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WO2025242693A1 - Ruban, tuyau thermoplastique renforcé comprenant le ruban, et procédé de fabrication et d'utilisation du ruban - Google Patents

Ruban, tuyau thermoplastique renforcé comprenant le ruban, et procédé de fabrication et d'utilisation du ruban

Info

Publication number
WO2025242693A1
WO2025242693A1 PCT/EP2025/063897 EP2025063897W WO2025242693A1 WO 2025242693 A1 WO2025242693 A1 WO 2025242693A1 EP 2025063897 W EP2025063897 W EP 2025063897W WO 2025242693 A1 WO2025242693 A1 WO 2025242693A1
Authority
WO
WIPO (PCT)
Prior art keywords
tape
fibres
rtp
array
thermoplastic
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/EP2025/063897
Other languages
English (en)
Inventor
Recep YALDIZ
Faisal Abdulaziz AL-MANA
Ali Mohammed S ALGHAMDI
Yousof Mustafa GHAZZAWI
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SABIC Global Technologies BV
Original Assignee
SABIC Global Technologies BV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by SABIC Global Technologies BV filed Critical SABIC Global Technologies BV
Publication of WO2025242693A1 publication Critical patent/WO2025242693A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/105—Coating or impregnating independently of the moulding or shaping step of reinforcement of definite length with a matrix in solid form, e.g. powder, fibre or sheet form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D23/00—Producing tubular articles
    • B29D23/001—Pipes; Pipe joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B32B1/08—Tubular products
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L9/00—Rigid pipes
    • F16L9/16—Rigid pipes wound from sheets or strips, with or without reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2597/00—Tubular articles, e.g. hoses, pipes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L9/00—Rigid pipes
    • F16L9/12—Rigid pipes of plastics with or without reinforcement
    • F16L9/127—Rigid pipes of plastics with or without reinforcement the walls consisting of a single layer
    • F16L9/128—Reinforced pipes

Definitions

  • TITLE A tape, a reinforced thermoplastic pipe comprising the tape, and a method of manufacturing and uses of the tape
  • the present disclosure relates to a tape, a reinforced thermoplastic pipe (RTP) comprising the tape, a method of manufacturing the tape and to uses of the tape.
  • RTP reinforced thermoplastic pipe
  • fibre-reinforced polymer compositions are composite materials with a wide range of applications in industry, for example in the automotive industry.
  • the term "composite” can apply to any combination of individual materials, for example to a thermoplastic polymer (the matrix) in which fibres (reinforcing filler) have been dispersed.
  • the reinforced plastics industry has used glass fibres and fibrous textiles in different forms for reinforcing polymer matrices to produce a diversity of products.
  • Fibre-reinforced thermoplastic UD tapes are endless tapes that are reinforced with continuous fibres, wherein the fibres, e.g., glass, basalt, or carbon fibres, are unidirectionally aligned and embedded (covered/dispersed) in a thermoplastic material of the tape.
  • the UD tapes are often used in spoolable reinforced thermoplastic pipes (RTPs), that are for example used for transporting fluids, like hydrocarbon fluids.
  • RTPs are sought in oil and gas transport to replace carbon steel pipes, which have the tendency to corrode.
  • An RTP usually comprises an inner liner, through which the hydrocarbon fluid flows, an outer jacket, and, positioned between the inner liner and the outer jacket, a reinforcement layer.
  • the reinforcement layer comprises the UD tape.
  • thermoplastic materials that are used in the different layers of the RTP may not be completely impermeable to the components in the fluid, for example a hydrocarbon fluid like oil, that flows through the RTP.
  • a hydrocarbon fluid like oil
  • oil contains aliphatic and aromatic hydrocarbons, but also CH 4 , H 2 S, CO 2 and H 2 O.
  • gases can migrate through the inner liner and/or the reinforcement layer and accumulate at the interfaces between the layers of the RTP, thus for example at the interface between the inner liner and the reinforcement layer. The accumulation of these gases may cause delamination and/or ballooning/swelling issues.
  • the reinforcing fibres are susceptible to attack by water and acidic gases like H 2 S and CO 2 . These destroy the strength of the fibres and thus, weaken the RTP’s integrity.
  • EP 1473132 A2 relates to materials and methods for producing preform materials for impact-resistant composite materials suitable for liquid moulding.
  • An interlayer comprises a spunbonded, spun laced, or mesh fabric is introduced between noncrimped layers of unidirectional reinforcing fibres o produce a preform for use in liquidmoulding processes to produce composite materials.
  • EP O 504 708 A 1 relates to a fibre reinforced plastics hollow object consisting of a resin-impregnated winding of high-strength fibres using a curing resin.
  • RTP reinforced transportation pipe
  • a tape comprising an array of a plurality of longitudinally oriented fibres, wherein said array of fibres has two longitudinal sides, wherein one longitudinal side of the array is at least partially covered by a thermoplastic material.
  • the channels present between the longitudinally oriented fibres in the tape allow moisture and corrosive gases that diffuse through polymeric material of one or more layers of an RTP, e.g., the thermoplastic inner liner, the reinforcing layer, and the thermoplastic outer jacket, to be removed at such a rate before accumulation of the moisture and corrosive gases, such as acidic gases like H 2 S and CO 2 , at interfaces between the layers of the RTP can cause damage to said RTP.
