 29 D 23/12, 1969).

 A device is also known for forming long spirals from layered composite materials using mandrels and a steel tape for tempering and receiving mechanisms from opposite sides relative to the mandrels in contact with the material. (RF patent N 2000941 for application N 5005032/05 (072780) with priority from 10.16.91, B 29 C 43/30, B 29 D 9/00, 1993).

 The closest analogue to the method of manufacturing an elastic flexible tape spiral from composite materials, selected as a prototype, is the method according to USSR copyright certificate N 280821.

 The closest analogue of the device for the manufacture of an elastic flexible tape spiral from composite materials, selected as a prototype, is a device according to the USSR copyright certificate N 226134.

SUMMARY OF THE INVENTION
The main task is to create a tape spiral from composite materials of a multilayer structure with a high degree of accuracy of the location of the reinforcing threads over the layers of the tape, which has a high competitive ability compared to its market counterparts.

 The technical result from the use of the invention is to improve the manufacturing quality of the tape spiral, its strength, giving the tape over the entire surface of the spiral elastic properties without cracking the tape both during technological operations of its production and when applied to the pipeline being repaired, increasing the reliability of repair, production efficiency and application tape spiral.

 The main problem is solved and the technical result is achieved by changing the operations of the method of forming multilayer coils of the spiral, choosing the effective volumetric ratio of the reinforcing filler and the polymer binder, its composition and the modes of winding and curing the binder, creating a device that implements a new concept of the formation of the spiral, the inclined location of the sites, bearing bobbins with rolled material, the introduction of new additional elements.

To do this, in a method of manufacturing an elastic flexible tape spiral from composite materials, which consists in winding a mandrel of a reinforcing filler from filament systems impregnated with a polymeric binder, laying flexible elastic separating material with anti-adhesive properties between the turns of the tape, jointly heat treating them, curing the binder, and removing it from the mandrel and machining to a given size, winding on the mandrel of a reinforcing filler, pre-impregnated with a polymer binder, produce the following Tel'nykh penetration polymeric binder on opposite sides of packaged tape layers spiral heating rolls at a speed of movement of the reinforcing material from 0.007 to 0.03 m / sec, a tension of 250 to 700 kgf, heating temperature and heating binder podpressovochnyh rolls from 120 ^o C to 150 ^o C and the angles of their girth of the reinforcing material moving to the mandrel from 120 ^o C to 150 ^o C, and the curing of the binder is carried out according to the mode:
- rise in temperature to 100 ^o C - 3 - 4 hours;
- rise in temperature from 100 ^o C to 130 ^o C - 2 - 2.5 hours;
- temperature rise from 130 ^o C to 160 ^o C - 3 - 3.5 hours;
- exposure at a temperature of 160 ^o C - 6 - 6.5 hours;
- cooling to a temperature of 60 ^o C - 5 - 6 hours,
moreover, the reinforcing filler is used in the form of fabric or fabrics with a ratio of warp and weft threads across the spiral from 1: 1 to 3: 1 and a polymer binder of epoxy resin and phenol-formaldehyde varnish, respectively - 70% and 30%, incubated in bulk ratio from 1: 0.37 to 1: 0.57. After curing, operations are carried out to remove the workpiece of the tape spiral from the mandrel, unwind its coils while peeling off the release release material from their surfaces and rewind the turns of the tape spiral to its original state or in the direction with the reverse arrangement of coils.

According to the second option, in a method for manufacturing an elastic flexible tape spiral from composite materials, which consists in winding a reinforcing filler from systems of threads impregnated with a polymeric binder onto a rotating mandrel, laying flexible separating material with adhesive properties between the turns of the tape, jointly heat treating them and removing them from the mandrel using unwinding methods , according to the invention, the winding on the mandrel impregnated with a binder of a reinforcing filler with the formation of turns of a tape spiral produced simultaneously it is possible to introduce layers between layers of a spiral, an impregnated fabric layer or tapes with enhanced heat shrink properties, while prior to winding the mandrel, they are simultaneously packaged with the polymer binder melted from the opposite sides of the stacked layers by heating rolls at a speed of reinforcing fillers from 0.007 to 0 , 03 m / s, tension 250 - 700 kgf and heating temperatures on heating shafts from 120 to 150 ^o C and coverage angles of heating shafts of the filler moving to the mandrel from 120 to 150 ^o C, and reinforcing filler is used in the form of fabric or fabrics with satin, linen or twill weaving of threads with a ratio of warp threads in the direction of the spiral and weft threads across the spiral from 1: 1 to 3: 1, as a polymer binder, an epoxy resin composition of 70% is used and phenol-formaldehyde varnish - 30% with a volume ratio of fabric or fabric yarns and polymer binder in the spiral material from 1: 0.37 to 1: 0.57, the curing of the tape spiral composition is carried out in a heat chamber on a mandrel together with heat-shrink separators impregnated layers of fabric on the regime:
- rise in temperature to 100 ^o C - 3 - 4 hours;
- rise in temperature from 100 ^o C to 130 ^o C - 2 - 2.5 hours;
- temperature rise from 130 ^o C to 160 ^o C - 3 - 3.5 hours;
- exposure at a temperature of 160 ^o C - 6 - 6.5 hours;
- cooling the temperature to 60 ^o C - 5 - 6 hours
followed by operations to remove the strip spiral preform from the mandrel, unwind its coils while peeling layers from their surfaces, a layer of non-impregnated heat-shrink fabric with the formation of tape surface mesh perforation on the surfaces of the coils and rewinding the coil coils to their original state or with the reverse arrangement of coils.

 Layer, layers of non-impregnated fabric or tapes are made from polyester fabric or tapes with enhanced heat shrink properties.

 Moreover, according to the first and second variants of the method of manufacturing an elastic tape spiral after heat treatment, the tape spiral on the mandrel is machined with the removal of gloss and the formation of cuts, grooves, holes and end bevels with a decrease in the width of the tape from the smallest radius of curvature to the largest, and then wound from the mandrel with simultaneous removal separation release and / or heat-shrinkable layers located between the turns of the tape spiral, and rewind without release and / or heat-shrink puffs in the original state or with the reverse arrangement of turns. In a device for manufacturing an elastic flexible tape spiral made of composite materials containing a mandrel connected to its rotation drive, a main heating shaft, overhead shafts and belt-shaped tempering mechanisms with bobbin holders installed on the base, according to the invention, the base of the tempering mechanisms with bobbin holders is provided with parallel supporting platforms made with a slope at an acute angle, with the apex directed to the mandrel, and an additional heating shaft installed between at a heating main shaft and crossover rollers and located above a plane passing through the main shaft and upper heating saddle shaft or below the plane extending through the main shaft and lower heating saddle shaft. Under the main heating shaft and / or above it, additional tempering mechanisms with bobbin holders are installed for rolls of separating materials with release properties, for example, fluoroplastic film and / or heat-shrinkable polyester non-impregnated fabrics, and the base of the tempering mechanisms is additionally equipped with load-bearing belt-shaped pads installed parallel to the main , and on which it is also tiered and / or stepwise with increasing height in comparison with the main bobbin holders for woven and / or p vengovogo, and the dried preimpregnated prepreg rolled up state filler.

