A method of manufacturing a high-strength pipe shells made of composite materials (options)

 

(57) Abstract:

The invention relates to mechanical engineering and can be used in the manufacture of the casing pipe made of composite materials used in the products of aviation and space technology, pressure cylinders, pipelines, petrochemical and gas industry, construction, laying communications method of manufacture of the casing pipe, the mandrel is wound unidirectional yarns, impregnated with a polymeric binder. When the impregnation of the threads are formed in the form of a rigid structure, the sheath-core. In the core of injected high modulus yarn, put a shell made of thermosetting epoxydodecane binder weight equal to 30-45% of the mass of the nucleus, utverjdayut her fully on this thread. The obtained filament rigid structure is applied polymer binder, which is used as thermoplastic binder weight 30-45% of the mass of thread patterns sheath-core. Winding lead thread of the new structure with the subsequent formation of them bearing layer pipe coating. In another embodiment, the method as a polymeric binder used elastic binder type rubber, polyurethane. 2 N. p. F.-ly, 4 Il.

The invention relates to the field of engineering is in the products of aviation and space technology, the pressure cylinders, pipelines, petrochemical and gas industry, construction, laying switching.

Known methods of manufacturing zelenokamennykh shells made of composite materials, including impregnation of the binder threads, laying strands of filaments in the form of a tape on a mandrel with a different angle to the axis of its rotation with the formation of the bearing layer, the heat treatment to cure the binder and removing the mandrel (U.S. patent N 3047191, CL 220-83, 1962, [1].

The main problem of such membranes is the provision of sealing. Therefore, in the manufacture of high strength membranes under wound layers of reinforcing filaments enter the sealing layers (French patent N 1414309, B 64 D) [2].

The introduction of the sealing layers increases the weight of the products, which is undesirable.

In the patent [3] after winding layers of strips of unidirectional yarns, impregnated with a binder, the layers additionally coprophiliac and compresses to seal, followed by curing. The introduction of additional impregnation increases the complexity and energy consumption for the manufacture of the shell.

In the application [4] on the mandrel before the winding layers of impregnated yarns put rigid durable and vozdukhe the high modulus aramid fibers.

To obtain an airtight membranes form layers in combination with thermoplastic films stacked between them [5].

The resulting structure reinforcement on the physicomechanical properties remains heterogeneous across the wall thickness of the shell does not ensure compatibility between the filament and the matrix, which affects the manifestation of shear deformation, resulting in delamination.

In high-strength pipes [6] to increase the interlaminar strength use layers of fiberglass. To ensure the best interaction with the reinforcing fiber used modified thermoplastics [7].

The design of the shells is based on assumptions that the binder acts as a medium that propagates evenly voltage across wound construction, the maximum allowable deformation of the binder above deformation of the fiber. The use of a suitable binder, a modulus of elasticity which is considerably lower than the elastic modulus of the fiber, ensures that there will be destruction of the fiber, and not binding, and thereby maximize efficiency [8].

However, as shown by pipe testing (Handbook of composite materials, book II, by the editor. J. Liu, the received characteristics are nonlinear, due to the delamination starts to leak protection. The effectiveness of pipes made of high-modulus fibers may be increased, as indicated, with thermoplastic layers and due to seal threads. Because of the different orientation of the fibers between the plies of interlayer shear stresses, leading to premature failure of the pipe (Kelly And durable materials, - M.: Mir, 1976, S. 202-206).

The phenomenon of destruction of the binder in the deformation process takes place due to brittle fracture layer, stretch across the grain, which leads to a significant reduction in the rigidity of the material. Discontinuity composite material occurs at loads far from destroying. This is evidenced by the beginning of the non-linear portion of the strain of the internal pressure. Cracking of the binder degrades fatigue data to a number of other adverse events, in particular the loss of pressure. The introduction of the protective coating degrades mass characteristics of the product (I. F. Samples in. A. Vasiliev, V. A. Burakov, Optimal reinforcement shells of revolution made of composite materials, - M: Machinista Ogulin, Technology of tire production, ed. 2-E. M.: Chemistry, 1975, S. 93, 96). However, this solution is not enough - thread grated.