  • an RTP e.g., the thermoplastic inner liner, the reinforcing layer, and the thermoplastic outer jacket
  • the invention in a second aspect, relates to a reinforced transportation pipe (RTP) configured for transporting fluids, said RTP comprising from a centre to a periphery a thermoplastic inner liner, a reinforcing layer comprising at least one layer of helically wound tape according to claim 1 , and a thermoplastic outer jacket, wherein said tape has a longitudinal side facing towards the periphery of the RTP and a longitudinal side facing towards the centre of the RTP, wherein on the other longitudinal side of the array channels are present which channels are each defined by two adjacent longitudinally oriented fibres, the thermoplastic material of said tape and one of the thermoplastic inner liner, the thermoplastic outer jacket and thermoplastic material of another layer of helically wound tape in said reinforcing layer, which channels allow for the transport of one or more gases along a helical direction of the RTP.
  • RTP reinforced transportation pipe
  • the invention relates to a method of manufacturing a tape according to the first aspect, comprising the steps of:
  • thermoplastic material 1) providing the thermoplastic material
  • thermoplastic material melt 2) melt compounding the thermoplastic material provided in step 1) in an extruder, preferably at 230 to 360 °C, to obtain a thermoplastic material melt;
  • step 3 providing the array comprising the plurality of longitudinally oriented fibres; 4) contacting the one longitudinal side of the array of fibres provided in step 3) with the thermoplastic material melt obtained in step 2), such that the one longitudinal side of the array of fibres is covered by the thermoplastic material melt and subsequently solidifying to obtain the tape.
  • the invention relates to a use of a tape according to the first aspect or manufactured according to the method according to the third aspect for a reinforced thermoplastic pipe (RTP) configured for transporting of fluids.
  • RTP reinforced thermoplastic pipe
  • the invention relates to a use of a tape according to the first aspect of manufactured according to the method according to the third aspect for transporting one or more gases that accumulate in channels present on the other longitudinal side of the array of fibres along a helical direction of a reinforced thermoplastic pipe (RTP).
  • RTP reinforced thermoplastic pipe
  • non-polar polymer is meant a type of polymer that lacks significant polar functional groups or has a symmetrical molecular structure that results in an even distribution of charge.
  • the electronegativity of the atoms involved is relatively balanced, leading to a lack of a net dipole moment within the polymer molecule.
  • Non-polar polymers typically exhibit properties such as low surface energy, resistance to polar solvents, and lower reactivity with other polar substances. They are often used in applications where these characteristics are advantageous, such as in packaging materials, insulating coatings, and non-stick surfaces.
  • polyolefin is meant a polymer of olefin monomers, having the general formula (CH 2 CHR) n where R is an alkyl group.
  • examples are polyethylene, polypropylene, and polymethylpentene.
  • PE polyethylene which is according to the structure below:
  • PE is usually a mixture of similar polymers of ethylene, with various values of n. It is a thermoplastic, non-polar polymer and can be low-density or high-density and many variations thereof. PE is relatively cheap and therefore commonly employed in packaging materials, containers, and various plastic products.
  • PP polypropylene which is according to the structure below:
  • PP is a thermoplastic, non-polar polymer and is very similar to PE, but a much stronger polymer. Like PE, it is a relatively cheap polymer making it a popular choice in manufacturing.
  • PMP polymethylpentene which is according to the structure below:
  • PMP is a thermoplastic, non-polar polymer that has high heat resistance and low density. It has similar properties of PE and PP, although it is more brittle and more gas permeable.
  • PTFE polytetrafluoroethylene according to the structure below:
  • Polytetrafluoroethylene is a fluorocarbon solid, as it is a high-molecular-weight polymer consisting wholly of carbon and fluorine.
  • PPS polyphenylene sulphide
  • the at least one non-polar polymer is selected from the group consisting of a polyolefin - such as polyethylene (PE), polypropylene (PP) and polymethylpentene (PMP) - polytetrafluoroethylene (PTFE), polyphenylene sulphide (PPS), polyphenylene oxide (PPO), and a combination of two or more thereof, preferably a polyolefin, such as polyethylene (PE) and polypropylene (PP).
  • a polyolefin - such as polyethylene (PE), polypropylene (PP) and polymethylpentene (PMP) - polytetrafluoroethylene (PTFE), polyphenylene sulphide (PPS), polyphenylene oxide (PPO), and a combination of two or more thereof, preferably a polyolefin, such as polyethylene (PE) and polypropylene (PP).
  • polar polymer is meant a type of polymer that contains polar functional groups or asymmetric structures, leading to an uneven distribution of charge within the polymer molecule.
  • Polar functional groups typically involve electronegative atoms, such as oxygen, nitrogen, or fluorine, which create regions of partial negative and positive charges within the molecule.
  • the thermoplastic material comprises at least one polar polymer, such as polyester, polyamide, aliphatic polyketone, aromatic polyketone, polyurethane, polyether sulfone, polyetherimide, polyvinyl chloride, polyvinylidene fluoride, polyvinyl acetate, polyacrylonitrile, polycarbonate.
  • polar polymer such as polyester, polyamide, aliphatic polyketone, aromatic polyketone, polyurethane, polyether sulfone, polyetherimide, polyvinyl chloride, polyvinylidene fluoride, polyvinyl acetate, polyacrylonitrile, polycarbonate.