The invention is presented in the drawings, where
in FIG. 1 shows a device for manufacturing an elastic flexible tape spiral from composite materials;
in FIG. 2 shows a second embodiment of a winding device for manufacturing a tape spiral;
in FIG. 3 shows the layout of a winding device for the manufacture of a tape spiral with one separation layer of a release fluoroplastic film;
in FIG. 4 shows the possibility of using in the same arrangement of a winding device for the manufacture of a tape spiral of additional release adhesive separation layers with increased heat shrinkage;
in FIG. 5 is a schematic diagram of the winding of a tape spiral by the inventive method and device at the initial stage of its formation;
in FIG. 6 shows a view of a strip spiral preform with surface mesh perforation resulting from the use of additional separating non-impregnated fabric layers with increased heat shrinkage;
in FIG. 7 shows the design of the release mechanism with a braking device that allows to provide the calculated tension of the cloths of fiberglass and separation layers in the process of forming a tape spiral;
in FIG. 8 is a view of a winding device for manufacturing a tape spiral from above;
in FIG. 9 shows a diagram of the melt of the polymer binder of the packaged layers of fiberglass blanks of a tape spiral on an additional heating shaft 15;
in FIG. 10 shows a diagram of the melt of a polymer binder of the packaged layers of a fiberglass preform of a tape spiral on a main heating shaft from the opposite side of the preform of a tape spiral;
in FIG. 11 shows a top view of the inventive device for the manufacture of a tape spiral, which shows the possibility of molding the proposed device at once several tape spirals, including different geometric sizes, nomenclature and unequal degree of "elastic memory";
in FIG. 12 shows a view of a mandrel with already molded on it by the inventive manufacturing method and device for its implementation of elastic flexible tape spirals of the same nomenclature;
in FIG. 13 shows a view of a multi-stage mandrel design on which, using the inventive method and device, it is possible to simultaneously produce batches of tape spirals of practically unlimited nomenclature;
in FIG. 14 shows the formation of blanks of tape spirals on a stepped mandrel;
in FIG. 15 shows the types of blanks of tape spirals taken from a stepped mandrel;
in FIG. 16-17 show tape spirals in a half-expanded (Fig. 16) and transportation (collapsed) state (Fig. 17);
in FIG. 18 - I var. Figures 1–3 show variants of tape spirals with different reinforcement structures;
in FIG. 19 shows options for end shanks of tape spirals;
in FIG. 20 - 23 show options for finished tape spirals in the unfolded (unwound) state;
in FIG. 24 - 26 show other possible options for tape spirals made of composite materials intended for the repair of defective sections of pipelines;
in FIG. 27 - 29 show the same versions of tape spirals located directly on the defective surfaces of pipelines (in the form of multi-layer protection of their defective surfaces);
in FIG. 30 shows an application of a tape spiral made of composite materials at the time of its fixing to the defective pipeline surface with adhesive tape;
in FIG. 31 shows the moment of fixing the first turn of the tape spiral on the pipeline with its second turn (with the flexible tape already removed);
in FIG. 32 shows a view of a defective pipeline section repaired by means of a tape spiral with a multilayer protection formed from it in the form of a rigid retaining ring;
in FIG. 33 is a diagram of the basic mechanical properties of an elastic flexible tape spiral material.

 A device for manufacturing an elastic flexible tape spiral from composite materials (Fig. 1 - 2, 7) contains a mandrel 1 connected to a drive of its rotation 2, the main heated shaft 3, roll shafts 4 - 5, a rigid platform 6 that can freely move relative to the longitudinal axis of the mandrel and / or relative to it in a stationary, fixed state. The base 6 is equipped with platforms 7 - 8, rigidly fixed to it by means of frame structures 9 - 10 and bolted joints. Pads 7 - 8 are set in parallel to each other, but set in relation to the base and the mandrel with an inclination at an acute angle 11 with the apex 12 directed towards the mandrel. On platforms 7 - 8, tempering mechanisms are mounted (Figs. 1 - 2, 7), designed to fix bobbins 13 with fiberglass woven fabric filler 14, pre-impregnated and dried in impregnation plants to a prepreg state.

 The bobbins 13 with fiberglass rolls are mounted on the threaded shaft 15 of the release mechanism and fixed from displacement by the threaded nut 16. In turn, the shaft 15 together with the bearings are mounted on the supports 17 - 18 and fixed from displacement by the linings 19 - 20 and threaded connections 21 - 22. A drum 23 is put on one end of the shaft 15 and is rigidly fastened to the support 18 by bolted joints 24. Brake pads 26 are rigidly connected to the drum 23, by means of which the rotation of the shaft 15 is braked; due to the inhibition of the rotation of the shaft, the tension of the fiberglass fabric filler 14 is adjusted (Fig. 7).

 The implementation of the method of manufacturing a tape spiral and the operation of the device for its implementation is as follows.

 First, the outer diameter of the mandrel 1 is determined, on which later the strip spiral preform will be formed by winding methods. This size is determined by calculation for reasons of the possibility of laying turns of the tape spiral on the outer defective surface of the pipeline without gaps. The outer diameter of the mandrel 1 for shaping the tape spiral is determined by the winding parameter determined from the ratio K = d / D = 0.28 - 0.68 (see Table 1), where d (mm) is the required diameter of the mandrel, and D ( mm) is the outer diameter of the defective surface of the pipeline. For large pipeline diameters (in the range from 1000 to 1500 mm), the parameter K = 0.25 - 0.4, for medium-sized pipelines (in the range from 500 to 1000 mm), the parameter K = 0.35 - 0.6, for small sizes of pipelines (in the range from 200 to 500 mm) parameter K = 0.45 - 0.7.

 After selecting the mandrel in geometric dimensions, it is being prepared for forming ribbon spiral blanks on it. To do this, the outer surface of the mandrel is cleaned, degreased and covered with release grease 26 (see Fig. 3 - 6). Technological flexible steel or fiberglass tape 27 with a thickness of 0.1 to 1.5 mm is installed on the release agent lubricant along the forming mandrel and fixed on the outer surface of the mandrel without sagging, for example, with adhesive tapes 28 of adhesive tape type. Thus prepared mandrel 1 is installed in the winding device (see Fig. 1, 2) and connected to the drive of its rotation 2.

 In parallel with the preparation for winding the mandrel 1, bobbins 13 with roll pre-impregnated and dried fiberglass fabric filler 14 (Fig. 1-3) are being installed on the dispensing mechanisms, unwinding of their ends with passing through the transfer shafts 4-5 and the heating shafts 15 and 3 and fixing to the outer surface of the mandrel. After fixing the ends of the roll of fabric filler on the mandrel, the mandrel is turned on and, simultaneously with the mandrel rotation, the transverse feed of the base 6 is turned on and the layers 29 are then wound to form the technological shell 30 to the calculated size, which determines the exact outer diametric size of the mandrel and the size of the inner surface of the first turn of the tape spiral.

 The main purpose of the technological shell 30 is to provide more accurate dimensions of the first 31 and all subsequent turns 70 of the tape spiral. An additional purpose of the technological shell 30 is to provide a more reliable fixation on it, for example, by means of an adhesive tape (adhesive tape) of all ends of cloths 33 (Fig. 4), which are used directly for the manufacture of a tape spiral from composite materials, and all ends from release adhesives, for example fluoroplastic films 34 used to separate the surfaces of the turns of a tape spiral.

 Note. The simultaneous fastening and retention of all ends of the fiberglass cloths 33, already used directly in the formation of the tape spiral, and all ends of the cloths 34 (tapes) of anti-adhesive material used to separate the surfaces of the turns of the tape spiral, directly to the lubricated surfaces 26 of the mandrel 1 cannot be carried out purely by technical reasons - they cannot be glued to the grease 26 of the mandrel.

 The third purpose of the technological shell 30 is to prevent mechanical damage to the inner surface of the first turn of the tape spiral and the outer surface of the mandrel when removed from it by unwinding the turns of the tape spiral. The purpose of the flexible tape 27 is to prevent mechanical damage to the outer surface of the mandrel when removing layers 29 of the technological shell 30 from it.

 The following is a set of technological operations for the formation of a tape spiral from composite materials in accordance with the proposed method. All fiberglass webs 14 used during molding of the technological shell 30 are cut off (Fig. 3), bobbins with underused fiberglass webs are removed, and instead of them (Fig. 4), other coils of a similar design with pre-wound and pre-soaked and dried to the prepreg state are installed reinforcing fillers 33, 35 - 36 with plain, satin or twill weaving.

 The ends of the fillers 33, 35 - 36, as well as during molding of the technological shell 30, are threaded onto the mandrel 1 through the transfer shafts 4 - 5 and the heating shafts 15 and 3 (Fig. 4) and secured to the mandrel, for example, by the ends of the webs 14 of the technological shell 30 , sticky tape (adhesive tape) and / or adhesive mass. At the same time, under the ends of the fillers 33, 35 - 36 directly on the surface of the technological shell 30 (Fig. 4), the layers of release release material 34 are also fixed, for example, from a fluoroplastic film fed directly to the forming zone of the tape spiral from the coil 37. The process of filling the ends of the reinforcing fillers 33, 34 - 36 and release film 37 are carried out at low speeds of rotation of the mandrel without tensioning the sheets of the reinforcing filler and with the heating of the heating shafts 3 and 15. turned off. As the ends 3 3 - 36 on the mandrel 1 (full fastening of the ends on the mandrel is achieved in one revolution of the mandrel), include heating of the shafts 3 and 15 and adjust the tension of all paintings reinforcing filler through the brake pads 25 (Fig. 7).

