Pipe section having bonded composite barrier layer
Pipe sections and methods for forming pipe sections are disclosed. A pipe section includes a hollow body formed from a metal material, the hollow body having an inner surface and an outer surface, the inner surface defining an interior. The pipe section further includes a barrier layer surrounding and bonded to the hollow body, the barrier layer having an inner surface and an outer surface. The barrier layer is formed from a continuous fiber reinforced thermoplastic material. Such pipe sections may be lightweight and flexible while exhibiting improved strength characteristics.
1. A pipe section, comprising:
a hollow body formed from a metal material, the hollow body having an inner surface and an outer surface, the inner surface defining an interior;
a barrier layer surrounding and bonded to the hollow body, the barrier layer having an inner surface and an outer surface, the barrier layer formed from a continuous fiber reinforced thermoplastic material, wherein the thermoplastic material is a polyarylene sulfide composition comprising a polyarylene sulfide and a crosslinked impact modifier.
2. The pipe section of claim 1 , wherein the barrier layer is a tape.
3. The pipe section of claim 2 , wherein the tape is wrapped generally helically around the hollow body with respect to a longitudinal axis of the hollow body.
4. The pipe section of claim 1 , wherein the continuous fibers are generally unidirectional.
5. The pipe section of claim 1 , wherein the hollow body is formed from a steel.
6. The pipe section of claim 1 , wherein the continuous fibers are carbon fibers.
7. The pipe section of claim 1 , wherein the continuous fibers are glass fibers.
8. The pipe section of claim 1 , wherein the continuous fibers are aramid fibers.
9. The pipe section of claim 1 , wherein the hollow body is formed from a plurality of interlocking strips.
10. The pipe section of claim 1 , wherein the barrier layer is a plurality of barrier layers.
11. A method for forming a pipe section, the method comprising:
forming a tape, comprising:
flowing a thermoplastic resin through a manifold assembly of a die, the manifold assembly comprising a plurality of branched runners;
coating at least one fiber roving with the resin; and
traversing the coated roving through an impregnation zone of the die to impregnate the roving with the resin;
surrounding a hollow body with a barrier layer such that the barrier layer is in contact with an outer surface of the hollow body, the hollow body formed from a metal material, and wherein the barrier layer is the tape formed from a continuous fiber reinforced thermoplastic material;
heating the barrier layer to a consolidation temperature; and
consolidating the hollow body and the barrier layer.
12. The method of claim 11 , wherein the surrounding step comprises wrapping the barrier layer generally helically around the hollow body with respect to a longitudinal axis of the hollow body.
13. The method of claim 11 , wherein the thermoplastic material is a polyarylene sulfide composition comprising a polyarylene sulfide and a crosslinked impact modifier.
14. A method for forming a pipe section, the method comprising:
surrounding a hollow body with a barrier layer such that the barrier layer is in contact with an outer surface of the hollow body, the hollow body formed from a metal material, the barrier layer formed from a continuous fiber reinforced thermoplastic material, wherein the thermoplastic material is a polyarylene sulfide composition comprising a polyarylene sulfide and a crosslinked impact modifier;
heating the barrier layer to a consolidation temperature; and
consolidating the hollow body and the barrier layer.
15. The method of claim 14 , wherein the surrounding step comprises wrapping the barrier layer generally helically around the hollow body with respect to a longitudinal axis of the hollow body.
16. The method of claim 14 , wherein the barrier layer is a tape formed from the continuous fiber reinforced thermoplastic material.