Reinforcing Matrix for Spoolable Pipe
A spoolable pipe is disclosed, the spoolable pipe having an internal pressure barrier formed about a longitudinal axis, and a reinforcing layer(s) enclosing the internal pressure barrier that includes a solid hydrocarbon matrix. The pipe can also include an energy conductor(s) integrated with and/or located between the internal pressure barrier and/or the reinforcing layer(s).
1 . A spoolable pipe, comprising:
an internal pressure barrier formed about a longitudinal axis;
at least one reinforcing layer enclosing the internal pressure barrier and comprising fibers and a solid hydrocarbon matrix, wherein said solid hydrocarbon matrix is solid at about 25° C. and said matrix comprises hydrocarbons having an average molecular weight of less than about 20,000 grams/mole; and
an external layer enclosing the at least one reinforcing layer.
2 .- 19 . (canceled)
20 . A spoolable pipe, comprising:
an internal pressure barrier formed about a longitudinal axis;
at least one reinforcing layer enclosing the internal pressure barrier and comprising fibers and a solid matrix wherein said solid matrix has a tensile modulus between about 10 and 90,000 psi, and wherein said reinforcing layer is formed at least by applying to said fibers a substantially liquid matrix composition having a viscosity between about 10 and about 10,000 cPs at 25° C.
21 . The spoolable pipe of claim 20 , wherein the at least one reinforcing layer comprises at least two plies of fibers.
22 . The spoolable pipe of claim 21 , wherein the two plies of fibers have at least a partial helical orientation relative to the longitudinal axis.
23 . The spoolable pipe of claim 20 , wherein said substantially liquid matrix composition is capable of flowing between said fibers.
24 . The spoolable pipe of claim 20 , wherein said substantially liquid matrix composition has a viscosity between about 100 and about 5000 cPs.
25 . The spoolable pipe of claim 20 , wherein said substantially liquid matrix composition is an emulsion, a suspension, a colloid, a immiscible fluid blend, or two-phase system.
26 . (canceled)
27 . The spoolable pipe of claim 26 , wherein said substantially liquid matrix composition comprises at least one of: an emulsifier, tackifier, binder and a surfactant.
28 . The spoolable pipe of claim 26 , wherein said substantially liquid matrix composition comprises at least one of: polyethylene, polyethylene oligomers, polypropylene, polypropylene oligomers, polyolefins, polyolefin oligomers, paraffin waxes, or a grease.
29 . The spoolable pipe of claim 20 , wherein said substantially liquid matrix composition comprises polymer particles.
30 . The spoolable pipe of claim 29 , wherein said polymer particles have an average diameter between about 10 nm and about 10 μm.
31 . The spoolable pipe of claim 20 , wherein said substantially liquid matrix composition comprises anionic or cationic moities that are capable of forming a solid upon evaporation, drying, curing or gelling.
32 . The spoolable pipe of claim 31 , wherein said substantially liquid matrix composition comprises a compound comprising an amine or an ammonium moiety.
33 . The spoolable pipe of claim 20 , wherein said substantially liquid matrix composition comprises inorganic solids.
34 . The spoolable pipe of claim 20 , wherein said substantially liquid matrix composition comprises a water-based dispersion.
35 . The spoolable pipe of claim 20 , wherein said internal pressure barrier comprises at least one of: a metal, polyethylene, cross-linked polyethylene, polyvinylidene fluoride, polybutylene, polyamide, polypropylene, polyethylene terphthalate, or polyphenylene sulfide.
36 . (canceled)
37 . The spoolable pipe of claim 35 , wherein the permeability of said reinforcing layer is higher than the permeability of said internal pressure barrier.
38 . The spoolable pipe of claim 20 , further comprising an external layer.
39 . The spoolable pipe of claim 38 , wherein said external layer wherein the permeability of said external layer is higher than the permeability of said solid matrix.
40 . The spoolable pipe of claim 38 , wherein said external layer comprises at least one of: polyethylene, cross-linked polyethylene, polybutylene, polyvinylidene fluoride, polyamide, polypropylene, polyethylene terphthalate, or polyphenylene sulfide.
41 . The spoolable pipe of claim 38 , wherein said external layer comprises a foam.
42 . The spoolable pipe of claim 41 , wherein said foam comprises at least one of: a thermoset polymer, a thermoplastic polymer, an elastomer, a rubber, closed cells and open cells.
43 . The spoolable pipe of claim 20 , wherein said fibers comprise a glass, an aramid, a carbon, a ceramic, a metal, a mineral, or a polymer, or combinations thereof.
44 . The spoolable pipe of claim 20 , further comprising an energy conductor.
45 . The spoolable pipe of claim 20 , wherein said spoolable pipe further comprises at least one of: afire retardant, a UV stabilizer, an oxidative stabilizer, and a thermal stabilizer.
46 . The spoolable pipe of claim 20 , wherein said spoolable pipe further comprises a pigment.
47 . The spoolable pipe of claim 20 , wherein said solid matrix is formed by further drying, curing and/or crosslinking said substantially liquid matrix composition.
48 . A method for producing a spoolable tube comprising: providing an inner layer of said spoolable tube;
applying a substantially liquid matrix composition comprising at least one of:
polyethylene, polyethylene oligomers, polypropylene, polypropylene oligomers, polyolefins, polyolefin oligomers, a wax, and/or a grease to fibers at a temperature between about 20° C. and about 40° C.;
drying said fibers so that a solid matrix composition between the fibers is formed; and
winding said fibers around said inner layer.
49 .- 54 . (canceled)