 On the heating shafts 3 and 15 they create the necessary temperature fields sufficient to melt the polymer binder, which is impregnated with fiberglass. The winding parameters of the tape spiral blank are regulated, they depend: on the geometric dimensions of the tape spiral (its inner diameter, width, thickness of the turns of the tape spiral, their number, etc.), and on the types of reinforcing fillers used in the manufacture of the tape spiral and the materials connecting them , and from the technical requirements for finished products (in terms of strength, elasticity, heat resistance, "elastic memory", etc.).

 In the table. Figure 2 shows the main technological parameters of forming by methods of winding elastic flexible tape spirals from composite materials for glass fillers (fiberglass) with linen, satin and twill weaving of threads with tape spiral thicknesses from 0.2 to 3 mm and the number of layers of winding fiberglass in each turn of the tape from 2 to ten.

 Given in the table. 2 technological modes of winding (shaping) of an elastic flexible tape spiral are preferred for tape spirals of finite length from six to forty meters and only for multilayer spirals consisting of two to ten layers of layered material, where each layer of this material has a certain structure of weaving of threads - namely: consists of two systems of interwoven yarns in the form of a fabric with an arrangement of weft yarns in the axial direction, a spiral, and warp yarns - in its spiral direction with a volume ratio of warp yarns s and weft from 1: 1 to 3: 1 and each layer of the tape spiral is made in the volume ratio of interwoven yarns and polymer binder from 1: 0.37 to 1: 0.57, and the polymer binder itself, in turn, is formed as a composition: epoxy resin - 70% and phenol-formaldehyde varnish - 30%. In cases of forming elastic flexible tape spirals of other geometric sizes and from other materials (with different ratios of reinforcing fibers, threads and binders), these molding modes should be adjusted.

A method of manufacturing an elastic flexible tape spirals is carried out as follows: the drive 2 of the mandrel 1 is turned on and sequentially wound the packaged layers of fabric 33, 35 - 36 under tension. Since the fabric rolls are installed in tiers on inclined platforms 7-8 (see Figs. 1-4), each subsequent fabric tape passing over the previous one without intersecting with it is fed, respectively, in groups to the lower and upper transfer rolls 4-5, and from them - onto an additional heated shaft 15, and after it - onto the main heating shaft 3, and at the final stage it is wound simultaneously with several layers 33, 35 - 36 (from two to ten in a bag) together with separation layers 34 of a material with release adhesives properties on the mandrel 1 in the number of turns in necessary to obtain a tape spiral. On the surfaces of the additional and main heating shafts 15, 3, a temperature of 150 ± 10 ^o C is created, appropriate and sufficient for melting the binder from epoxy resin - 70% and phenol-formaldehyde varnish - 30%, for the above speeds of the packed layers of fiberglass 33, 35 - 36 k mandrel 1 (Fig. 1, 2, 4).

 The main heating shaft 3 provides the penetration of the binder of the entire lower part of the layers 33 and 35 of the packed layers of the tape spiral (the entire lower tier).

 An additional heating shaft 15 provides the penetration of the binder of the entire upper part of the packed layers 35 and 36 of the tape spiral (the entire upper tier).

 The binder penetration scheme implemented in the device provides complete penetration of the binder in all packed layers 33, 35 - 36 of the tape spiral. A packet of fiberglass layers passing through the main heating shaft 3 can be additionally sealed with a plate 38 having a rounded edge (Fig. 1), or with a roller 39 (Fig. 2) mounted above the heating shaft 3 and moving tape layers 33, 35 - 36.

 To increase the "elastic memory" of the turns of the tape spiral, all layers 33, 35 - 36 of the tape spiral can be additionally compressed by using additional non-impregnated fabric layers with increased heat shrink. In particular, for these purposes, non-impregnated polyester (dacron) fabrics can be used. They can be used both for prepressing the entire workpiece of the tape spiral (after forming all the turns of the tape spiral), and for additional pressing of each turn of the tape spiral.

 In the first version of the prepress, the entire preform of the tape spiral after its formation is wrapped with additional non-impregnated fabric layers with increased heat shrinkage, and then, together with them, the separation film and the mandrel are subjected to heat treatment according to the curing mode of the binder tape spiral, followed by unwinding of the outer heat-shrink layers and unwinding of the tape turns spirals with separation of the release release agent, for example, a fluoroplastic film.

 In the second embodiment, according to the authors of this invention, more technologically and economically more expedient, and therefore preferable, additional non-impregnated woven fabrics, for example, made of polyester fabric, are introduced onto the outer surface layers of the tape spiral preform in the process of packaging and transformation into a spiral spiral possessing increased heat shrinkage, and then, together with them, a separating fluoroplastic film and a mandrel, heat-treat the workpiece of the tape spiral, followed by unwinding from the mandrel and the separation divider (PTFE) film and the heat-shrinkage (polyester) layers.

The heat treatment of the workpiece of the tape spiral (and in the first version - external prepress by heat-shrink fabrics, and in the second version - with layer-by-layer prepress of turns of the tape spiral) are carried out according to the following mode:
- rise in temperature to 100 ^o C - 3 - 4 hours;
- rise in temperature from 100 ^o C to 130 ^o C - 2 - 2.5 hours:
- temperature rise from 130 ^o C to 160 ^o C - 3 - 3.5 hours:
- exposure at a temperature of 160 ^o C - 6 - 6.5 hours;
- cooling to a temperature of 60 ^o C - 5 - 6 hours.

 The second variant of prepressing the turns of the tape spiral with heat-shrinkable non-impregnated fabrics fits very effectively into the main technological scheme of the formation of the tape spiral, which is the basis for the proposed method for manufacturing an elastic flexible tape spiral and device for its implementation.

 The second variant of prepressing the turns of the tape spiral in accordance with the proposed method is as follows (Fig. 1, 2, 4): coils (bobbins) with impregnated fabric filler 35 and 36 are replaced with similar, but containing non-impregnated woven materials with large heat shrink.

 All ends of the fillers (both from the impregnated, the main fabric - in this embodiment, coming only from rolls 33), and from the non-impregnated heat-shrinkable - in this embodiment, coming from rolls 35 and 36) are also passed through the transfer shafts 4 - 5 and the heated shafts 3 and 15 and fixed on the technological shell 30 located on the mandrel 1.

 Further, the entire cycle of forming and heat treatment of a tape spiral completely repeats the previously described method of manufacturing a tape spiral with the only difference that in this embodiment it is not necessary to use the main separation layers 34 of a fluoroplastic film - shrink layers 35 and 36 in this case can perform three independent functions - and separating (by means of these layers, the surfaces of the turns of the tape spiral can be easily separated from each other during unwinding), and prepress (due to heat shrinkage, the strength and elasticity are increased these properties of the tape spiral), including the "elastic memory" of its turns), and preparatory ones - by using heat-shrinkable layers after they are unwound, it eliminates the need to remove the gloss from the outer surfaces of the tape spiral, they have mesh perforation (Fig. 6), which when converting a tape spiral into a multilayer protection of defective areas of the pipeline increases their strength and operational characteristics.

 Thus, in the inventive method of manufacturing an elastic flexible tape spiral from composite materials and a device for its implementation are solved, as it were, two close in concept, but significantly different in technical execution solutions.

 In the first embodiment, an elastic flexible tape spiral is made from composite materials only with the use of a release release agent, for example, a fluoroplastic film.

 In this embodiment, an elastic flexible ribbon spiral has rather high physical and mechanical characteristics (see Table 3), the ribbon spiral thus obtained has glossy surfaces.

 In the second version of the method, an elastic flexible ribbon spiral is made from composite materials using non-impregnated, for example, polyester fabrics with high heat shrink.

 In this embodiment, an elastic-flexible tape spiral has rather high physical and mechanical characteristics and higher technological parameters.

 It has a higher "elastic memory", it is easier to wrap (apply) to defective surfaces of the pipeline and actually does not require preparatory work (machining to remove gloss, cleaning, degreasing, etc.).

 In addition, in the second variant of the method, a tape spiral with a perforated mesh structure is obtained on the surfaces of the turns of the tape spiral, which makes it possible to obtain a multilayer protection of the defective zone of the pipeline from it with a higher transverse (tear-off) strength of the adhesive joints, and therefore with a higher operational reliability. However, the design of the tape spiral, obtained but the second version of the method, have a higher cost (due to the greater complexity of manufacturing and greater consumption of heat-shrinkable fabrics).