  • polyester is meant a polymer that contains an ester functional group in every repeat unit of their main chain and is according to the structure below:
  • polyesters are polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, and liquid-crystal polyester.
  • PET polyethylene terephthalate according to the structure below:
  • PET is a thermoplastic, polar polymer that consists of repeating (CI 0 H 8 O 4 ) units. It was formerly produced from ethylene glycol (monoethylene glycol, MEG) and dimethyl terephthalate (DMT) but mostly produced now by the reaction of MEG with terephthalic acid (purified terephthalic acid, PTA).
  • MEG monoethylene glycol
  • DMT dimethyl terephthalate
  • PBT polybutylene terephthalate according to the structure below:
  • PBT is a thermoplastic, polar polymer that is closely related to PET. Compared to PET, PBT has slightly lower strength and rigidity, slightly better impact resistance, and a slightly lower glass transition temperature.
  • PEN polyethylene naphthalate according to the structure below: PEN is a thermoplastic, polar polymer derived from naphthalene-2,6-dicarboxylic acid and ethylene glycol (MEG). It is related to PET, but with superior barrier properties.
  • liquid-crystal polyester which is a polymer having the property of forming a liquid crystal melt, usually containing aromatic rings as mesogens.
  • meogen is meant a compound that displays liquid crystal properties and can best be described as disordered solids or ordered liquids because they arise from a unique state of matter that exhibits both solid- and liquid-like properties called the liquid crystalline state.
  • polyamides a polymer comprising amide bonds.
  • polyamides such as aliphatic polyamides, aromatic polyamides or polyphthalamides. Examples are polyamide 11 and polyamide 12.
  • PA11 polyamide 11 , also known as nylon 11 , according to the structure below:
  • PA11 is a type of synthetic polyamide known for its high strength, flexibility, and chemical resistance.
  • PA12 polyamide 12, also known as nylon 12, according to the structure below:
  • PA12 is a versatile thermoplastic polymer valued for its flexibility, impact resistance, and chemical stability.
  • aliphatic polyketone a polyketone comprising aliphatic comonomer(s) (POK), such as carbon monoxide, ethylene, and propylene monomers, according to the structure below:
  • POK aliphatic comonomer(s)
  • POK polyketone polymer that is built from aliphatic comonomers.
  • POKs are a family of thermoplastic polymers comprising polar ketone groups in the polymer backbone. They are prepared by polymerizing carbon monoxide with an olefin as comonomer (e.g., ethylene). POK come in different types depending on 1) the number of comonomers and; 2) the types of comonomer(s). When one olefin comonomer is used the term copolymer is often used and when two olefin comonomers are used the term terpolymer is often used.
  • the two most common types of aliphatic POK are copolymers built from the monomers carbon monoxide and ethylene (R being hydrogen), and terpolymers built from the monomers carbon monoxide, ethylene, and a second olefin comonomer which can be propylene, butylene (e.g., 1-butene), hexylene, octene, or dodecene (in the comonomers, R is methyl, butyl, hexyl, octyl, or dodecyl).
  • R being hydrogen
  • a second olefin comonomer which can be propylene, butylene (e.g., 1-butene), hexylene, octene, or dodecene (in the comonomers, R is methyl, butyl, hexyl, octyl, or do
  • POKs have polar ketone groups in the polymer backbone and the presence of these ketone groups provides strong attraction between polymer chains, which increases the material’s melting point to about 260 °C for the copolymer (having carbon monoxide and ethylene monomers) and about 220 °C for the terpolymer (having carbon monoxide, ethylene, and propylene monomers).
  • aromatic polyetherketone a polyetherketone comprising comonomer(s) having aromatic groups (PEK).
  • PEKs are polymers whose backbone contain alternating ketone (R-CO-R) and ether (R-O-R) functionalities. The most common are PAEKs.
  • PAEK polyaryletherketone. This is a family of PEK whose molecular backbone contains alternately ketone (Aryl-CO-Aryl) and ether groups (Aryl-O-Aryl), wherein Aryl is a 1 ,4-substituted aryl group. These polymers are semi-crystalline thermoplastics with high-temperature stability and high mechanical strength.
  • PEEK polyetheretherketone according to the structure below:
  • PEEK is a PEK, more specifically of the PAEK family.
  • PEEK is a semicrystalline thermoplastic with excellent mechanical and chemical resistance properties that are retained to high temperatures. The processing conditions used to mould PEEK can influence the crystallinity and hence the mechanical properties.
  • PEKK polyetherketoneketone according to the structure below:
  • PEKK is also a PEK, more specifically of the PAEK family.
  • PEKK is a semicrystalline thermoplastic with excellent mechanical and chemical resistance properties that are retained to high temperatures.
  • PU polyurethane, also often abbreviated as PUR. It is a class of polymers composed of organic units joined by carbamate (urethane) links. It can be produced from a wide range of starting materials leading to a variety of polyurethanes with different chemical structures and thus, different properties.
  • An example of a PU is the structure below:
  • PU is typically produced by reacting an isocyanate with a polyol (resulting in the polyurethane structure above). Since a polyurethane contains two types of monomers, which polymerize one after the other, they are classed as alternating copolymers. Both the isocyanates and polyols used to make a polyurethane contain two or more functional groups per molecule.