The closest analogue, selected as a prototype, is a method of manufacturing a high-strength pipe shells made of composite materials, including wound on a mandrel unidirectional yarns, impregnated with a polymeric binder, forming the bearing layer, followed by curing [8]. The problem of reliability of the casing pipe depends on what found a technical solution to effective communication fibers and binder in the selected structure reinforcement. Prior art in the selected areas can be achieved either in the selection of the elastic properties of fibers and a binder, or by introducing a sealing layers and coatings. And in both cases the pipe shell made of composite materials have due to the introduction of the factor of safety increased weight, intensity, complexity and energy consumption.

The main objective of the development is the creation of the casing pipe made of composite materials such new ways, which would eliminate the above disadvantages, their implementation would provide were the targets.

The technical result that can be obtained from the use of new technical solutions is to increase the strength and reliability of the casing pipe made of composite materials, reducing weight, reducing the safety factor to the lowest stable value, lower consumption of materials and energy recycling.

The main problem is solved and the technical result is achieved due to a different approach to the interaction of the reinforcing filaments and the binder in the composite structure pipe-shell-based implementation of the proposed technical solutions in order shear stresses and strains did not lead to the destruction of the threads in the transverse direction and premature structural failure and malfunction. The idea is that there will be no transverse and interlaminar fracture, fiber thread and the thread itself were fixed durable and high rigid binder as effectively and the resulting thread was enclosed in plastic or elastic matrix-binder of the composite structure, which under no circumstances deformation, except in the case of extreme loading, did not lead to the destruction of the product.

A new concept of realizovala, including the winding on the mandrel unidirectional yarns, impregnated with a polymeric binder, forming the bearing layer, followed by curing, unidirectional yarn impregnation shape in the form of a rigid structure, the sheath-core, the core of which impose high modulus filament, the sheath is applied from thermosetting epoxydodecane binder weight 30-45% of the mass of the nucleus, it is fully utverjdayut thread, then applied polymer binder, which is used as a thermoplastic type of thermoplastic or elastic binder type rubber, polyurethane, a mass equal to 30-45% of the mass of thread patterns sheath-core, and thread the new structure form a load-bearing layers of the pipe shell.

Distinctive features of the proposed method of manufacturing a high-strength pipe shells made of composite materials are the following characteristics (option 1):

- the formation of unidirectional filaments with impregnation in the form of a rigid structure, the sheath-core.

application and curing of the shell in this structure of thermosetting epoxydodecane connecting directly to the core of high-strength material - high modulus yarn,

mass content of the shell 30-45% attributed the mass ratio of polymer binder to the weight of the yarn structure, the sheath-core, equal to 30-45%;

the same characteristics, except for the impregnation of the composite reinforcing structure of the tube-shell used as a polymeric binder elastic binder type rubber, polyurethane.

Distinctive features are essential, because each of them separately and together is aimed at solving the problem and achieving a new technical result. The failure of the operations associated with the full-curing unidirectional threads, put on them thermosetting epoxydodecane binder, at the stage of impregnation, application of thermoplastic or elastic binder and forming them bearing layer pipe coating does not allow to obtain high strength and reliability. Of the proposed solutions in order to obtain high-strength pipe, it is necessary to strengthen unidirectional filament to a high stiffness to winding on the mandrel, it is strengthening to do with thermosetting binders, their covering. Winding to produce threads of the new rigid structure sheath-core, but with the already printed on them are thermoplastic or elastic binder, which is subject overiden the General material properties of products.

These distinctive essential features are new for methods of manufacturing high-strength pipe shells made of composite materials, because their use in the prior art, analogs and prototype not found, which allows to characterize the proposed technical solutions, alternatives that match the criterion of "Novelty".

One set of new essential features with commonly known essential features allows to solve the problem of two parallel variants, to achieve new technical result, which allows to characterize new technical solutions significant differences from the prior art, analogs and prototypes. New technical solutions are the result of research work, creative input, obtaining non-traditional way, without the use of standard design solutions, development or any known recommendations in this technical field, for its originality and content meet the criterion of "Inventive step".