 In accordance with the proposed manufacturing method and device for its implementation, elastic flexible tape spirals can be made from composite materials with various physical, mechanical and thermophysical characteristics (see table. 3).

 They can have different structures (Fig. 18, var. 1-3), different geometric sizes and shapes (Figs. 19, 24-26), different "elastic memory", various technological, operational and other characteristics.

 In particular, in accordance with the proposed technical solutions, several types of tape spirals can be made of composite materials of various classes and purposes on the same mandrel and under the same heat treatment modes.

 The proposed method and device allows to receive tape spiral designs on the same mandrel both sequentially, with stop and readjustment of the device for manufacturing tape spirals of various geometric sizes and shapes, and simultaneously: immediately a batch (Fig. 8 - 12). In FIG. 1 - 4, 8 - 14 shows how this is done through the claimed technical solutions.

 First, on the mandrel 1 (Fig. 3, 8) by any known methods, winding the layers 29 of the technological shell 30 to the desired design size. For this, all coils 13 with fiberglass fabric fillers 14 fixed to them by a binder are spread apart over the entire length of the mandrel so that when layered on mandrel 1, fillers 14 cover the entire surface of the mandrel with an overlap of joints of 10-30 mm. Then, after the formation of layers 29 of the technological shell 30, the ends of the fiberglass fillers 14 are cut off, the coils 13 are removed, and other coils with other reinforcing fillers 33, 35 - 36, for example, impregnated with binder fiberglass, are installed; all coils are placed on the dispensing mechanisms of the winding device in tiers, one above the other (see Fig. 1 - 2, 4, 8 and 11), the ends of the reinforcing fillers are passed through the transshipment 4 - 5 and the heating shafts 3, 15 and are filled on the outer surface of the technological the shell 30 together with the release release liners (or tapes) 34, for example, of a fluoroplastic film, tucked into the forming zone of the tape spiral preform directly under the layers of sheets of reinforcing fillers 33, 35 - 36 and molding the first 31, and then Cex subsequent turns 70 of the tape 32 spirals.

 In FIG. 4, 8 - 10, 12 show how the manufacture of one tape spiral from composite material of the same size is carried out on one mandrel. In FIG. 11, 13 - 15 show how ribbon spirals can be made on the same mandrel from composite materials of various sizes with sequential and parallel shaping processes. This is carried out as follows: first, from layers of fiberglass material 33, 35 - 36, impregnated with a binder composition, by means of pass 4 - 5 and heated shafts 3 and 15 (Figs. 1 - 2, 4, 8, 11), layers 33, 35 are packaged. - 36 with the penetration of their binder mass on opposite sides of the packaged tape 31 (Fig. 1 - 2, 4, 9 - 10). Then, the already packaged layers 31 are wound onto the process shell 30 together with release release liners or tapes 34 to form a ribbon coil blank 32 from them.

 Moreover, in FIG. 1 - 2, 4, 8 explains how the molding of the tape spiral blanks 32 is carried out on one mandrel in a sequential manufacturing cycle. First, one blank 32 of the spiral strip is formed on the mandrel, then, after the calculated length of its turns is formed, the ends of the fiberglass filler 33, 35 - 36 and the release film 34 are cut off, the winding device is moved along the mandrel to the calculated distance L, again according to the previously described the ends of the fiberglass filler 33, 35 - 36 and the ends of the release film 34 onto the process sheath 30 are filled with the method and the next preform of the tape spiral is formed, then this process We repeatedly repeat until a large number of blanks 32 of the ribbon spiral are obtained on the mandrel (Fig. 12). Next, the entire batch of tape spiral blanks located on the mandrel is fed to a heat chamber for heat treatment, where they are heat treated according to the above-described regime, and then they are removed from the mandrel by unwinding methods with separation of the release film from the surfaces of the turns of the tape spiral. Further, in the same way, the manufacture of blanks of tape spirals of the next batch, etc., is carried out.

 Using the proposed method, it is possible to simultaneously form on one mandrel a whole batch of blanks of tape spirals 32.

 In FIG. 4 and 11, it is explained how this can be carried out in a production environment by means of the inventive winding device. The main distinguishing feature of the inventive winding device is that in its layout on the base 6 and (or its frame) you can mix several tiers of unconnected tempering mechanisms with coils with reinforcing fillers 33, 35 - 36 and release adhesion films 34 (Fig. eleven). Due to the multi-tiered arrangement of tempering mechanisms and coils with dividing films, it is possible to simultaneously produce on one mandrel 1 an entire batch and even batches of blanks of tape spirals of various structures and geometric shapes.

 In the case of using step-shaped mandrels (Figs. 13-15), for example, by winding on the cylindrical surface of the technological shell 30 step thickenings 37-38, the proposed technical solutions (method and device) can significantly expand the range of tape spirals. On the stepped mandrel shown in FIG. 13, both sequential and parallel manufacturing of tape spirals is acceptable.

 This is carried out as follows (Fig. 13-15): first, the mandrel 1 along its entire length with an overlap of layers of 10-30 mm by known methods wind the fiberglass layers 29, forming the main technological shell 30 from them (Fig. 13). Then, fiberglass thickenings 37–38 are wound onto the outer surface of the technological shell 30. Additional technological shells 39–40 are wound onto these thickenings 37–38 by known methods. The main technological thickening 30 and additional 39–40 are basic. In future, in accordance with the proposed technical solutions, they are sequentially (with a time offset) or parallel (simultaneous) forming blanks of tape spirals 41 - 43 (Fig. 14) of different geometric sizes and structures, followed by their simultaneous heat treatment in a heat chamber together with a mandrel (Fig. 12) according to the curing mode of the applied binder mass and unwinding of finished products 44 - 46 (Fig. 15). At the same time, on each of the technological shells 30, 39 - 40 (Fig. 13) of a step mandrel in accordance with the proposed technical solutions, it is possible to manufacture (form) by winding several pieces of ribbon spiral blanks of various structures and geometric sizes.

 In FIG. 16 shows the preform of the tape spiral 32 in a half-expanded form (just wound from the mandrel). The outer and inner surfaces 46 - 47 of this workpiece have a fairly high gloss. Such surfaces, when glued with a glue mass, will have low peel strength (transverse strength) and, therefore, the multilayer protection obtained from such a tape spiral blank for a defective zone of the pipeline will have low operational characteristics.

 To increase the bonding strength of the surfaces of the tape spiral, its glossy surfaces 46 - 47 must be mechanically and / or chemically treated before they are glued to the defective area of the pipeline and formed a multilayer protection until the surfaces of the tape spiral are matte. Gloss removal on the surfaces of the tape spiral can be carried out: surface treatment 46 - 47 with an abrasive wheel, sandpaper, shot and / or chemical reagents.

The machining of the surfaces of the tape spiral is carried out until the surface roughness R _z = 40 - 50 is formed, the chemical treatment of the surfaces is carried out until the mesh perforation 48 - 49 appears on the surfaces of the turns of the tape spiral (Fig. 16 - 19). As a rule, chemical etching of the outer surfaces of the tape spiral (or their mechanical processing) is carried out on workpieces that are in half-expanded (Fig. 16) or fully unfolded (Figs. 20-23).

 Then, the workpiece of the tape spiral processed by the above methods is folded into the working (folded) state (Fig. 19) and in this form it is stored in a warehouse or transported directly to the place of repair and restoration work of the pipeline. The outer and / or inner shanks of the tape spirals 32 can be made with steps 50 - 52 (Fig. 17, I, II; Fig. 19, III) or with smooth elliptical or spherical transitions 53 (Fig. 19, II). In some cases (with stepwise execution of liners), this is done to facilitate and reduce the time for repair and restoration work on the pipeline, in others (with smooth transitions of liners) to reduce the local thickness of adhesive joints and increase the transversal strength of multilayer protection.

 In FIG. 18, I, var. Figures 1-3 show structural versions of tape spirals used for the multilayer protection of defective pipeline zones. In FIG. 18, I, var. 1 shows the structure of a satin-woven fiberglass fabric, FIG. 18, I, var. 2 shows the structure of fiberglass with plain weaving of threads, FIG. 18, I, var. 3 shows the structure of fiberglass with twill weaving. In FIG. 18, I. var. Figures 1-3 show: position 54 — warp fibers (filaments), position 55 — weft fibers (filaments), 56 — polymer composite matrix.