  • polyethersulfone according to the structure below. This is a thermoplastic polymer comprising ether bonds, aromatic rings, and sulfone bonds in the backbone:
  • PVC polyvinylchloride according to the structure below:
  • PVC is produced by polymerization of the vinyl chloride monomer (VCM). The presence of the chloride groups gives the polymer very different properties from the structurally related PE.
  • PVDF polyvinylidene fluoride, being a fluorinated type of polyolefin. It has the following structure:
  • PVDF is a thermoplastic fluoropolymer produced by the polymerization of vinylidene difluoride.
  • PVA polyvinyl acetate according to the structure below:
  • PC polycarbonate according to the structure below:
  • PC is a group of thermoplastic polymers containing carbonate groups in their chemical structures.
  • the main PC material is produced by the reaction of bisphenol A (BPA) and phosgene (COCI 2 ).
  • BPA bisphenol A
  • COCI 2 phosgene
  • An alternative route to produce PC entails transesterification from BPA and diphenyl carbonate.
  • the thermoplastic material may have: a melt mass-flow rate (MFR) of at least 30 g/10min, preferably at least 60 g/10min, more preferably at least 100 g/10min, most preferably between 30 and 150 g/10min measured at 240 °C with a load of 2.16 kg according to ASTM D1238-23; and/or a viscosity of at most 100 Pa s, preferably at most 70 Pa s, measured about 20 °C above the melting temperature of the composition according to ISO 6721.
  • MFR melt mass-flow rate
  • the MFR of a polyamide or polyester can be adjusted by controlling the moisture present in the melt by selecting the drying time of the polar polymer.
  • the MFR of a PP can be adjusted by controlling its molecular weight by 'cracking' of the PP.
  • each of said non-polar and polar polymers preferably has a viscosity of from about 50 to about 100 Pa s, measured at 240 °C according to ISO 6721.
  • said thermoplastic material comprises at least one non-polar polymer, at least one polar polymer, or a polymer blend of at least one non-polar polymer and at least one polar polymer, preferably said thermoplastic material comprises polyethylene (PE) or polypropylene (PP).
  • PE polyethylene
  • PP polypropylene
  • the fibres in the array which may be reinforcing fibres, are covered by the thermoplastic material, preferably such that they are unidirectionally aligned in the thermoplastic material in order to obtain the fibre-reinforced thermoplastic tape according to the first aspect of the invention.
  • the fibres may be selected from the group consisting of glass fibres, carbon fibres, basalt fibres, ceramic fibres, aramid fibres, hemp fibres, flax fibres, sisal fibres, and one or more combinations thereof, preferably glass fibres, carbon fibres, and/or basalt fibres. This broad range of types of fibres that are suitable for reinforcing the thermoplastic material provides extra flexibility to the manufacturing process and makes it less dependent on one or a few types of fibres.
  • unidirectionally aligned reinforcing fibres is meant that substantially all fibres, preferably all fibres, are aligned in a single direction.
  • single direction is meant the longitudinal direction of the tape, i.e., the machine direction in which the tape is manufactured.
  • the reinforcing fibres are continuous strands of fibres that are positioned in parallel to each other in the longitudinal direction of the tape.
  • the fibres in the fibre- reinforced thermoplastic tape are generally supplied as a plurality of continuous, very long filaments, and can be in the form of strands, rovings, or yarns.
  • a filament is an individual fibre of reinforcing material.
  • a strand is a plurality of bundled filaments.
  • Yarns are collections of strands, for example strands twisted together.
  • a roving refers to a collection of strands wound into a package.
  • continuous in connection with fibres, filaments, strands, yarns, or rovings is meant that the fibres, strands, filaments, yarns, or rovings generally have a significant length. However, it should not be understood to mean that the length of the fibres, strands, filaments, yarns, or rovings is perpetual or infinite.
  • Continuous fibres, such as continuous filaments, strands, yarns, or rovings have a length of more than 100 mm, preferably more than 1000 mm, depending on the length of the of the tape. Most preferably, the fibres have the same length as the tape.
  • fibres that are added to the thermoplastic material with the purpose of improving the thermoplastic material’s strength.
  • fibres that reinforce the thermoplastic material are meant fibres that reinforce the thermoplastic material.
  • glass fibres is meant a material that consists of numerous extremely fine fibres of glass. Thin strands of silica-based or other formulation glass are extruded into many fibres with small diameters suitable for textile processing.
  • the most common type of glass fibre is E-glass, which is alumino-borosilicate glass. E-glass has less than 1 wt.% alkali oxides and is mainly used for glass-reinforced plastics.
  • A-glass alkali-lime glass with little or no boron oxide
  • E-CR-glass Electro/Chemical Resistance; alumino-lime silicate with less than 1 wt.% alkali oxides, with high acid resistance
  • C-glass alkali-lime glass with high boron oxide content, used for glass staple fibres and insulation
  • D-glass borosilicate glass, named for its low dielectric constant
  • R-glass alumino silicate glass without MgO and CaO with high mechanical requirements as reinforcement
  • S-glass alumino silicate glass without CaO but with high MgO content with high tensile strength
  • carbon fibres are meant carbon fibres (alternatively OF or graphite fibre) having a diameter of about 5 to 10 micrometres that are composed mostly of carbon atoms, arranged in a graphitic structure. Specifically, the graphene planes are oriented parallel to the carbon fibre’s axis.
