US20180045341A1

US20180045341A1 - Method and Apparatus of Making Porous Pipes and Panels Using a Treated Fiber Thread to Weave, Braid or Spin Products

Info

Publication number: US20180045341A1
Application number: US15/552,868
Authority: US
Inventors: Michael J. Parrella
Original assignee: Exotex Inc
Current assignee: Exotex Inc
Priority date: 2015-02-23
Filing date: 2016-02-23
Publication date: 2018-02-15
Also published as: US20180044849A1; WO2016137958A1; WO2016137951A1; US11754205B2

Abstract

Porous pipes and porous materials are providing having maximum porosity, together with methods for making the same. The porous materials and pipes have high tensile strength and caustic resistance. The porous pipe may include a fabric layer forming a hollow pipe and made from fiber thread; an epoxy resin bound to the fiber thread; and a plurality of pores formed through the pipe and dispersed along the length of the pipe. The fabric layer can be created by weaving the fiber thread into a woven material; by spinning the fiber thread into a spun material; by knitting the fiber thread into a knit material or by braiding the fiber thread into a braided material.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/119,497, filed Feb. 23, 2015, which is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

Currently, porous pipes are used in oil wells, gas wells, water wells, drainage, and other applications where fluid flow into or out of the pipe is required. An example of an oil well application using a porous pipe is shown in FIG. 1a . In the example shown in FIG. 1a , a porous pipe 100 is positioned in the ground and has porous sections 105 that are designed for the intake of oil into the pipe 100, so it can be pumped to the surface. The porous sections 105 of the pipe 100 are positioned in a sandstone reservoir 120 and a limestone reservoir 130, which are surrounded by shale seals 110 a and 110 b.
The porosity of the porous pipes is created by creating slots or holes in the pipes or materials used in making the pipes to allow flow to occur. FIG. 1b shows an example of a slotted liner 150, comprising a pipe 151 having a plurality of slots 152, according to the prior art. FIG. 1c shows an example of a porous pipe 160, comprising a pipe 161 having a plurality of pores 162, according to the prior art.
For oil wells, a porous structure such as a pipe is usually made of steel. Referring to FIGS. 1b and 1c , the porosity of prior art slotted liners 150 or porous pipes 160 is determined by the number of slots 152 or holes 16 created in the pipe 151, 161. Each additional slot 152 or hole 162 that is created in the pipe to increase flow correspondingly decreases the strength of the pipe material.