 In the proposed method for manufacturing an elastic flexible tape spiral from composite materials, it is assumed to use pre-impregnated and dried fiberglass to the state of "prepreg" of satin fiberglass (Fig. 18, I, var. 1), linen (Fig. 18, I, var. 2) and twill (Fig. 18, I, var. 3) weave two systems of threads.

 Satin weave fabrics can be four, six and eight hemp, that is, the warp thread can pass over 4, 6 or 8 weft threads. With an increase in the number of heaps, the portion of the non-bent thread increases, as a result of which its strength decreases to a lesser extent and the mechanical properties of the material of the ribbon spiral improve (see Table 3).

 In plain weave fabrics, warp and weft are mutually interwoven (Fig. 18, I, var. 2), their strength in the direction of the spiral is slightly lower than satin weave fiberglass; on the other hand, they have higher flexibility, are more technologically advanced and, therefore, more effective when carrying out repair and restoration work on defective pipeline surfaces (they simply fit better on defective pipeline surfaces without gaps between the surfaces of the coils, thereby increasing the tear-off transversal strength of multi-layer adhesive joints pipeline). In addition, plain weave fabrics are much cheaper than satin weave fabrics, which, ceteris paribus (along with manufacturability) gives them a significant advantage when carrying out repair work on defective pipeline surfaces.

 Twill weave fabrics have slightly worse (compared to satin and linen weave fabrics) strength indicators in the direction along the warp (along the spiral), but they have higher strength indicators across the warp (across the tape spiral). In addition, fiberglass twill weave yarns (in comparison with fabrics of satin and plain weave yarns) have a higher specific impact strength (Fig. 33 and table. 3).

 It should be noted here that the strength, rigidity, and other physicomechanical and thermophysical properties of an elastic flexible tape spiral for multi-layer protection of a pipeline depend on many design parameters of fiberglass fabrics from which it (multi-layer protection) is made: these are the thickness of the fibers and the order of the strands weaved into threads and their twist, and patterns of weaving threads.

 Typically, the thickness of the fibers used for the aforementioned fiberglass, and their number in the strands varies in very small limits, and therefore these factors practically do not affect the physicomechanical and operational characteristics of the multilayer protection of defective zones of the pipeline. The order of weaving the strands in the thread also does not have a significant effect on the strength and performance characteristics of the multilayer protection of the pipeline. But twisting the threads of which fiberglass is made, significantly affects the properties of the multilayer protection of the pipeline.

 So, for example, the tensile strength of the material of the multilayer protection of the pipeline in the annular direction (in the direction of the spiral) made of fiberglass from 16 strands of thread and twist of 10 to 50 twists / meter is 105 to 120% of the strength of the same material, but with twist of threads 250 twists / meter. The water absorption of materials on fabrics of threads with a lower twist is lower than that of the same materials, but with a high twist of the threads. Improving the properties of the material of the multilayer protection of the pipeline with a decrease in the twist of the thread is explained by the quality of the impregnation of the threads with a binder.

 According to the authors of this invention, the positive effect of reducing the twist of the thread on the properties of the material will increase with a decrease in the contact compression of the packet of layers of the tape spiral, which is directly dependent on the tension of the fabrics when forming an elastic flexible tape spiral from composite materials. Therefore, the authors of this invention recommend forming multilayer protection of defective areas of pipelines from tape spirals obtained from weakly twisted warp and weft threads with loose structures, namely, fiberglass plain, satin and twill weave have such fabrics. It should also be borne in mind that the material of the multilayer protection of the pipeline from the tape spiral should not only have high physical, mechanical and thermal characteristics, it should also have high electrical insulation properties. This means that both the threads used for the elastic flexible tape spiral and the polymer matrix connecting them must be non-conductive. This is done in order to avoid cathodic corrosion during pipeline operation and thereby increase the operational reliability of the applied multilayer pipeline protection.

 In the method for obtaining multilayer protection of a pipeline from an elastic flexible tape spiral with improved operational properties (physical, mechanical, thermal, electrical insulation, "elastic memory", water permeability, etc.), the authors recommend the use of non-conductive fiberglass fabrics formed from non-conductive aluminoborosilicate fibers with a diameter of the filaments from 5 to 15 microns and a twist from 10 to 200 twists / meter, and a non-conductive polymer cured matrix of epoxy binder and phenol-formaldehyde Foot varnish.

In the claimed method of manufacturing an elastic flexible tape spiral for multilayer protection of defective areas of the pipeline, it is proposed:
- to form an elastic flexible ribbon spiral multilayer of two to ten layers of composite material, packaged together;
- perform each layer of the tape spiral from two systems of interwoven threads in the form of fiberglass (or fiberglass) with the weft threads in the axial direction, and warp threads in its spiral direction with a volume ratio of warp and weft from 1: 1 to 3: 1;
- to form a composite material of a tape spiral from fiberglass (or fiberglass) impregnated with a polymer binder consisting of a composition: epoxy resin - 70% phenol-formaldehyde varnish - 30% with a volume ratio of interwoven threads and composition from 1: 0.37 to 1: 0.57 ;
- forming an elastic-flexible ribbon spiral by winding onto a rotating mandrel a fiberglass filler pre-impregnated with the above polymer composition and dried in a heat chamber to the state of "prepreg";
- forming an elastic flexible ribbon spiral with simultaneous simultaneous melting (heating) of the aforementioned polymer composition from opposite sides of the stacked layers of the ribbon spiral heating rolls at speeds of reinforcing filler (fiberglass) from 0.007 to 0.03 m / s, its (their) tension of 250 up to 700 kgf the temperature of the composition heating on heating shafts from 120 to 150 ^o C, and the coverage angles of heating shafts with filler from 120 to 150 ^o C;
- winding (molding, packaging) of the layers of the tape spiral lead simultaneously with the introduction between them of a layer (or layers) of a release release agent (or materials), for example, from a fluoroplastic film (or films) and (or) release adhesive
heat-shrinkable non-impregnated fabric layers (layer), for example, from polyester (dacron) fabric and (or) tapes;
- heat treatment of the workpiece (or workpieces, in the case of forming several batches of workpieces on one mandrel at once) simultaneously with the mandrel, release and / or heat-shrink layers in the following mode;
- rise in temperature to 100 ^o C - 3 - 4 hours;
- rise in temperature from 100 ^o C to 130 ^o C - 2 - 2.5 hours;
- temperature rise from 130 ^o C to 160 ^o C - 3 - 3.5 hours:
- exposure at a temperature of 160 ^o C - 6 - 6.5 hours;
- cooling the temperature to 60 ^o C - 5 - 6 hours
followed by unwinding from the mandrel of the coils of the tape spiral and simultaneously separating from the surfaces of the coils of the tape spiral separating, for example, fluoroplastic films and / or heat-shrinkable materials from impregnated polyester (dacron) fabric or tapes with the formation of smooth glossy surfaces of the coils of the tape spiral (in cases of use for the separation of the surface of the turns of smooth anti-adhesive fluoroplastic films) or perforated surfaces with a mesh perforation structure (in case of zovaniya for the separation surfaces of untreated tape spiral turns, e.g., polyester fabrics with improved shrink properties).

 The proposed manufacturing method also provides other operations to improve the ability of winding coils of the tape spiral on the defective surface of the pipeline (and to each other) without gaps or with small gaps.

 This is carried out in accordance with the proposed method as follows: after heat treatment, the workpiece of the tape spiral located on the mandrel is machined, for example, on a lathe, with the formation of end bevels 61 - 62 (Fig. 25 - 26) with a corresponding decrease in the width of the tape spiral from the smallest the radius of curvature to the largest (Fig. 22 - 23), and then wound from the mandrel while peeling and removing the release (fluoroplastic) and / or shrink (non-impregnated polyester) layers, followed by rewinding spiral turns of the tape in the initial state or the reverse arrangement of coils.