  • Carbon fibres have several advantages: high stiffness, high tensile strength, high strength to weight ratio, high chemical resistance, high-temperature tolerance, and low thermal expansion.
  • basalt fibres are meant fibres that are produced from basalt rocks by melting them and converting the melt into fibres.
  • Basalt fibres or more specifically basalt continuous fibres, can be used for the production of reinforcing materials and composite products.
  • Basalt fibres are made from a single material, crushed basalt, from a carefully chosen quarry source.
  • Basalt of high acidity (over 46% silica content) and low iron content is considered desirable for fibre production.
  • Basalt fibres are fire resistant and do not burn, which makes them very suitable as a reinforcing material in a tape that requires good flame retardancy.
  • basalt fibres when basalt fibres are used to strengthen polymers, its composites have good strength, high working temperature range, good chemical resistance, excellent heat and sound insulation properties and low water absorption.
  • basalt fibres are easy to process, environmentally friendly, and relatively cheap.
  • ceramic fibres are smalldimension filaments or threads composed of ceramic material, usually alumina and silica, used in lightweight units for electrical, thermal, and sound insulation.
  • ceramic fibres are of two types: ceramic oxide fibres and ceramic non-oxide fibres.
  • Ceramic oxide fibres mostly consist of alumina (AI 2 O 3 ) and alumina-silica (AI 2 O 3 -SiO 2 ) mixtures and are generally used for high-temperature applications due to their high melting points. Ceramic oxide fibres are used both as insulation and as reinforcement material.
  • the mostly known examples for oxide ceramic fibres are composed of oxides such as silica (SiO 2 ), mullite (3AI 2 O 3 2SiO 2 ), alumina (AI 2 O 3 ), and zirconia (ZrO 2 ) having different characteristic properties.
  • Silicon carbide-based fibres have an excellent combination of high strength, modulus, and thermal stability, including good oxidation resistance and mechanical properties (compressive-tensile strength) at high temperatures. Silicon carbide-based fibres are generally applied as continuous fibre in ceramic matrix. This type of ceramic matrix composites (CMCs) is used in hot section of engines for power, etc.
  • CMCs ceramic matrix composites
  • aromatic polyamide fibres which are a class of heat-resistant and strong synthetic fibres.
  • the chain molecules in the fibres are highly oriented along the fibre axis. As a result, a higher proportion of the chemical bond contributes more to fibre strength than in many other synthetic fibres.
  • Aramids have a very high melting point (>500 °C).
  • Aromatic in the name refers to the presence of aromatic rings of six carbon atoms. In aramids these rings are connected via amide linkages each comprising a CO group attached to an NH group.
  • Aramids are divided into two main types according to where the linkages attach to the rings: para-aramids and meta-aramids.
  • para-aramids have the linkages attached at positions 1 and 4, while meta-aramids have them at positions 1 and 3. That is, the attachment points are diametrically opposite each other in para-aramids, and two atoms apart in metaaramids.
  • hemp fibres vegetable fibres that are generally based on arrangements of cellulose, often with lignin, derived from the hemp plant under the species Cannabis.
  • flax fibres vegetable fibres that are extracted from the bast or skin of the stem of the flax plant (Linum usitatissimum L).
  • fibres vegetable fibres that are derived from the plant under the species Agave Sisalana.
  • the fibres should have a suitable size applied to them.
  • the size is selected to protect the fibre during handling, but also to provide good adhesion to the thermoplastic polymer, thereby increasing the strength of the tape.
  • the size on the fibre has to be selected according to the thermoplastic material.
  • distributed of fibres throughout the tape is meant the distribution of the fibres over the width of the fibre-reinforced thermoplastic tape transverse to the longitudinal direction (i.e., machine direction) of the fibres.
  • a relatively uneven distribution may result in the tape having undesirable and/or unpredictable structural characteristics.
  • a relatively even distribution means that the continuous unidirectionally aligned fibres are evenly distributed in the tape and provides a tape having desirable and/or predictable structural characteristics.
  • the distribution of the fibres is relatively even.
  • the average distance between the top or bottom surface of the fibre-reinforced thermoplastic tape and the fibres embedded in or covered by the fibre-reinforced thermoplastic tape is between 5 and 20 % of the thickness of the fibre-reinforced thermoplastic tape.
  • the fibres may have a diameter of between 4 and 20 pm, preferably between 8 and 13 pm and/or a length of at least 100 mm, preferably at least 1000 mm.
  • the fibres of this specific diameter and/or length provide sufficient strength to the tape over the whole length (in the longitudinal direction) of the U tape. Furthermore, it also allows the preparation of a fibre-reinforced thermoplastic tape having a relatively low thickness.
  • said longitudinally oriented fibres are unidirectionally aligned reinforcing fibres that extend in the longitudinal direction of the tape.
  • the tape according to the first aspect of the present disclosure is thus a fibre-reinforced thermoplastic unidirectional (UD) tape.
  • UD thermoplastic unidirectional
  • Such an orientation of the fibres not only has the function of transporting diffusing gases, but it also improves the strength of the tape over the whole length (in the longitudinal direction) of the tape while maintaining the flexibility of the tape.