SUMMARY OF THE INVENTION

The present invention relates to porous pipes having maximum porosity, and methods for making the same, and to porous materials having high tensile strength and caustic resistance that can be used in the creation of porous pipes or other porous products.
According to a first aspect of the invention, a porous pipe is provided comprising a fabric layer forming a hollow pipe and made from fiber thread; an epoxy resin bound to the fiber thread; and a plurality of pores formed through the pipe and dispersed along the length of the pipe. The fabric layer can be created by weaving the fiber thread into a woven material; by spinning the fiber thread into a spun material; by knitting the fiber thread into a knit material or by braiding the fiber thread into a braided material. According further to the first aspect of the invention, fiber thread can be made from a fiberglass material, a basalt material, or an alternative material.
According to an embodiment of the porous pipe in accordance with the first aspect of the invention, the fiber thread is saturated in the epoxy resin to bind the epoxy resin to the fiber thread prior to creating the fabric layer. The spaces in between the fiber threads that are not filled by epoxy resin form the pores in the pipe.
According to a further embodiment of the porous pipe in accordance with the first aspect of the invention, the fabric layer is saturated in the epoxy resin to bind the epoxy resin to the fiber thread while the fabric layer is created from the fiber thread or after the fabric layer is created from the fiber thread. Air pressure is applied to the fabric layer saturated in the epoxy resin to remove epoxy resin in spaces in between the fiber threads to form the pores in the pipe and then cured.
According further to the first aspect of the invention, the porous pipe further comprises additive materials configured to adjust one or more properties of the porous pipe, the properties including one or more of thermal or electrical conductivity, friction within the pipe, cure time of the pipe during manufacture or improving the binding of the epoxy resin to the fiber threads. The one or more of the additive materials can be combined with the epoxy resin and are applied to the fiber threads simultaneous with the epoxy resin. Additionally or alternatively, one or more additive materials are applied to the fiber threads separately from the epoxy resin. The porous pipe can be configured to have at least two sections along the pipe configured with different properties, including one or more of different pore sizes, thermal or electrical conductivity, friction inside the pipe or structural integrity.
According further to the first aspect of the invention, the epoxy resin of the porous pipe comprises polyamides, bismaleimides and cyanate esters.
The porous pipe according to the first aspect comprising one or more sensors configured to provide feedback on a fluid flow through the porous pipe.
According further to the first aspect of the invention, the pores are provided through the fabric layer along the entire length of the pipe.
According to a second aspect of the present invention, a method for creating a porous pipe is provided. The method for creating the porous pipe comprises forming a fabric layer from a fiber thread, wherein the fabric layer is formed into the shape of a hollow pipe; binding an epoxy resin to the fiber thread; and creating a plurality of pores through the pipe dispersed along the length of the pipe. According to the second aspect of the invention, forming the fabric layer may comprise weaving the fiber thread into a woven material; forming the fabric layer comprises spinning the fiber thread into a spun material; by knitting the fiber thread into a knit material or braiding the fiber thread into a braided material. According further to method of creating porous pipe in accordance with the second aspect of the invention, the fiber thread can be made from a fiberglass material, a basalt material or an alternative material.
According to one embodiment of the method according to the second aspect of the invention, the method further comprises saturating the fiber thread in the epoxy resin to bind the epoxy resin to the fiber thread prior to forming the fabric layer. The spaces in between the fiber threads that are not filled by epoxy resin form the pores in the pipe.
According to a further embodiment of the method according to the second aspect of the invention, the method further comprises saturating the fabric layer in the epoxy resin to bind the epoxy resin to the fiber thread during the formation of the fabric layer from the fiber thread or after the formation of the fabric layer from the fiber thread. The method further comprises applying air pressure to the fabric layer saturated in the epoxy resin to remove epoxy resin in spaces in between the fiber threads to form the pores in the pipe and then curing the pipe.
According further to the method according to the second aspect of the invention, the method further may further comprise providing additive materials configured to adjust one or more properties of the porous pipe, the properties including one or more of thermal or electrical conductivity, friction within the pipe, cure time of the pipe during manufacture or improving the binding of the epoxy resin to the fiber threads. The method may further comprise combining one or more additive materials with the epoxy resin and applying the additive materials to the fiber threads simultaneous with the epoxy resin. Additionally or alternatively, the method may further comprise applying one or more additive materials to the fiber threads separately from the epoxy resin. According to certain embodiments of the method of the second aspect of the invention the method may further comprise providing the porous pipe with at least two sections along the pipe configured with different properties, including one or more of different pore sizes, thermal or electrical conductivity, friction inside the pipe or structural integrity.
According further to the second aspect of the invention, the epoxy resin may comprise polyamides, bismaleimides and cyanate esters.
According further to the second aspect of the invention, the method may further comprise integrating one or more sensors in the porous pipe configured to provide feedback on a fluid flow through the porous pipe.
According further to the second aspect of the invention, the pores are created through the fabric layer along the entire length of the pipe.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1a shows a porous pipe in an oil well in accordance with the prior art;

FIG. 1b shows a slotted liner in accordance with the prior art;

FIG. 1c shows a porous pipe in accordance with the prior art;

FIG. 2a shows a side view of a porous pipe in accordance with an embodiment of the present invention;

FIG. 2b shows an interior view of a porous pipe in accordance with an embodiment of the present invention;

FIG. 2c shows an inner surface of a porous pipe in accordance with an embodiment of the present invention;

FIG. 3 shows an example of a wide woven panel of material with porous flow paths for use in a porous pipe in accordance with the present invention;

FIG. 4 shows an example of a filament fiber in accordance with the present invention;

FIG. 5a shows an example of a satin weave of fiber filament without epoxy resin, in accordance with the present invention;

FIG. 5b shows an example of a tri-axial weave of a fiber filament without epoxy resin, in accordance with the present invention;

FIG. 6a shows an example of a bundled fiber filament without epoxy resin, in accordance with the present invention;

FIG. 6b shows an example of a bundled fiber plain weave of fiber without epoxy resin, in accordance with the present invention;

FIG. 7a shows a first example of a biaxial braided pipe of twisted yarn without epoxy resin, in accordance with the present invention;

FIG. 7b shows a second example of a biaxial braided pipe of twisted yarn without epoxy resin, in accordance with the present invention;

FIG. 8a shows a process for manufacture of porous pipe in accordance with an embodiment of the present invention;

FIG. 8b shows a process for manufacture of porous fiber material in accordance with an embodiment of the present invention;

FIG. 9a shows an example of braiding porous pipe in accordance with the present invention; and

FIG. 9b shows an example of spinning pipe in accordance with the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