The proposed manufacturing method also provides for other additional operations to improve the conditions for repair and restoration work on defective surfaces of the pipeline by means of a tape spiral. This is carried out as follows: after heat treatment and removal from the mandrel, the surfaces of the turns of the tape spiral 48 - 49 are machined, for example, on an abrasive wheel to R _z = 20 - 40, or perforated (Fig. 18 - 23). Then, in the process of rewinding the tape spiral from one edge shank 57 to another 58 (Figs. 20-23), they are cuts (cutouts) 59-60, or grooves 62 (Figs. 26, III) by machining, for example, by milling. -III) and / or drill technological holes 63 - 64, 68. This is done for the following technological reasons: when winding, not every elastic flexible tape spiral can be easily, and, most importantly, without gaps laid on the defective surface of the pipeline.

 Particular difficulties usually arise when laying turns of a tape spiral on a surface having double curvature. In such cases, in accordance with the proposed method, they perform operations to form holes 63 - 64 grooves, cuts and even cuts 59 - 60, 61 and / or corresponding perforations 48 - 49 on the surfaces of the turns of tape spirals (Fig. 18 - 23).

 In special cases, when it is necessary to restore defective sections of the pipeline with variable curvature, the tape spiral is made of variable width, tapering from one edge shank 57 to another 58 (Fig. 22 - 23). The edge shanks themselves perform with step 52 or smooth 53 transitions (Fig. 19, II, III).

 Variants of the designs of tape 32, which can be obtained by implementing the proposed solutions (method and device) are presented in FIG. 20 to 29. In FIG. 20 to 23 show options for tape spirals 32 in a fully deployed (unwound) state. In this state, the preparation of the surfaces of the tape spirals for the application of adhesive mass on them. The surface treatment of the turns of the tape spiral 32 can be carried out mechanically - by shot, abrasive wheel, emery tools, chemical etching and / or one of the variants of the proposed manufacturing method. According to this option, initially, at the stage of packaging the base layers of the tape 33, of which the first 31 and all subsequent turns 70 of the tape spiral 32 are formed (Fig. 6), during its formation into the tape spiral on both sides of the tape 33 (additional bottom and top) layers 35 - 36 of non-impregnated, for example, polyester (lavsan) fabric with enhanced heat shrink properties. These additional heat-shrink layers 35 - 36 together with the base layers 33 when wound on a rotating mandrel 1 are converted into a workpiece of a tape spiral. The ribbon spiral preform obtained in this way, together with the heat-shrinkable layers 35 - 36 and the mandrel, is heat treated in a heat chamber according to the curing mode that binds the ribbon spiral composition. After heat treatment, the turns of the workpiece of the tape spiral are unwound from the mandrel with the separation of layers 35 - 36 of heat-shrink fabric from the surfaces of the turns 31 and 70 of the tape spiral 32.

 When separating the non-impregnated layers 35 - 36 from the base layers 33 of the tape spiral, mesh perforations 71 are formed on the outer and inner surfaces of the turns 31 and 70 of the tape spiral, the mesh patterns of which 71 repeat the mesh patterns of the non-saturated layers 35 - 36 (Fig. 6).

 Mesh perforation printed in such a way on the surfaces of the tape spiral 32 makes it possible to obtain a multi-layer pipeline protection from the tape spiral with a higher transverse (tear-off) bond strength of its layers. The perforated tape spiral transformed by winding methods into a multilayer pipeline protection will have higher performance characteristics and, therefore, will have higher operational reliability. In addition, due to the heat shrinkage of layers 35 and 36, the elastic properties of the tape spiral will be simultaneously changed, its "elastic memory" will be increased. Due to this effect, the technological conditions for the formation of multilayer pipeline protection are also improved - the turns of the tape spiral will be easier to fit on defective surfaces of the pipeline without gaps.

 In FIG. 24 - 26 shows the options for tape spirals 32, made in accordance with the proposed method, in a folded, transportation state. They can be made of constant thickness and width (Fig. 24, I-I), of variable width and with tapering walls 61 (Fig. 25, II-II).

 To reduce the time and reduce the complexity of repair and restoration of pipelines produced by tape spirals, as well as to improve the quality of the work performed by increasing the possibility of denser laying of the surfaces of the turns of the tape spiral to each other without gaps or with small gaps in the tape spirals, the calculated number of cuts 59 - 60 (Fig. 21, 23 - 24, 26), bevels 61 or grooves 62 (Fig. 24 - 26, sections II-II and III-III), as well as technological holes 63 - 64, 68 (Fig. 18 - 32).

In FIG. 27-29 show variants of multilayer shieldings of the pipe 65 formed from tape spirals 32 (Figs. 24-26). Repair and restoration work on the defective surface of the pipeline 65 by means of tape spirals 32 made in accordance with the proposed technical solutions is carried out in the following sequence of operations (Figs. 30–32): first, a corrosion-resistant coating is applied to the defective surface of the pipeline 65 (Fig. 30) 66, for example, based on epoxy resins with additives of corrosion-resistant additives, then the first turn 31 of the tape spiral 32 is applied to this coating, which is fixed from displacement on the surface piping in the area of the end shank 58 with adhesive tape (adhesive tape) 67 having through holes 68 through which a fast-curing adhesive composition, for example, based on α-ciacric acid, is introduced into the shank fixing zone. After fixing the end of the shank 58 on the outer defective surface of the pipeline 65 due to the "elastic memory" of the turns 70 of the tape spiral 32, sequential layering of the first turn 31 of the tape spiral 32, and then of all its subsequent turns 70. Before winding the second turn of the tape spiral adhesive tape 67 removed and on the entire surface of the first turn 31 (or part thereof), an adhesive epoxy composition 69 is applied (Figs. 30 to 31), this composition is kept for 10-30 minutes in air at a temperature of 15-30 ^° C and the next turn is wrapped ok spiral, etc .; all operations to rewind the turns of the spiral tape 70 onto the defective surface of the pipeline 65 (Figs. 31–32) are repeated until a multilayer protection of the calculated thickness (Fig. 32) is formed, followed by curing of the adhesive joints 66, 69 according to the polymerization conditions of their compositions. After the curing of the adhesive joints 66, 69 of the multilayer protection of the pipe 65 is carried out, the resulting composition is flawed and, in case of defects - air gaps, non-glueing and other defects are detected, the walls of the multilayer protection are trepaned - additional holes are drilled in the detected defective zones and additional adhesive masses are pumped through them their subsequent curing. The injection of additional adhesive masses can be carried out through technological holes 63 - 64 (Fig. 32), specially provided for the exit of air gaps during the injection of adhesive masses. At the last stage of the repair and restoration work of the pipeline 65, operations are carried out to seal all the technological holes, grooves and cutouts formed in the multilayer protection - they are all putty with special adhesive pastes that are compatible with the materials of the multilayer protection of the pipeline, followed by their curing.

Examples
At present, the Avangard production enterprise has carried out experimental work to create designs of elastic flexible tape spirals from composite fibrous materials (KVM) intended for the repair of defective surfaces of pipelines of various classes and purposes. At the same time, work was carried out at the Avangard production enterprise: on the creation of a new winding equipment - a device for manufacturing tape spirals from composite fibrous materials, new technological equipment (impregnation machines, heat chambers, mandrel designs, heating shafts, tempering mechanisms, means of their control and control) and new technological processes necessary for the manufacture of tape spirals in an industrial way. The work was carried out:
- in the direction of studying issues of the possibility of using elastic flexible tape spirals from KVM to repair defective areas of pipelines;
- in the direction of choosing the optimal and geometric relationships of tape spirals as applied to the existing geometric dimensions of functioning pipelines;
- in the direction of the choice of reinforcing fillers and binders;
- in the direction of the search for the most optimal modes of forming (winding) blanks of tape spirals and their curing;
- in the direction of studying the strength, stiffness, thermophysical and operational properties of materials, elastic flexible tape spirals obtained by winding methods in accordance with the proposed technical solutions.

 Conducted and ongoing research and development work shows the high efficiency of using elastic flexible tape spirals made of composite fibrous materials for the repair of defective pipeline surfaces.

 Currently, the company "Avangard" in accordance with table. 2, experimental batches of elastic flexible tape spirals were manufactured for repair of defective zones of pipelines in the diameter range from 200 to 1500 mm. The tests of prototypes of elastic flexible tape spirals made in accordance with the claimed technical solutions, gave a positive result.