  • longitudinal direction is meant the machine direction in which the tape is produced.
  • the thermoplastic material of the tape may comprise one or more additives.
  • the one or more additives is preferably selected from the group consisting of compatibilizers, adhesion-enhancing copromotors, stabilizers, impregnation agents, lubricants, antioxidants, and flame retardants.
  • additives an additive for the thermoplastic polymers used that may be present in the thermoplastic material. Additives are often used to improve the properties of the thermoplastic polymers. Examples include compatibilizers and stabilizers.
  • Compatibilizers an additive that aids in the compatibility between different thermoplastic polymers.
  • Compatibilizer are polymers that have functional groups similar to both non-polar and polar polymers. Without them, immiscible polymers in the molten state when shearing is stopped would segregate into two layers like oil and water.
  • Block copolymers comprise of two or more homopolymer subunits linked by covalent bonds. They are made up of blocks of different polymerized monomers. Examples are diblock copolymers, which have two distinct blocks (e.g., ⁇ A-A-A-A-A-B-B-B-B ⁇ ), and triblock copolymers, which have three distinct blocks (e.g., ⁇ A-A-A-A-B-B-B-B-C- C-C-C-).
  • Graft copolymers are segmented copolymers with a linear backbone of one chain segment and randomly distributed branches of another chain segment, which is structurally different from the former chain segment forming the linear backbone.
  • a terpolymer is a copolymer that contains three types of repeat units. Hence, a terpolymer is formed from the polymerization of three different monomers. The resulting polymer chain contains repeating units of all three monomers.
  • An example is a random terpolymer of ethylene, acrylic ester, and glycidyl methacrylate.
  • thermoplastic material in the present description, with “adhesion-enhancing copromotors” is meant a substance, being a copromotor, that enhances the adhesion of the thermoplastic material and the fibres covered by the thermoplastic material.
  • stabilizers an additive that aids in the prevention of heat, oxidation, and chemical degradation of the fibre-reinforced thermoplastic composite.
  • examples include phenolic alkylene dicarboxylates that provide stabilization against degradation with a reduced tendency to yellow discoloration and improved melt, processing performance over an extended period of time, aluminium phosphate or aluminium silicate treated with polyethylene glycol that improves the colour stability of the material, and zinc oxide or lead stabilizer that also improves the colour stability and furthermore improves the thermal stability of POK and its processing temperature window.
  • impregnation agent or “impregnating agent” is meant a material that is compatible with the thermoplastic polymer to be reinforced and may even be soluble in said polymer.
  • impregnation agent or “impregnating agent” is meant a material that is compatible with the thermoplastic polymer to be reinforced and may even be soluble in said polymer.
  • suitable combinations based on general knowledge, and may also find such combinations in the art.
  • the impregnating agent is non-volatile, and/or substantially solvent-free.
  • non-volatile means that the impregnating agent has a boiling point or range higher than the temperatures (about 230-240 °C) at which the polymer’s melt impregnation is conducted over the reinforcing fibres.
  • substantially solvent-free means that the impregnating agent contains less than 10 wt.% of solvent, preferably less than 5 wt.% of solvent based on the impregnating agent. In a preferred embodiment, the impregnating agent does not contain any organic solvent.
  • lubricants is meant a material that helps to reduce friction between surfaces in mutual contact, which ultimately reduces the heat generated when the surfaces move.
  • examples are stearamides and stearates, such as EBS, calcium stearate or magnesium stearate.
  • antioxidant additive a compound that inhibits oxidation, a chemical reaction that can produce free radicals.
  • the antioxidant additive may comprise one, two or more phenolic groups. These phenolic antioxidant additives may be sterically hindered phenolic additives. Examples are tris(2,4-di-tert- butylphenyl)phosphite, commercially available as Irgafos 168, and octadecyl-3-[3,5- di-tert-butyl-4-hydroxyphenyl]propionate, available from BASF as Irganox 1076.
  • flame retardants is meant a material that is activated by the presence of an ignition source and is intended to prevent or slow the further development of ignition by a variety of different physical and chemical methods. They may be added as a copolymer during the polymerisation process, or later added to the polymer at a moulding or extrusion process or applied as a topical finish.
  • Examples are minerals such as aluminium hydroxide (ATH), magnesium hydroxide (MDH), huntite and hydromagnesite, organohalogen compounds such as organochlorines, organobromines, and polymeric brominated compounds, organophosphorus compounds such as organophosphates, phosphonates, and phosphinates, and organic compounds such as carboxylic acid and dicarboxylic acid.
  • ATH aluminium hydroxide
  • MDH magnesium hydroxide
  • huntite and hydromagnesite examples are minerals such as aluminium hydroxide (ATH), magnesium hydroxide (MDH), huntite and hydromagnesite, organohalogen compounds such as organochlorines, organobromines, and polymeric brominated compounds, organophosphorus compounds such as organophosphates, phosphonates, and phosphinates, and organic compounds such as carboxylic acid and dicarboxylic acid.
  • the tape according to the first aspect of the present disclosure comprises a plurality of longitudinally oriented fibres that is partially covered by the thermoplastic material.
  • the tape comprises a parallel array of fibres covered by the thermoplastic material.
  • the tape may have channels present on both longitudinal sides of the array of fibres that allow the transport of one or more gases along a longitudinal direction of the tape or along a longitudinal direction of the RTP, respectively.
