Flexible pipe body and method of manufacture

1. A method of manufacturing a flexible pipe body comprising:

providing two or more composite filaments as a filament bundle, each composite filament comprising a length of composite matrix material in pre-preg form and reinforcing fibres;

applying a braid element around the filament bundle as a braided bundle;

providing a further filament bundle;

applying a braid element around the further filament bundle as a further braided bundle; helically wrapping the braided bundle and further braided bundle around a flexible pipe body layer to form a layer, wherein the or each braided bundle is pre-formed to a helix by guides, wherein the or each pre-formed braided bundle retains its pre-formed helix prior to curing of the bundle matrix as a result of comprising stiffening elements;

and then curing the composite filaments.

2. A method as claimed in claim 1 further comprising applying a lubricant or uncured resin to the filament bundle prior to applying the braid element.

3. A method as claimed in claim 1 further comprising applying a composite matrix material between the two or more composite filaments.

4. A method as claimed in claim 1 wherein the two or more composite filaments comprise a unidirectional composite fibre.

5. A flexible pipe body for transporting fluids from a sub-sea location, comprising:

an inner layer; and

an armour layer provided over the inner layer, wherein said armour layer is obtainable by:

providing two or more composite filaments as a filament bundle, each composite filament comprising a length of composite matrix material in pre-preg form and reinforcing fibres;

applying a braid element around the filament bundle as a braided bundle;

providing a further filament bundle;

applying a braid element around the further filament bundle as a further braided bundle

helically wrapping the braided bundle and further braided bundle around the inner layer to form a layer as the armour layer, wherein the or each braided bundle is pre-formed to a helix by guides, wherein the or each pre-formed braided bundle retains its pre-formed helix prior to curing of the bundle matrix as a result of comprising stiffening elements;

and then curing the one or more composite filament.

6. A flexible pipe body as claimed in claim 5 wherein the two or more composite filaments comprises a unidirectional composite fibre.

7. A flexible pipe body as claimed in claim 5 wherein the two or more composite filaments comprise a thermosetting or thermoplastic material.

8. A flexible pipe body as claimed in claim 5 wherein the reinforcing fibres are glass fibres, carbon fibres, a polypropylene, a polyethylene, a polyester, a polyamide, a fluoropolymer, a PVDF, a polymer tape, polymer fibres, a reinforced polymer tape, a fibre yarn, thermoplastic material, thermoset material, glass fibre composite tape, aramid fibre yarn, metallic wires, tapes or fibres with thermoplastic encapsulation, tapes or fibres with partial thermoset matrix impregnation, or a combination thereof.

9. A flexible pipe body as claimed in claim 5 wherein the braid element comprises a polymer tape, polymer fibres, glass fibres, carbon fibres, a polypropylene, a polyethylene, a polyester, a polyamide, a fluoropolymer, a PVDF, a reinforced polymer tape, a fibre yarn, thermoplastic material, thermoset material, glass fibre composite tape, aramid fibre yarn, metal wires, tapes or fibres with thermoplastic encapsulation, tapes or fibres with partial thermoset matrix impregnation, any of the above fibres or tapes combined with or coated with PTFE, or a combination thereof.

10. A flexible pipe body as claimed in claim 5 wherein said at least one composite filament comprises one of: a substantially rectangular cross-section; a substantially circular cross-section, a substantially Z shaped cross section, a substantially T shaped cross section, a substantially C shaped cross section, or an X cross section.

11. A flexible pipe body as claimed in claim 5 wherein a combination of shapes are used in the same layer of pipe body.

12. A flexible pipe body as claimed in claim 5 wherein bonding between the braided bundle and the further braided bundle during the curing process for the composite filaments is prevented by the braid elements of the braided bundle and the further braided bundle.

13. A flexible pipe body as claimed in claim 5 wherein the curing process for the composite filaments is achieved or assisted by the direct heating of elements within the filament bundle by induction.

14. A flexible pipe body as claimed in claim 5 wherein the curing process for the composite filaments is achieved or assisted by the use of infra-red or microwave or direct radiant, conducted or convected heating.

15. A flexible pipe body as claimed in claim 5 wherein the one or more composite filaments comprises a lubricant of oil, wax, or uncured resin.

16. A flexible pipe body as claimed in claim 5 wherein the armour layer is obtainable by the process of providing a further filament bundle, applying a braid element around the filament bundle as a further braided bundle, prior to the steps of helically wrapping the braided bundle and further braided bundle and curing the composite filaments.

17. A flexible pipe comprising a flexible pipe body as claimed in claim 5 and one or more end fittings connected thereto.