The present invention will now be described with reference made to the Figures.
According to the present invention, a fibrous porous pipe is providing having the entire surface area of the porous pipe is made porous. An example of a porous pipe 200 in accordance with the present invention is shown in FIGS. 2a-2c . The amount of porosity is determined by the weave, knit, braid or spin, and the size of the flow paths created. In contrast to the structures of FIGS. 1b and 1c , by providing a pipe according to the teachings hereof that is porous across its entire surface area, flow of fluids through the pipe is increased and maximized.
Using a fiber such as micron basalt filament or E-glass in a weaving, braiding or spinning process with the proper epoxy resin, various products can be created that have porous flow paths for fluids along the entire surface area of a pipe or panel. The porous pipe according to the invention can be created in at least two manners. According to a first method, the porous pipe can be created by treating the fiber threads with epoxy resin before the braiding, knitting, weaving or spinning occurs and not saturating the surface area of the pipe or panel. This leaves flow paths for fluids between the fiber threads and structural strength at the bonding points where the fiber threads meet. According to a second method for creating the porous pipe according to the invention, a pipe is woven from the fibrous material and is saturated with the epoxy resin, and is then subjected to a blower which clears epoxy resin residing between fibers.
The size of the flow paths or pores determines the total porosity of the product. If the pores are small, the pipe or panel can be used for filtering applications.
FIG. 3 shows a woven, braided or spun material 300 of fibers 301 in a grid structure, provided with a wide weave to create flow paths. At the points where the fibers 301 intersect, an epoxy resin bonding point 302 is made to hold the structure 300 together. The amount of epoxy resin is chosen so as to create the desired tensile strength in the structure 300. The space between bonding points 302 allows for fluid flow through pores 303, also referred to as flow paths. For a given grid size, there is a tradeoff in the amount of epoxy used at each bonding point 302. If the space that is occupied by epoxy increases by increasing the amount of epoxy used or decreasing the air pressure applied to the epoxy resin soaked pipe, the strength of the structure increases, but the porosity decreases.
A fiber thread is used that is grooved or cut, which allows epoxy adhesive, which can be made primarily of similar material as the thread to reside internally in the threads to mechanically and chemically bond the joint between fiber threads. The possible fiber base materials include basalt, stainless steel, steel, iron, aluminum, carbon fiber, Teflon, polypropylene (PP), polyethylene (PE), fiberglass such as E-glass, urethane and S-2.
The fiber material allows multiple processing and design formats for combining with the epoxy resin, including spray, transfer molding, soaking or encapsulation to ensure complete adherence and strength created by the use of the base material.
The epoxy resin is used to encapsulate or saturate the woven, non-woven or blended materials, creating a material capable of withstanding high temperatures and pressures, which outperforms prior art materials.
The epoxy resin may consist of 25-75% (by volume) polyamides, 5-25% (by volume) bismaleimides and 2-7% (by volume) cyanate esters. Filler materials can also be included in the volume of the epoxy resin. By mixing these components and adding additive materials, and then treating fiber with the resulting combination, variable product characteristics can be achieved. By adjusting the additives, the product characteristics change. An advantage of the epoxy is its high heat capability and the ability to change the heat and electrical conductivity of the final products, while maintaining the tensile strength of the fiber used.
Additives, such as in the form of fine spheres and/or powdered material, can be mixed with the epoxy base materials to adjust the epoxy resin to the required product specifications.
The additives listed in Table 1 can be used with the epoxy resin to adjust the product characteristics required, and can be used with any of the aforementioned fiber base materials.

TABLE 1

Additives and Respective Primary Impact

Additive	Impact

Phenolics (micrometer spheres)	Insulation (Thermal & Electric)
	Filler
Benzoxazines	Low conductivity - Increase
	adhesiveness
Phthalonitrites (micrometer spheres)	High conductivity
Xeon gas	Allows low temperature
Molybdenum disilicide (coating)	Reduce cost/friction
Boron nitride (coating)	Reduce cost/friction
Methyl	Cure time
Cyanoacrylate	Cure time