  • both longitudinal sides of the array of fibres are partially covered by the thermoplastic material.
  • gases/moisture may diffuse from both the outside and inside of the RTP through the thermoplastic material.
  • the gases/moisture diffusing from the centre towards the periphery of the RTP (thus diffusing through the thermoplastic inner liner) and diffusing from the periphery towards the centre of the RTP (thus diffusing through the thermoplastic outer jacket) can be removed before they can damage the RTP.
  • the one longitudinal side of the array of fibres that is at least partially covered by the thermoplastic material is completely covered by the thermoplastic material.
  • the tape may have a width of at least 2 cm, preferably between 5 and 20 cm, more preferably between 8 and 15 cm and/or has a thickness of between 100 and 800 pm, preferably between 150 and 500 pm, more preferably between 250 and 350 pm.
  • a tape of these dimensions provides optimal balance between flexibility and applicability and strength. This makes them particularly suitable for the production of complex component shapes.
  • the longitudinal sides of the array of fibres each have a thickness and wherein a ratio between said thicknesses of the longitudinal sides of the array of fibres is between 20:1 and 1 :20, preferably between 10:1 and 1 :10, more preferably between 3: 1 and 1 :3, such as between 2:1 and 1 :2.
  • thermoplastic material of the tape it is desirable to convert the thermoplastic material of the tape to a thermoset material. This can for example be done via heat-induced cross-linking.
  • the cross-linking of the thermoplastic material is performed after production (shaping or moulding) of the article comprising the tape, such as the UD tape.
  • thermoplastic material of the tape comprises at least one crosslinked non-polar polymer and/or at least one cross-linked polar polymer. This is beneficial, as the tape is more resistant to creep, and this allows for the use above the lowest melting point of the polymers in the tape for short periods of time.
  • thermoplastic material melt Contacting of the one longitudinal side of the array of fibres with the thermoplastic material melt is preferably done by impregnating.
  • the impregnating the array of fibres contacted with the thermoplastic material melt is done by extruding a thin layer, also known as a film layer, of the thermoplastic material melt over the array of fibres and passing the array of fibres contacted with the thermoplastic material melt through hot rollers.
  • the thickness at the die opening is about 0.8 mm and the film layer get thinner when falling onto fibres.
  • the melt/resin flow is controlled knowing that the resin can flow and be pushed through thickness and in plane (width direction) when going along the impregnation rollers.
  • the thickness of the film layer gets to about 0.15 mm thickness.
  • the film layer is thus in the order of 0.1 to 0.3 mm depending on the tape thickness.
  • solidification is meant that the tape goes through rollers for cooling and calendaring.
  • the contacted (impregnated) side of the array of fibres is partially or almost completely, preferably completely, covered by the thermoplastic material melt.
  • the impregnation rollers process settings like temperature and pressure, can be tuned accordingly.
  • tapes having sections like 1 -2 cm wide sections along the length of the tape, that are partially impregnated. Lower amounts of resin could be applied from the die on the tape at those sections, which may result into partially impregnated bands of tape. This may be on one or both longitudinal sides of the tape.
  • step 4) of the method according to the third aspect of the present disclosure the other longitudinal side of the array of fibres may be contacted with the thermoplastic material melt obtained in step 2) in a similar manner as the one longitudinal side.
  • the tape can be made in a continuous process and can be collected as a roll.
  • the tape according to the first aspect or manufactured according to the third aspect is used for an RTP configured for transporting hydrocarbon fluids.
  • RTP configured for transporting hydrocarbon fluids.
  • fluids liquids, such as water, and gasses, such as butane.
  • an RTP includes from the centre of the RTP to the periphery of the RTP at least the following layers: a thermoplastic inner liner, a reinforcement layer comprising one or more windings of tape, and a thermoplastic outer jacket. The outer jacket provides protection of the tape windings from external mechanical damage.
  • the RTP may further comprise at least one vent positioned at an end fitting of the RTP arranged for releasing one or more gases that accumulate in and are transported through the channels along the helical direction of the RTP.
  • Another option is to strip a section of the outer jacket, e.g., 1 cm wide, close to the end fitting for releasing the one or more gases. This allows faster removal of the gases and reduces the issues of delamination and/or ballooning/swelling even further. The risk of material degradation, of for example the fibres in the tape, is also further reduced.
  • Figure 1 shows a tape according to the present disclosure
  • Figure 2A shows a close-up view of part of one longitudinal side of the array of fibres of the tape of Fig. 1 ;
  • Figure 2B shows a close-up view of part of another longitudinal side of the array of fibres of the tape of Fig. 1 ;
  • Figure 3 shows a cross-sectional view of the tape of Fig. 1 ;
  • Figure 4 shows a schematic representation of an end part of an RTP
  • Figure 5 shows a schematic representation of part of an RTP comprising a tape helically wound around the thermoplastic inner liner of the RTP;
  • Figure 6 shows schematically a method of manufacturing the tape according to the present disclosure.
  • Fig. 1 shows a tape 1 of glass fibres covered by a polypropylene material 9.
  • the tape 1 comprises an array 3 comprising a plurality of glass fibres that are oriented in the longitudinal direction of the tape 1 (indicated by the arrow).
  • the glass fibres are partially covered by the polypropylene material 9.
