Method for producing a flexible composite pipe, and thermoplastic composite pipe

Inventor: Andreas Kessler (Pullach im Isartal, DE)

Assignee: Fibron Pipe GESMBH

B29D23/001 B29C53/58 B32B1/08 B32B5/26 B32B27/32 B32B27/34 F16L9/128 B32B2260/023 B32B2260/046 B32B2262/0269 B32B2262/101 B32B2262/106 B32B2597/00

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Quick Facts

Patent No.: US 12697793
App. No.: 18/857,132
Granted: Aug 4, 2026
Kind: B2

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Abstract

A method for producing a flexible thermoplastic composite pipe, wherein the method comprises the following steps: applying a first ply of a reinforcing layer onto a plastics pipe; consolidating the first ply of the reinforcing layer with the plastics pipe, wherein at least the first ply of the reinforcing layer is brought to a first temperature which leads to at least partial melting of the first ply of the reinforcing layer, such that the first ply of the reinforcing layer and the plastics pipe are rigidly interconnected, in particular in a fused manner; applying a second ply of the reinforcing layer onto the first ply of the reinforcing layer; consolidating the second ply of the reinforcing layer with at least the first ply of the reinforcing layer, wherein at least the second ply of the reinforcing layer is brought to a second temperature which leads to at least partial melting of the second ply of the reinforcing layer, such that the second ply of the reinforcing layer and the first ply of the reinforcing layer are rigidly interconnected, in particular in a fused manner; applying at least a third ply of the reinforcing layer onto the second ply of the reinforcing layer; consolidating the at least one third ply of the reinforcing layer with at least the second ply of the reinforcing layer, wherein at least the third ply of the reinforcing layer is brought to a third temperature which leads to at least partial melting of the third ply of the reinforcing layer, such that the third ply of the reinforcing layer and the second ply of the reinforcing layer are rigidly interconnected, in particular in a fused manner, and thermoplastic composite pipe and the use of a thermoplastic composite pipe.

Claims (34)

1 . A method for producing a flexible thermoplastic composite pipe, comprising:

applying a first ply of a reinforcing layer onto a plastics pipe;

consolidating the first ply of the reinforcing layer with the plastics pipe, wherein at least the first ply of the reinforcing layer is brought to a first temperature which leads to at least partial melting of the first ply of the reinforcing layer, such that the first ply of the reinforcing layer and the plastics pipe are rigidly interconnected in a fused manner;

applying a second ply of the reinforcing layer onto the first ply of the reinforcing layer;

consolidating the second ply of the reinforcing layer with at least the first ply of the reinforcing layer, wherein at least the second ply of the reinforcing layer is brought to a second temperature which leads to at least partial melting of the second ply of the reinforcing layer, such that the second ply of the reinforcing layer and the first ply of the reinforcing layer are rigidly interconnected in a fused manner;

applying at least a third ply of the reinforcing layer onto the second ply of the reinforcing layer;

consolidating the at least one third ply of the reinforcing layer with at least the second ply of the reinforcing layer, wherein at least the third ply of the reinforcing layer is brought to a third temperature which leads to at least partial melting of the third ply of the reinforcing layer, such that the third ply of the reinforcing layer and the second ply of the reinforcing layer are rigidly interconnected in a fused manner,

wherein the third temperature is greater than the first and/or second temperature.

2 . The method according to claim 1 , characterized in that the first temperature and the second temperature are substantially the same.

3 . The method according to claim 1 , characterized in that the first ply of the reinforcing layer comprises a first reinforcing belt which is wound around the plastics pipe in a substantially spiral shape in a first spiral-shaped direction, as first winding direction, such that a plurality of axially spaced belt sections and gaps or respectively splits between the sections are formed, and in that the first ply of the reinforcing layer comprises a second reinforcing belt which is wound substantially in a spiral shape in the first spiral-shaped direction, as first winding direction, around the plastics pipe such that a plurality of axially spaced belt sections is formed, which sections are arranged in the gaps or respectively splits of the first reinforcing belt of the first ply of the reinforcing layer.

4 . The method according to claim 3 , characterized in that the first reinforcing belt of the first ply of the reinforcing layer and the second reinforcing belt of the first ply of the reinforcing layer are wound around the plastics pipe substantially simultaneously or immediately one after the other, by means of a two-coil winding device, the two-coil winding device being a taping machine.

5 . The method according to claim 3 , characterized in that the first reinforcing belt of the first ply of the reinforcing layer and the second reinforcing belt of the first ply of the reinforcing layer are arranged in the axial direction, directly adjacent to one another, and/or not overlapping.

6 . The method according to claim 3 , characterized in that the first reinforcing belt of the first ply of the reinforcing layer and/or the second reinforcing belt of the first ply of the reinforcing layer and/or the first reinforcing belt of the second ply of the reinforcing layer and/or the second reinforcing belt of the second ply of the reinforcing layer and/or the first reinforcing belt of the third ply of the reinforcing layer and/or the second reinforcing belt of the third ply of the reinforcing layer is a reinforcing belt which is impregnated and/or coated with plastic being polyolefin, polyethylene, high density polyethylene (HDPE), polypropylene or polyamide, and comprising unidirectionally arranged fibers being glass fibers and/or plastic fibers and/or carbon fibers and/or aramid fibers.