The epoxy resin base materials and additives are mixed under a process that controls the production of a strong epoxy bond to the chosen fiber. In one embodiment, the epoxy resin can be sprayed on the mantle of an extrusion or spinning pipe machine or weaving machine, and in doing so, the epoxy resin can be mixed and adjusted with additives of to achieve the planned product specifications. As previously described, the epoxy resin can also be applied to the fiber thread using other methods.
An important condition that must be met is the adhesion of the spheres or other additives that conduct or reject thermal transfer via the epoxy resin. This is accomplished using an epoxy formula that controls the makeup of the material to achieve a product that has excellent resistance to moisture, oxidation, alkaline, shock, acid and solvent. Full encapsulation is accomplished by adding or reducing plasticizers formulated in the epoxy resin.
For high-speed coatings, an epoxy formula of methyl-based or cyanoacrylate-modified additives may be used to adjust the cure time of the product. Each of the coatings positively affects the barcol hardness and fluid dynamics of the surface conditions inside the pipe. Coatings may be applied internally and/or externally to the surface during production. The additives combined with epoxy resin can create adhesion and eliminate the potential of dry lamination between the epoxy and the fabric.
Standard temperature capability ranges may be accomplished, ranging from 250° C. to 700° C. The temperature capability of a planned product can be achieved by parametric entry of data that will instruct the machine manufacturing the material how to control the mixing and application of additives and coatings. The machinery used for creating the porous pipe and material is provided with sensors that verify the adjustments required for each mix and use of the epoxy resin. These sensors may be placed at the extruding location and the form controlling section of the machinery.
Extreme temperature requirements for the finished material may result in an adjustment in the epoxy resin formula, causing some additives to be titanium carbide-based, which will allow for the capacity to reach extreme high temperatures and extreme pressures. Temperature resistances may be reached as high as 2800° F. and can be adjusted to match the requirements of the application.
Sensors, including X-ray and spectral analysis, can determine the chemical reaction within the interchange of the epoxy, the additives and the coatings applied during extrusion. Viscous flow and crystallization may be determined during sample or pilot production once the data has been entered and the epoxy formula is adjusted. Distortion of the crystallization alignment and its orientation are verified and tested during this inspection.
The methods of the present invention for creation of the epoxy with additives allows for the adjustment and control of the flexibility, the modular strength, the sheer, the tensile stress capacities and the complete control of the exposure to high temperature or temperature variances.
Esther linkages may be adjusted by material augmentation to create post-cure relaxation of the combination of epoxy resin and fiber formed in the shape of a round pipe or woven fabric. Off-gas and post-cure time are dependent upon the formula and catalyst of the epoxy resin.
The epoxy resin uses standard, known high temperature materials with the addition of thermal adjustable, encapsulated, coatings and bonded shapes that allow fiber and connectivity to work toward a superior energy output. Cost and existing conditions may be applied to each extrusion.
The thickness, weight and modulus density of the epoxy resin may be reduced to less than the comparative alternative materials. This epoxy fabric material will be adjustable to depth pressure gradients as seen in field applications. The transfer of heat specifically may be customized and tuned to match the requirements and output unit to generate energy.
Coatings of the epoxy resin that are applied to the porous pipe post-cure may be derived of boron nitride or molybdenum disilicide, capable of withstanding temperatures well over 1000° C. to 1200° C. The coating can reduce production cost and reduce friction inside of the porous pipe and be impregnated directly into the epoxy and fabric. The finish and surface design may be adjusted for speed and accuracy in the transfer of fluids flowing through the pipe.
Using the epoxy resin with fillers and additives to create thermal and electric conductivity or non-conductivity can be designed and changed dynamically by selecting the correct percentages of the additives used to create the epoxy. Designed filler materials can be added that will not weaken the composite but add to the variability of the result. Filler materials can be included with the epoxy resin particularly where the cost of the epoxy resin used is high, to reduce the amount of epoxy resin required. Use of the materials and the additives will control mixing, hardening and surface conditioning that will allow for the adjustment to create custom pipes or material weaves to meet each environmental condition and location required for a product.
As the porous pipe is created, different sections of the pipe can be treated with different epoxy resins mixed with different additives. As a result, the properties of the porous pipe can be varied along the length of the pipe. For example, different sections of pipe can be configured to have different levels of thermal conductivity. Epoxy resin ingredients and formula may be blended to thermally adjust to temperature retention or temperature conductivity.
The fibrous thread-like material is woven, knit, braided or spun into a fabric that forms the underlying porous pipe material. Different weaves, braiding and spinning formations change the performance of the products, examples of which are shown in FIGS. 5, 6 and 7. For example, a woven or braided pipe has a higher tensile strength than a spun pipe.
FIG. 5a shows a satin fabric weave 500 a, woven with nine micron basalt filament. The fabric is shown without epoxy resin so as to better show the woven structure. In FIG. 5b , a tri-axial fabric weave 500 b is shown, woven with thirteen micron basalt filament, without epoxy resin.
FIG. 6a shows a bundled eleven micron basalt filament 600 a. In FIG. 6b , a plain weave 600 b is shown using bundled basalt fiber filament, such as bundled filament 600 a. The plain woven fabric 600 b of FIG. 6b is shown without epoxy resin.
FIGS. 7a and 7b show examples of biaxial braided fabric structures without epoxy resin for clarity. FIG. 7a shows a biaxial braided pipe 700 a having a diameter of five centimeters, woven from basalt twisted yarn. FIG. 7b shows a biaxial braided pipe 700 b having a diameter of twenty centimeters, woven from basalt twisted yarn.
Structures woven, knit, braided or spun in such a way, with any of the fibrous base materials described herein shown by way of example, allow for multiple processing and design formats for incorporating epoxy resin including spray, transfer molding, soaking or encapsulation to ensure complete adherence and strength created by the use of this base material. After the fiber is knit, spun, braided or woven and before curing, air pressure can be applied to the created material to clear out epoxy resin that may have collected in the flow paths.
In accordance with the present invention, machines are designed for filament winding, production of pipe and weaving of fabric. Examples are shown in FIGS. 8a and 8b as well as FIGS. 9a and 9 b.