  • the partial covering of the glass fibres in the polypropylene 9 is shown in Fig 2A.
  • the close-up view of part of the surface of the one longitudinal side 7 of the array of fibres 3 of the tape 1 of Fig. 1 shows that the surface is relatively rough.
  • the rough surface is due to the array of fibres 3 being partially covered by the polymeric material (polypropylene) 9.
  • the fibres are partially impregnated with the polypropylene 9.
  • the partial covering results in channels 13 being present between the longitudinally oriented fibres. These channels 13 allow the transport of gases along the longitudinal direction of the tape 1 (indicated by the arrow).
  • Fig. 2B shows a close-up view of the other longitudinal side 7 of the array of fibres 3 of the tape 1 of Fig. 1 .
  • the other longitudinal side 7 shows a smooth surface indicating that this side 7 of the array of fibres 3 is completely, or nearly completely, impregnated by the polypropylene 9.
  • Fig.3 shows a cross-sectional view along the line A-A shown in Fig. 1 of the tape 1 . It clearly shows that the one longitudinal side 5 of the array of fibres 3 is (almost) completely covered by the thermoplastic material 9 and that the other longitudinal side 7 of the array of fibres 3 comprises multiple channels 13.
  • FIG. 4 an end part 17 of an RTP 1 1 is shown.
  • the end part 17 comprises multiple vents 15 that are arranged for releasing one or more gases that accumulate in and are transported through the channels 13 along the helical direction of the RTP 1 1 .
  • Fig. 5 shows part of an RTP 11 , wherein the tape 1 is wound around the thermoplastic inner liner of the RTP 11 in the helical direction, as indicated with the arrow.
  • the method 101 comprises the steps of 1) providing 103 the thermoplastic material 9; 2) melt compounding 105 the thermoplastic material 9 provided in step 1) in an extruder to obtain a thermoplastic material melt; 3) providing 107 the array comprising the plurality of longitudinally oriented fibres 3; 4) contacting 109 the one longitudinal side 5 of the array of fibres 3 provided in step 3) with the thermoplastic material melt obtained in step 2) such that the one longitudinal side 5 of the array of fibres 3 is covered by the thermoplastic material melt and subsequently solidifying to obtain the tape 1.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

Ruban (1) comprenant un réseau d'une pluralité de fibres orientées longitudinalement (3), ledit réseau de fibres (3) présentant deux côtés longitudinaux (5, 7), un côté longitudinal (5) du réseau (3) étant au moins partiellement recouvert d'un matériau thermoplastique (9). Tuyau de transport renforcé (RTP) (11) configuré pour le transport de fluides, ledit RTP (11) comprenant d'un centre à une périphérie une gomme intérieure thermoplastique, une couche de renfort comprenant au moins une couche de ruban enroulé en hélice (1) selon la revendication 1, et une enveloppe extérieure thermoplastique, ledit ruban (1) présentant un côté longitudinal tourné vers la périphérie du RTP (11) et un côté longitudinal tourné vers le centre du RTP (11), des canaux (13) étant présents sur l'autre côté longitudinal (7) du réseau (3), chaque canal (13) étant défini par deux fibres adjacentes orientées longitudinalement, le matériau thermoplastique (9) dudit ruban (1) et un élément parmi le revêtement intérieur thermoplastique, l'enveloppe extérieure thermoplastique ou le matériau thermoplastique (9) d'une autre couche de ruban enroulé en hélice (1) dans ladite couche de renfort, lesquels canaux (13) permettent le transport d'un ou de plusieurs gaz selon une direction hélicoïdale du RTP (11). L'invention concerne également un procédé (101) de fabrication dudit ruban (1), une utilisation dudit ruban (1) pour un tuyau thermoplastique renforcé (RTP) configuré pour le transport de fluides, et une utilisation dudit ruban pour transporter un ou plusieurs gaz qui s'accumulent dans des canaux (13) présents sur l'autre côté longitudinal (7) du réseau de fibres (3) le long d'une direction hélicoïdale d'un RTP.
PCT/EP2025/063897 2024-05-24 2025-05-20 Ruban, tuyau thermoplastique renforcé comprenant le ruban, et procédé de fabrication et d'utilisation du ruban Pending WO2025242693A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP24178101 2024-05-24
EP24178101.2 2024-05-24

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0504708A1 (fr) 1991-03-18 1992-09-23 PARABEAM Industrie- en Handelsonderneming B.V. Corps creux en matière plastique renforcé de fibres
WO1998036198A2 (fr) * 1997-02-14 1998-08-20 Ameron International Corporation Sections de tuyau a double enveloppe
EP1473132A2 (fr) 2003-05-02 2004-11-03 The Boeing Company Couches intermédiaires à haute porosité pour le renforcement de composites moulés à base de tissu et de liquide

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0504708A1 (fr) 1991-03-18 1992-09-23 PARABEAM Industrie- en Handelsonderneming B.V. Corps creux en matière plastique renforcé de fibres
WO1998036198A2 (fr) * 1997-02-14 1998-08-20 Ameron International Corporation Sections de tuyau a double enveloppe
EP1473132A2 (fr) 2003-05-02 2004-11-03 The Boeing Company Couches intermédiaires à haute porosité pour le renforcement de composites moulés à base de tissu et de liquide

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