7 . The method according to claim 1 , characterized in that the second ply of the reinforcing layer comprises a first reinforcing belt which is wound substantially in a spiral shape in a second spiral-shaped direction, as second winding direction, around the first ply of the reinforcing layer such that a plurality of axially spaced belt sections are formed, between which there are gaps or respectively splits, and in that the second ply of the reinforcing layer comprises a second reinforcing belt which is wound substantially in a spiral shape in the second spiral-shaped direction, as the second winding direction, around the first ply of the reinforcing layer such that a plurality of axially spaced belt sections of the second ply of the reinforcing layer are formed which are arranged in the gaps or respectively splits of the first reinforcing belt.

8 . The method according to claim 7 , characterized in that the first reinforcing belt of the second ply of the reinforcing layer and the second reinforcing belt of the second ply of the reinforcing layer are wound around the first ply of the reinforcing layer substantially simultaneously or immediately one after the other by means of a two-coil winding device, the two-coil winding device being a taping machine.

9 . The method according to claim 7 , characterized in that the first reinforcing belt of the second ply of the reinforcing layer and the second reinforcing belt of the second ply of the reinforcing layer are arranged in the axial direction, directly adjacent to one another, and/or not overlapping.

10 . The method according to claim 7 , characterized in that the second spiral-shaped direction or respectively second winding direction is substantially opposite to the first spiral-shaped direction or respectively first winding direction.

11 . The method according to claim 1 , characterized in that the third ply of the reinforcing layer comprises a first reinforcing belt which is wound substantially in a spiral shape in a third spiral-shaped direction, as third winding direction, around the second ply of the reinforcing layer, and in that the third ply of the reinforcing layer comprises a second reinforcing belt which is wound substantially in a spiral shape in the third spiral-shaped direction, as third winding direction, around the second ply of the reinforcing layer such that the second reinforcing belt of the third ply of the reinforcing layer and the first reinforcing belt of the third ply of the reinforcing layer overlap in sections.

12 . The method according to claim 11 , characterized in that the first reinforcing belt of the third ply of the reinforcing layer and the second reinforcing belt of the third ply of the reinforcing layer are wound around the second ply of the reinforcing layer substantially simultaneously or, immediately one after the other by means of a two-coil or four-coil winding device, the two-coil or four-coil winding device a taping machine.

13 . The method according to claim 11 , characterized in that the third spiral-shaped direction or respectively third winding direction substantially corresponds to the first spiral-shaped direction or respectively first winding direction or substantially corresponds to the second spiral-shaped direction or respectively second winding direction.

14 . The method according to claim 11 , characterized in that the first reinforcing belt of the third ply of the reinforcing layer and the second reinforcing belt of the third ply of the reinforcing layer comprise an overlapping area which is arranged substantially over the seam of the first and/or second ply of the reinforcing layer.

15 . The method according to claim 11 , characterized in that the overlap amounts to approximately 10% to 70% of the width of the belt, more specifically approximately 40% to 60% of the width of the belt.

16 . The method according to claim 1 , characterized in that the plastics pipe is or will be produced, by extrusion, from thermoplastic material being polyolefin, polyethylene, high-density polyethylene (HDPE), polypropylene or polyamide.

17 . The method according to claim 1 , characterized in that two third plies of the reinforcing layer are applied substantially simultaneously or, immediately one after the other, by means of a four-coil winding device, the four-coil winding device being a taping machine, and/or in that two third plies of the reinforcing layer are applied in the same winding direction or in substantially opposite winding directions.

18 . The method according to claim 1 , characterized in that two third plies of the reinforcing layer are applied immediately one after the other and then consolidated together in one step before further third plies are applied, wherein at least the two third plies of the reinforcing layer are brought to the third temperature, which leads to at least partial melting of the two third plies of the reinforcing layer, such that the two third plies of the reinforcing layer and the preceding ply of the reinforcing layer are rigidly interconnected in a fused manner.

19 . The method according to claim 1 , characterized in that after the consolidation of the at least one third ply of the reinforcing layer, a sheathing is applied by extrusion onto, and/or in that after at least one consolidation after the consolidation of the at least one third ply of the reinforcing layer, a cooling of the pipe, by means of a cooling apparatus, takes place.

20 . A method for producing a flexible thermoplastic composite pipe, comprising:

applying a first ply of a reinforcing layer onto a plastic pipe;

first consolidating the first ply of the reinforcing layer with the plastic pipe, wherein the first consolidating comprises heating at least a portion of the first ply of the reinforcing layer is to a first temperature which leads to at least partial melting of the first ply of the reinforcing layer and a bonding of the first ply of the reinforcing layer to the plastic pipe;

applying a second ply of the reinforcing layer onto the first ply of the reinforcing layer;

second consolidating the second ply of the reinforcing layer with the first ply of the reinforcing layer, wherein the second consolidating comprises heating at least a portion of the second ply of the reinforcing layer to a second temperature which leads to at least partial melting of the second ply of the reinforcing layer and a bonding of the second ply of the reinforcing layer to the first ply of the reinforcing layer;

applying at least a third ply of the reinforcing layer onto the second ply of the reinforcing layer;

third consolidating the third ply of the reinforcing layer with the second ply of the reinforcing layer, wherein the third consolidating comprises heating at least a portion of the third ply of the reinforcing layer to a third temperature which leads to at least partial melting of the third ply of the reinforcing layer and a bonding of the third ply of the reinforcing layer to the second ply of the reinforcing layer;

wherein the third temperature is greater than the first and/or second temperature.