The machinery for creating the porous pipe structure may include a rotating mandrel, plate, beams and may also include an inspection station. Such a machine supports filament placement at varying axes and rotations around the spinning mandrel.
Before spinning or weaving a filament, the filament may be preconditioned and saturated through a bath of epoxy resin formulated with two parts to activate its cure time. As the filament approaches the mandrel or the weaving point, injection ports may be provided to inject or spray thermally conductive (or non-conductive) spheres or powdered materials. Inspection and visual control may be fed back to one or more control systems to control the buildup thickness, strength, elasticity, and size as the pipe or fabric is manufactured. This process is continuous or runs for as long as the materials are provided. The control systems can be programmed to accept and adopt multiple choices of thermally conductive (or non-conductive) material.
According to the present invention, a continuous supply of filament, which can be spooled by a creel of materials chosen by the consumer specifically for an applicable use and site. Before the continuous filament is wound around the mandrel or used for weaving, there are various options for epoxy and filler for attachment to the filament. Full inspection may be conducted through visual sensors, spectral sensors, off gas sensors and other hyper spectral detection methods. The machine process and sensor process controls the hardening and coating to ensure the correct ground insertion and flow characteristics. The control may provide that no harmful off gases are created during the manufacturing process. After the fiber is spun in the mandrel, for example, a blower may be used to apply air pressure to the pipe material to clear out any epoxy resin that may have filled any flow paths.
The pipes can be continuously formed at their full, desired length for at the time of use. Pipes can be manufactured at fixed lengths and seamed or welded as one. Pressure variances will not affect the splicing or lamination to create the extreme length required of these pipes. The porous pipes can also be manufactured in the field to create seamless installations. Pre-woven, braided or spun pipes can be spooled and shipped prior to application of the epoxy resin, and the porous pipe manufacturing can be completed on-site. Similarly, spooled threads of fibrous material can be provided for use in manufacturing the porous pipe on-site.
Wrap angles are variable on such machines, and allow for adjustment of strength in coordination with pressure and strength requirements. Filament density enhances the wrap angle to accomplish additional strengths.
Machinery required to create the porous pipes from its woven material may be small and portable. Such portable manufacturing machines can be moved to a jobsite so the logistic cost of production can be greatly reduced. Such production machines will have elongation, non-conductivity or conductivity properties, high specific strengths and elastic energy absorption. Pressure resistance may be created by modification within the program of such a machine.
Because epoxy resin is embedded in the fabric, machined threading may be applied so as to enable splicing if necessary. These machined ends can be accomplished on the machine to the API 5B standard. In this way, breakage and failure will be at its minimal. Inspection may be maintained during the construction of pipe of any fonn to ensure the quality of each pipe.
Use of fillers and additives to create thermal and electric conductivity or non-conductivity can be designed and changed dynamically during the manufacturing process. Fillers of materials can be added that will not weaken the composite, but add to the variability of the result. Use of materials and their additives that will control mixing, hardening and surface conditioning will allow for the adjustment to create custom pipe or material weave to meet each environmental condition and location.
FIG. 8a shows an exemplary manufacturing process used for porous pipes and FIG. 8b shows an exemplary manufacturing process used for creating porous material, which can be used for the porous pipes or applications other than the porous pipes. Both figures include the process for creating the required fiber thread. These methods can be performed using any combination of the techniques (knitting, braiding, spinning or weaving), and fiber base materials, additives and epoxy resin described herein, or other materials that a person of skill in the art would find suitable for achieving the same purpose.
FIGS. 8a and 8b depict machinery that produces fiber pipe and woven material seamlessly to meet the following submitted flexible parameters: length, tensile strength, diameter, thickness, thermal characteristics, electrical characteristics, chemical resistance, flexibility, capacity, pressure, portability.
The amount of additives to achieve particular advantages may vary in cost and application. The combination of fibrous material with epoxy resin and additives allows material design to match different applications and thus reduce the high cost previously associated with pipe processing. The cost of both an epoxy-based high temperature resin and a high temperature fiber will allow low-cost and high-volume manufacturing of porous pipe.
Referring now to FIG. 8a in detail, each of the numbered steps in a process for manufacturing porous fiber pipe is shown as follows:
In step 801 a, the initial fiber material is collected and provided to the manufacturing machinery. In a preferred embodiment, the initial fiber material can be E-glass. Other materials may be used in further embodiments, such as basalt, stainless steel, steel, iron, aluminum, carbon fiber, Teflon, polypropylene (PP), polyethylene (PE), urethane and S-2. In step 802 a, the material is crushed by a crusher and treated. The crushed and treated material is then provided to a centrifuge, where it is spun and heated in step 803 a. While the material is being spun in the centrifuge, any additive materials that are to be included in order to alter one or more properties of the final product as described previously can be added in step 804 a. After the fiber material is spun and heated in step 803 a, in step 805 a, a thread die forms the fiber into a thread. Prior to beginning the pipe spinning process, the fiber thread can be spooled in step 806 a. Alternatively, the fiber thread can be fed directly into the pipe knitting, spinning, weaving and braiding process.
In step 807 a ₁, additives can be supplied as described herein, to saturate the thread before it is spun, knit, braided or woven. According to one embodiment of the invention, the epoxy resin may also be supplied at this stage, prior to forming the pipe structure, to saturate the threaded material.
In step 807 a ₂, the thread is formed into a pipe. The thread can be braided, knit, woven or spun into a number of patterns as previously described, including plain, satin, twill, crowfoot, flat, biaxial or tri-axial. The diameter of the pipe is dependent on the changeable mandrel (809 a). A different mandrel is used for different pipe sizes.
In step 808 a, the epoxy resin is added, if not added prior to the formation of the pipe structure. The epoxy resin can be applied to the fiber threads while the pipe is being woven, knit, spun or braided, such as by coating the mandrel, or applied after the pipe is formed. The epoxy resin may also be mixed with one or more additives in addition to or in lieu of providing additives in step 807 a ₁. In step 810 a, a blower is used to clear any epoxy resin that may have collected in the pores between fiber threads by applying air pressure is applied to the saturated pipe. The application of air pressure can vary in duration or amount over the length of the pipe so that some sections of pipe may have a pore size that differs from other sections of the pipe.