 The expected economic effect of the implementation of the proposed technical solutions can range from several hundred to billions of rubles of direct cost savings. The economic effect of the implementation of the proposed technical solutions can be achieved both at the stages of manufacturing batches of elastic flexible tape spirals (by reducing energy and labor costs, material consumption and time required for the simultaneous reproduction of elastic flexible tape spirals of different nomenclature and degrees of "elastic memory"), and by improving the quality of manufactured products, which ultimately will entail significant savings at the stages of repair work and operation from repaired sections of pipelines, that is, by increasing their operational reliability and durability.

 Thus, new technical solutions. The "Method and device for the manufacture of elastic flexible tape spirals" described above, according to technological and structural features are new and more technological and effective compared to the prior art.

 The scope of the proposed inventions should be understood broader than the specific implementation of the operations of the method and device for the manufacture of an elastic flexible tape spiral from composite materials described in the description, formulas and drawings.

 It should be borne in mind that the forms of carrying out the inventions described above in the application materials are only possible preferred options for their implementation, can be used and other, there may be more advanced embodiments of the inventions in the direction of choosing the shape, size, arrangement of individual elements, the design of the device mandrels and other nodes, as well as the choice of modes of molding, curing and removal of finished products. All this should be clarified by the next wave of inventions. The claimed technical solutions describe the industrial reproducibility of elastic flexible tape spirals of only a ring shape and certain geometric dimensions of the tape spiral, especially the thickness. Technological modes of forming elastic flexible ribbon spirals from KVM described above will be effective only when using materials of the above structure and volume content of power fibers and a binder.

 When applying (using) the method of manufacturing elastic flexible tape spirals of other fiberglass fabrics, for example, knitting-stitched, consisting of three or more interwoven reinforcing fibers (threads) in fabrics, and other binders (more fluid or more viscous), it will be necessary to introduce: a significant adjustment of the modes molding products and significant structural changes in the layout of the winding device itself.

The claimed and the method and device for the manufacture of elastic flexible tape spirals significantly differ from the methods described in the prototypes - US patent N 4700752 for CL. 138/172, 138/172 (Jnt Cl ⁴ F 16 l) and RF patent N 95108322 in the class F 16 l 15/18. These patents describe methods for manufacturing elastic flexible ribbon spirals from KVMs formed from unidirectional or mesh tape by wet winding methods, in the claimed method - all this is reproduced by the method of "dry winding" in the form of batch molding with a large number of fabrics (from 2 to 10), defined structures impregnated with a specific binder, their specific structural (in terms of the location of the fibers) and bulk (in terms of the ratio of reinforcing fibers and binder) content.

 In the above patents, in the manufacture of elastic flexible tape spirals, a combination of individual threads is used that are not connected to each other and practically oriented only in the direction of the spiral. This means that the designs of tape spirals according to the prototype have an increased tensile strength in the annular direction (in the direction of the spiral), which is 1700-2000 MPa and a very low tensile strength across the spiral - only 20 - 30 MPa (Table 3). In addition, the designs of tape spirals manufactured by American technology have very low shear characteristics (only 6 - 7 MPa) and low tensile strengths of the material of tape spirals when shearing in layers (only 20 MPa).

 In the claimed method, the same characteristics of tape spirals are already 38 - 50 MPa, that is, they are significantly (more than 2 times) higher. Very significant discrepancies in the elastic characteristics of the tape spirals made according to American technology. So, the tensile elasticity moduli in the direction of tape spirals manufactured by American technology are 53.3 ± 1.9 GPa, and across tape spirals these values are only 14.3 ± 1.6 GPa. A simple analysis shows that the strength of the multilayer defenses of defective surfaces of pipelines formed from tape spirals made according to American technology in the ring and axial directions differ by about 60 times. The same can be said for many other physical and mechanical characteristics of the material of tape spirals made according to American technology. For example, the compression strengths of materials of American tape spirals in the spiral direction are 500 ± 6.0 MPa, and in the transverse direction, similar characteristics (in the axial direction in the multilayer protection of the pipeline) have values of only 90 ± 5 MPa, that is, they differ from friend 5 times.

 This suggests that the tape spirals manufactured according to American technology can be used to prevent the development of defects and cracks only along the axis of the pipeline and are completely inapplicable (useless) for repairing ring joints and cracks, since they practically do not perceive axial loads. What are the advantages of ribbon spirals from KVM, manufactured in accordance with the proposed technical solutions, over the known ones.

 In the proposed manufacturing method for the formation of tape spirals, the use of fabric structures from interconnected threads (with satin, linen and twill weave) is proposed. The basics of these fabrics in the manufacture of tape spirals are oriented in the direction of the spiral, and when using tape spirals directly on defective sections of the pipeline, in the circular direction. Ducks of these fabrics in the manufacture of a tape spiral are oriented across the tape spiral, and when using tape spirals, respectively, in the defective sections of the pipeline, in the axial direction.

 With this orientation of the warp and weft threads in the tape spiral and the corresponding orientation of the threads on the defective surface of the pipeline, the most optimal (from the point of view of ensuring the strength of the defective sections of the pipelines) indicators are achieved.

 For example, for fiberglass plain weaving, the strength limits in the spiral direction (ring - in the pipeline) are 400 - 450 MPa, and in the transverse (in the ribbon spiral) and axial (in the pipe) the same ultimate strengths are 200 - 225 MPa, then there are strength limits of multilayer pipeline protection differ from each other by 2 times and it is in the same ratio that the stress states of pipelines operating under the influence of internal pressure differ.

 Approximately the same ratio of strength characteristics in materials from fabrics of satin and twill weave.

So, for example, for a variant of a tape spiral made of fabrics with satin interlacing of threads, the tensile strength (in the direction of the spiral) is 550 MPa, and across the tape spiral - 300 MPa, that is, the tensile characteristics differ 1.8 times, then there are also close to the optimal stress ratios in the pipeline operating under internal pressure. For twill weaving of the threads, the tensile strength in the spiral direction is 400 MPa (40 kg / mm ² ), across the tape spiral - 500 MPa (50 kg / mm ² ), that is, they also differ slightly (~ 1.2 times).

But in this embodiment, the elastic-flexible tape spiral has the highest (compared to linen and twill weaving) strength characteristics during shear - along the layers (in the spiral direction 110 MPa, and across the layers in the axial direction of the pipe - 90 MPa, and in compression axial direction - 350 MPa (35 kg / mm ² ).

 The analysis of the strength parameters of the materials of tape spirals manufactured in accordance with the proposed technical solutions shows that the use of the first two systems of interwoven threads (satin and linen) is more rational for repairing pipes with axial cracks (along the generatrix of the pipeline being repaired), and the use of two twill weave threads - more efficiently in circular seams, that is, elastic flexible tape spirals made of such material are better able to absorb axial loads. However, it should be noted: all three variants of tape spirals discussed above (both plain, and twill, and satin) weaves of threads can, with a sufficient degree of reliability, prevent the development of defects both along the pipeline axis (in the circular direction) and in the axial direction.

 Differences in the strength characteristics of all three variants of the tape spiral during repair work are easily compensated by additional turns of turns of the tape spiral, the number of turns of these spirals and their geometric parameters are determined by calculation, depending on the loads acting on the pipelines - pressure, temperature, alternating, shock, etc. .

 Ribbon spirals made according to the technologies presented in US patent N 4700752 for class. 138/172 and RF patent N 9510822 according to class. F 16 l, can prevent the development of defects along the axis of the pipeline (in the annular direction, that is, in the direction of the coils of the spiral), and practically do not perceive axial loads. This is their main drawback. As for the "elastic memory", that is, the manufacturability of reeling tape spirals on the repair surfaces of pipelines, the construction of tape spirals by American inventors is somewhat more effective, since the elastic moduli in the material of these tape spirals in the ring direction are higher (about 1.8 - 2 times) . It should be noted that repair work on defective sections of pipes is carried out not with the purpose of resolving the issues of rewinding efficiency, but with the aim of ensuring the strength and reliability of the repair work. However, the technological issues of rewinding tape spirals into pipelines are easily resolved, that is, it is not necessary to use tape spirals with a high degree of "elastic memory" in repair work - the construction of elastic flexible tape spirals from composite materials with sufficient "elastic memory" is necessary, that is, the estimated memory that is necessary and sufficient for rewinding tape spirals on defective surfaces of pipelines, in practice, the selection of this "elastic memory" is easily solved by and by selecting the appropriate geometrical proportions of the dimensions of the outer surfaces of the mandrels (first of all, their diametrical dimensions), on which tape spirals made of composite materials are formed (wound), and the outer surfaces of the repaired pipelines. The geometric dimensions of tape spirals are easily (analytically) determined depending on the geometric dimensions of the outer surfaces of the pipes (their curvature), from the ratio d / D = 0.3 - 0.7 (see Table 2), where d is the diameter of the mandrel 1, on which, in accordance with the proposed method, an elastic-flexible tape spiral 32 of KVM is formed by winding methods; D is the diameter of the outer, defective surface of the pipeline 65, on which the same elastic flexible tape spiral 32 should be layered to form a multilayer protection on it.