In step 811 a, the completed and uncured pipe, if necessary, can now be shaped. A hydraulic press produces force against the rollers that shape the pipe. In step 812 a, rollers may be used to apply force to shape the soft pipe. The shape of the pipe may vary depending on the number of rollers utilized. Two rollers create an oblong shape, three rollers create a triangular shape and four rollers create a rectangular shape. After the shaping of the pipe, curing and coating of the pipe and potential sensor insertion occurs in step 813 a. Coatings can enhance the features of the pipes. Sensor insertion can create a product that can report back information during operating conditions while the porous pipe is in use. Curing can vary depending on the composition of the pipe which could include ultraviolet treatment, heat treatment, or other methods of curing. In step 814 a, the pipe can be cut into the appropriate lengths. Cutting does not need to occur in certain instances; such as if the pipe created is for laying continuous pipe with a portable fabrication unit.
A control system 815 a monitors and controls all the steps in the fabrication process. It accepts control input (parameters) for the timing and control of all events. The control system may comprise a non-transitory computer readable medium stored with a computer program and a processor configured to cause the execution of the program, which specifies the buildup construction of each and every product. The program can vary the fiber, the epoxy, the catalysts and open time as well as thermal condition specifically located on each and every product.
Referring now to FIG. 8b in detail, each of the numbered steps in a process for manufacturing porous fiber material is shown as follows:
In step 801 b, the initial fiber material is collected and provided to the manufacturing machinery. In a preferred embodiment, the initial fiber material can be E-glass. Other materials may be used in further embodiments, such as basalt, stainless steel, steel, iron, aluminum, carbon fiber, Teflon, polypropylene (PP), polyethylene (PE), urethane and S-2. In step 802 b, the material is crushed by a crusher and treated. The crushed and treated material is then provided to a centrifuge, where it is spun and heated in step 803 b. While the material is being spun in the centrifuge, any additive materials that are to be included in order to alter one or more properties of the final product as described previously can be added in step 804 b. After the fiber material is spun and heated in step 804 b, in step 805 b, a thread die forms the fiber into a thread. Prior to beginning the material formation process, the fiber thread can be spooled in step 806 b. Alternatively, the fiber thread can be fed directly into the material formation process.
In step 807 h ₁, additives can be supplied as described herein used to saturate the fabric before it is knit, spun, braided or woven. According to one embodiment of the invention, the epoxy resin may also be supplied at this stage to saturate the threaded material.
In step 807 b ₂, the thread is woven, knit, spun or braided into material the size of the material is dependent on the capabilities of the process used. The dimensions of the material are determined by the process used. Different techniques and machines can be used for different material sizes.
In step 808 h, the epoxy resin can be added, if not previously added before the weaving/spinning/knitting/braiding step. The epoxy resin can be applied to the fiber threads while the material is being woven, spun knit or braided, or applied after the material is formed. The epoxy resin may also be mixed with one or more additives in addition to or in lieu of providing additives in step 807 b ₁. In step 809 b, a blower applies air pressure to the material to clear out any epoxy resin that may have collected in the flow paths. The application of air pressure can vary in duration or amount over the length of the material so that some sections of the material may have a pore size that differs from other sections of the material.
The completed and uncured material, if necessary, can now be shaped in step 810 b. In step 811 lb, a hydraulic press produces force against a stamping tool that shapes the material. In step 812 b, the stamping tool applies force to shape the soft material. After the shaping, the curing, coating and sensor insertion occur, as needed by the material to be formed, in step 813 b. Coatings can enhance the features of the material while in use. Sensor insertion can create material that can report back information during operating conditions. Curing can vary depending on the composition of the pipe which could include ultraviolet treatment, heat treatment or other methods of curing. In step 814 b, the material can be cut into the proper lengths or dimensions. Cutting does not occur in certain instances, such as if creating rolls of material.
A control system 815 b monitors and controls all the steps in the fabrication process. It accepts control input (parameters) for the timing and control of all events. The control system may comprise a non-transitory computer readable medium stored with a computer program and a processor configured to cause the execution of the program, which specifies the buildup construction of each and every product. The program can vary the fiber, the epoxy, the catalysts and open time as well as thermal condition specifically located on each and every product. The control system 815 a or 815 b can be configured to: thin, thicken and change weave orientation dynamically per entered parametric values to create strength, flexibility and thermal characteristics; monitor temperature, density and refresh rates for quality control; be parametrically controlled for external input to build pipe and/or material to exact performance requirements; match flow rate to maintain thermal range, tension of surrounding materials, corrosive resistance and other properties to insure product stability; compensate for angle, depth and longevity via surface tension; allow for dynamic shape adjustments to allow for product variability; allow for a unique die design during manufacturing of the material for product shaping; allow for variable curing techniques like: ultra-violate, heat and chemical treatment; allow for coating of one or both sides of the pipe and/or material for additional performance features; allows for designed pushing or insertion pressure at the mandrel to control and balance the process to eliminate any damage; allow for the cutting or continuous fabrication depending on requirements; allow for product use immediately after fabrication with an initial cure period of, for example, 24 hours and permanent curing after, for example, 7 days; and allow for pultruding or extruding at high feed rate.
FIG. 9a shows a braiding pipe process and FIG. 9b shows a spinning pipe process.
The product characteristics, which can vary depending on the presence of further additives, include: high strength, light weight, stability, moisture, fire and chemical resistance, thermal and electric conductivity, adjustable thermal conductivity, elasticity, resistance to stress corrosion, resistance to oil field chemicals, easy spooling, on-site manufacturability, ductile behavior, flexibility, cost effectiveness, high elongation, elastic energy absorption, resistance to electromagnetic interference, variable insulation property and zero delamination potential.
Example characteristics of a porous material and pipe made from a basalt fiber are shown in Tables 2-4.

TABLE 2

Material Characteristics

	Melting Point (lava)	2800° F.
	Operating Range	−40 C. to 580° C.
	Surface Density	140-380 g/m²
	Thickness	.05 inches (or variable)
	Breaking Load	500-1400 kg
	Flexural Strength	110-134+ ksi
	Width standard	4.0-120 inches
	Width optional	4.0-120 inches
	Plain weave	1 thread × 1 thread, 5 threads × 3
		threads
	Twill weave	2 threads × 1 thread, 3 threads ×
		1 thread, 5 threads × 3 threads
	Crowfoot weave	1 thread × 1 thread, 5 threads × 3
		threads
	Flat weave	4 threads × 5 threads
	Bi-axial	5 threads × 5 threads

TABLE 3

Pipe Characteristics

	Melting Point	2,800° F.
	Operating Range	−40 to 580° C.
	Pipe diameter	1 inch to 80 inches
	Surface density	140-380 g/m²
	External Pressure	7,800 psi
	Internal Pressure	40-500 bar (580-12,250 psi)
	Thickness	Variable
	Breaking Load	500-1400 kg

According to the teachings hereof, by using advanced fiber and material concepts to create porous products, such as pipes, there is a significant reduction in the weight and cost of the product, and a significant increase in strength and caustic/abrasion resistance. Table 4 shows a listing of chemicals and temperatures at which the woven material according to the invention did not suffer any attack.

TABLE 4

Causticity Testing

	Chemical	Temperature (° C.)

	Ammonia Liquid	250
	Acetic Acid (Conc.)	200
	Benzene	100
	Brake Fluid	250
	Ethylene Glycol (50% Aq.)	250
	Hydrochloric Acid (12%)	100
	Hydrogen Sulfide (gas)	250
	Hydraulic Fluid	30
	Heavy Aromatic Naphtha (100%)	250
	Jet A Fuel	30
	Methanol	100
	Methane Gas	250
	Petroleum Oil	100
	Sea Water	250
	Sodium Bisulfite (50% Aq.)	250
	Sodium Hydroxide (50%)	250

While there have been shown and described and pointed out fundamental novel features of the invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices and methods described may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice.

Claims

What is claimed:

1. A porous pipe comprising:

a fabric layer forming a hollow pipe and made from fiber thread;

an epoxy resin bound to the fiber thread; and

a plurality of pores formed through the pipe and dispersed along the length of the pipe.

2. A porous pipe in accordance with claim 1, wherein the fabric layer is created by weaving the fiber thread into a woven material.

3. A porous pipe in accordance with claim 1, wherein the fabric layer is created by spinning the fiber thread into a spun material.

4. A porous pipe in accordance with claim 1, wherein the fabric layer is created by braiding the fiber thread into a braided material.

5. A porous pipe in accordance with any of claims 2 through 4, wherein the fiber thread is saturated in the epoxy resin to bind the epoxy resin to the fiber thread prior to creating the fabric layer.

6. A porous pipe in accordance with claim 5, wherein the spaces in between the fiber threads that are not filled by epoxy resin form the pores in the pipe.