 More precisely, the geometric dimensions and "elastic memory" of the tape spirals are determined taking into account the stiffness characteristics of the materials of the tape spirals, as well as the modes of their molding and curing. More precisely, the "elastic memory" of the turns of the tape spiral is calculated analytically taking into account the material of the mandrel 1 itself for forming the tape spiral.

 The "elastic memory" of the turns of the tape spiral can be increased by creating additional tension on the glass fillers in the tape spiral.

 Additional tension of glass fillers can be achieved: by increasing the braking forces in the dispensing mechanisms of the proposed device for forming tape spirals (Fig. 7), by using additional non-impregnated woven, for example, polyester materials with enhanced heat shrink properties when forming tape spirals (described above in the materials of the description), by increasing the volume and / or linear dimensions of the mandrel, etc. However, it should be noted that the discussion here is already related to the optimization of the "elastic memory" of tape spirals and they go beyond the scope of the claims set forth in the claims.

 In conclusion of the description provided, it should be said that the proposed technical solutions "Method and device" are not limited to their use only for the manufacture of elastic flexible tape spirals from composite materials and can be used, for example, for the manufacture of high-strength shells, pipes, spring coils with increased strength, stiffness, thermophysical and elastic properties described in the application materials.

 A new technical solution in the proposed substantial combination of essential features of the method and device for the manufacture of a tape spiral meets the criterion of "Industrial applicability", that is, the level of inventions.

Claims (10)

1. A method of manufacturing an elastic flexible tape spiral made of composite materials, which consists in winding a reinforcing filler from systems of threads impregnated with a polymeric binder onto a rotating mandrel, laying flexible release material with anti-adhesive properties between the turns of the tape, heat-treating them together and removing them from the mandrel by unwinding methods, characterized the fact that the winding on the mandrel of the reinforcing filler is produced with sequential penetration of the polymer binder from opposite sides of the packet layers of the tape spiral with heating shafts at a speed of reinforcing filler moving from 0.007 to 0.03 m / s, its tension from 250 to 700 kgf, binder heating temperature on heating shafts from 120 to 150 ^o C and coverage angles of heating shafts moving towards the reinforcing mandrel filler from 120 to 150 ^o C, and the reinforcing filler is used in the form of fabric or fabrics, with a ratio of warp threads in the direction of the spiral and weft threads across the spiral from 1: 1 to 3: 1, as the polymer binder, an epoxy resin composition of 70 % and phenol form dehydic varnish - 30% with a volume ratio of fabric or fabric threads and polymer binder in the spiral material from 1: 0.37 to 1: 0.57, the curing of the tape spiral composition is carried out in a heat chamber on a mandrel together with a release agent according to the mode: temperature rise to 100 ^o C 3 - 4 hours, temperature rise from 100 to 130 ^o C 2 - 2.5 hours, temperature rise from 130 to 160 ^o C 3 - 3.5 hours, holding at a temperature of 160 ^o C 6 - 6.5 hours , temperature, cooling to 60 ^o C 5 - 6 hours, followed by operations on the blank tape Pick-up Artist helix from the mandrel, it turns with the unwinding odnov TERM peeling separation from their surfaces antiadhesive material and the tape rewinding spiral turns in its original state or the reverse arrangement of coils.  2. The method according to claim 1, characterized in that after heat treatment the ribbon spiral on the mandrel is machined to remove the gloss and form cutouts, grooves, holes and end bevels with a decrease in the width of the tape from the smallest radius of curvature to the largest, and then wound from the mandrel with simultaneous removal of release release and / or heat-shrinkable layers located between the turns of the tape spiral and rewind without release and / or heat-shrink layers in the original state or with the reverse aspolozheniem turns.  3. The method according to claim 1, characterized in that a fluoroplastic film is used as a flexible release material.  4. The method according to claim 1, characterized in that the reinforcing filler is used in the form of fabric or fabrics with satin, linen or twill weaving. 5. A method of manufacturing an elastic flexible tape spiral made of composite materials, which consists in winding a reinforcing filler from systems of threads impregnated with a polymeric binder onto a rotating mandrel, laying flexible release material with anti-adhesive properties between the turns of the tape, heat-treating them together and removing them from the mandrel by unwinding methods, characterized the fact that the winding on the mandrel impregnated with a binder reinforcing filler with the formation of turns of a tape spiral is produced simultaneously with the introduction of m between coils of layers of a spiral, a layer of non-impregnated fabric or tapes, while before the winding process on the mandrel they are simultaneously packaged with the polymer binder melted from opposite sides of the stacked layers by heating rolls at a speed of reinforcing fillers from 0.007 to 0.03 m / s, tension 250 - 700 kgf and the heating temperature in the heating shafts 120 to 150 ^o C and coverage angles moving the mandrel the filler of heating rolls of 120 to 150 ^o C, wherein the reinforcing filler used in the form of a fabric or fabrics Aspect weave warp threads in the direction of the spiral and weft threads across the spiral from 1: 1 to 3: 1; as a polymer binder, a composition of epoxy resin - 70% and phenol-formaldehyde varnish - 30% is used with a volume ratio of fabric or fabric and polymer binder in the material spirals from 1: 0.37 to 1: 0.57, the curing of the composition of the tape spiral is carried out in a heat chamber on a mandrel together with separation heat-shrinkable non-impregnated fabric layers according to the regime: temperature rise to 100 ^o C 3 - 4 h, temperature rise from 100 ^o C up to 130 ^o C 2 - 2 , 5 hours, temperature rise from 130 ^o C to 160 ^o C 3 - 3.5 hours, holding at a temperature of 160 ^o C 6 - 6.5 hours, cooling the temperature to 60 ^o C 5 - 6 hours, followed by operations I remove the strip spiral preform from the mandrel, unwind its coils while peeling layers from their surfaces, a layer of non-impregnated heat-shrink fabric with the formation of surface mesh perforation on the surfaces of the coil coils and rewind the coil coils to the initial state or with the reverse arrangement of coils.  6. The method according to claim 5, characterized in that the layers introduced between the turns of the spiral, the layer of non-impregnated fabric or tapes are made of polyester fabric or tapes with enhanced heat shrink properties.  7. The method according to claim 5, characterized in that as the reinforcing filler use fabric or fabric with satin, linen or twill weave threads.  8. The method according to claim 5, characterized in that after heat treatment the ribbon spiral on the mandrel is machined to remove the gloss and form cutouts, grooves, holes and end bevels with a decrease in the width of the tape from the smallest radius of curvature to the largest, and then wound from the mandrel with at the same time removing the release release and / or heat-shrink layers located between the turns of the tape spiral and rewind without release and / or heat-shrink layers to the original state or with reverse distribution false turns.  9. A device for manufacturing an elastic flexible tape spiral made of composite materials, containing a mandrel connected to a drive for its rotation, a main heating shaft, overhead shafts and belt-mounted tempering mechanisms with bobbin holders installed on the base, characterized in that the base of the tempering mechanisms with bobbin holders is provided with bearing their parallel platforms, made with a slope at an acute angle, the top directed to the mandrel, and an additional heating shaft installed between at a heating main shaft and crossover rollers and located above a plane passing through the main shaft and a heating saddle the upper shaft, or by a plane passing through a heating main shaft and lower shaft saddle.  10. The device according to claim 9, characterized in that on the site under the main heating shaft and / or above it is installed additional tempering mechanisms with bobbin holders for rolls of separating materials, for example fluoroplastic film and / or heat-shrinkable polyester non-impregnated fabrics, and the base of the tempering mechanisms it is additionally equipped with supporting half-timbered platforms installed parallel to the main one, and on which additional holiday mechanisms with bobbin holders of equal, greater or lesser width and height in comparison with the main bobbin holders for woven and / or roving, pre-impregnated and dried to the state of prepreg roll filler.

Images