7. A porous pipe in accordance with any of claims 2 through 4, wherein the fabric layer is saturated in the epoxy resin to bind the epoxy resin to the fiber thread while the fabric layer is created from the fiber thread or after the fabric layer is created from the fiber thread.

8. A porous pipe in accordance with claim 7, wherein air pressure is applied to the fabric layer saturated in the epoxy resin to remove epoxy resin in spaces in between the fiber threads to form the pores in the pipe and then cured.

9. A porous pipe in accordance with any of claims 5 through 8, wherein the fiber thread is made from a fiberglass material.

10. A porous pipe in accordance with any of claims 5 through 8, wherein the fiber thread is made from a basalt material.

11. A porous pipe in accordance with any of claim 9 or 10, further comprising additive materials configured to adjust one or more properties of the porous pipe, the properties including one or more of thermal or electrical conductivity, friction within the pipe, cure time of the pipe during manufacture or improving the binding of the epoxy resin to the fiber threads.

12. A porous pipe in accordance with claim 11, wherein one or more of the additive materials are combined with the epoxy resin and are applied to the fiber threads simultaneous with the epoxy resin.

13. A porous pipe in accordance with claim 11 or 12, wherein one or more additive materials are applied to the fiber threads separately from the epoxy resin.

14. A porous pipe in accordance with claim 11, wherein the porous pipe is configured with at least two sections along the pipe configured with different properties, including one or more of different pore sizes, thermal or electrical conductivity, friction inside the pipe or structural integrity.

15. A porous pipe in accordance with claim 1, wherein the epoxy resin comprises polyamides, bismaleimides and cyanate esters.

16. A porous pipe in accordance with claim 1, further comprising one or more sensors configured to provide feedback on a fluid flow through the porous pipe.

17. A porous pipe in accordance with claim 1, wherein the pores are provided through the fabric layer along the entire length of the pipe.

18. A method for creating a porous pipe, comprising:

forming a fabric layer from a fiber thread, wherein the fabric layer is formed into the shape of a hollow pipe;

binding an epoxy resin to the fiber thread; and

creating a plurality of pores through the pipe dispersed along the length of the pipe.

19. A method for creating a porous pipe in accordance with claim 18, wherein forming the fabric layer comprises weaving the fiber thread into a woven material.

20. A method for creating a porous pipe in accordance with claim 18, wherein forming the fabric layer comprises spinning the fiber thread into a spun material.

21. A method for creating a porous pipe in accordance with claim 18, wherein forming the fabric layer comprises braiding the fiber thread into a braided material.

22. A method for creating a porous pipe in accordance with any of claims 19 through 21, further comprising saturating the fiber thread in the epoxy resin to bind the epoxy resin to the fiber thread prior to forming the fabric layer.

23. A method for creating a porous pipe in accordance with claim 22, wherein the spaces in between the fiber threads that are not filled by epoxy resin form the pores in the pipe.

24. A method for creating a porous pipe in accordance with any of claims 19 through 21, further comprising saturating the fabric layer in the epoxy resin to bind the epoxy resin to the fiber thread during or after the formation of the fabric layer from the fiber thread.

25. A method for creating a porous pipe in accordance with claim 24, further comprising applying air pressure to the fabric layer saturated in the epoxy resin to remove epoxy resin in spaces in between the fiber threads to form the pores in the pipe and then curing the pipe.

26. A method for creating a porous pipe in accordance with any of claims 22 through 25, wherein the fiber thread is made from a fiberglass material.

27. A method for creating a porous pipe in accordance with any of claims 22 through 25, wherein the fiber thread is made from a basalt material.

28. A method for creating a porous pipe in accordance with any of claim 26 or 27, further comprising providing additive materials configured to adjust one or more properties of the porous pipe, the properties including one or more of thermal or electrical conductivity, friction within the pipe, cure time of the pipe during manufacture or improving the binding of the epoxy resin to the fiber threads.

29. A method for creating a porous pipe in accordance with claim 28, further comprising combining one or more additive materials with the epoxy resin and applying the additive materials to the fiber threads simultaneous with the epoxy resin.

30. A method for creating a porous pipe in accordance with claim 28 or 29, further comprising applying one or more additive materials to the fiber threads separately from the epoxy resin.

31. A method for creating a porous pipe in accordance with claim 28, further comprising providing the porous pipe with at least two sections along the pipe configured with different properties, including one or more of different pore sizes, thermal or electrical conductivity, friction inside the pipe or structural integrity.

32. A method for creating a porous pipe in accordance with claim 18, wherein the epoxy resin comprises polyamides, bismaleimides and cyanate esters.

33. A method for creating a porous pipe in accordance with claim 18, further comprising integrating one or more sensors in the porous pipe configured to provide feedback on a fluid flow through the porous pipe.

34. A method for creating a porous pipe in accordance with claim 18, wherein the pores are created through the fabric layer along the entire length of the pipe.