In Fig. 1 presents a General view of the high strength pipe-shell made of composite materials; Fig. 2 - axial. the high Strength pipe-shell composite materials it contains the corresponding profile frame, made of repeating the thickness of its walls layer 1 systems of intersecting spiral and annular strips 2, 3 layers 1 of unidirectional filaments 4, fastened utverzhdennym polymeric binder 5. Unidirectional filament 4 intersecting spiral and annular strips 2, 3 of the layer 1 frame is made in the form of a rigid structure, the sheath-core, core 6 which contains high modulus filaments, and the shell 7 is made utverzhdenii of thermosetting epoxydodecane binder weight, equal 3-45% by weight of the core 6. On thread 4 applied thermoplastic or elastic binder 5 a mass equal to 30-45% of the mass of the threads of the new structure, the sheath-core.

A method of manufacturing a high-strength pipe shells made of composite materials is applied on high-modulus filament 6 thermosetting epoxydodecane binder 7 by passing it through a bath with a binder and the rolls or the die plate (not shown) followed by complete curing of the binder 7 thread 6 with education on it covering the shell in such a way that the thread 4 becomes rigid structure sheath-core, with sufficient flexibility in the longitudinal direction, not narrowing it winding on the mandrel, then this is the W layer 1 of the systems of intersecting spiral and annular strips 2, 3 of unidirectional filaments 4 to complete the education pipe-shell with such density that applied polymer binder 5 filled in all the gaps between the threads 4. Then the polymer binder 5 utverjdayut by placing the mandrel with the workpiece in a special chamber under specified conditions of polymerization. When the mass fraction of 30% of the binder for the formation of the shell 7 is provided continuous coverage of high modulus yarns 6, when the mass fraction is less than specified, the continuous coating of high modulus filaments 6 is not provided, the wall thickness of the shell 7 is uneven, resulting in the culling of 4 threads. When the mass fraction of 45% of the binder for the formation of the shell 7 is provided uniform sediment binders on high modulus filaments 6, when exceeding this proportion observed streaks binder deteriorates the processing technology of the thread 4. Given that the binding thread 6 is fully cured and is mass 30-45% of the mass of the nucleus, from the point of view of processing these marginal interest rate are optimal and effective for imparting unidirectional filaments 4 patterns sheath-core increased rigidity and strength, elementary high modulus fibers in the yarns 6 are not destroyed, vesprini 5, which can be used thermoplastic or elastic binder, applied to unidirectional filaments 4, ensures the continuity of the wall of the pipe coating, and its tightness. When the mass fraction of 45% polymer binder 5 is also provided a uniform pump connecting, sealing and reliability pipe-shell, if you exceed this mass fraction significantly increases the wall thickness and the weight of the pipe coating, which is unacceptable. The application of binder 5 within the mass fraction 30-45% provides the best adaptability processing of the material, enhanced durability, reliability and efficiency of the design. As a thermosetting binder 5 was used epoxydodecane binder type epoxyconazole resin. As the polymer binder 5 was used thermoplastic binder is a thermoplastic, polysulfone or elastic binder - rubber, isoprene rubber, polyurethane.

When loading pipe coating of the proposed options the interaction of unidirectional filaments with a binder is as follows.

Each unidirectional filament 4, consisting of high modulus yarns 6, having, as a rule, the beam El is ka-core, in the longitudinal direction this thread has sufficient flexibility that it provides processability in the product. When exposed to this thread transverse shear deformation, thread, its bonded fibers, not destroyed, and works in a range of deformation. As the matrix polymer binder 5 is a thermoplastic (option I) or elastic (option II), i.e., when the loading pipe coating pliable enough for the perception of shear deformation, the filament 4, bottom hardness and toughness, track these its elastic deformation curve up to the highest limits of loading.

The tests of the casing pipe 400 mm diameter made of composite materials made of the proposed methods, confirmed the high strength, integrity and reliability in contrast to the casing pipe is made using traditional manufacturing methods. Their effectiveness is reflected in a reduction of the wall thickness, the saving of reinforcing and polymer materials up to 10% and reducing energy consumption.

Therefore, new technical solutions in the manufacturing methods of the casing pipe made of composite materials have industrial Voprosi,

1. A method of manufacturing a high-strength pipe shells made of composite materials, including wound on a mandrel unidirectional yarns, impregnated with a polymeric binder, forming the bearing layer, followed by curing, characterized in that the unidirectional yarns in the form impregnation in the form of a rigid structure, the sheath-core, the core of which impose high modulus yarn, put a shell made of thermosetting epoxydodecane binder weight equal to 30 - 45% of the mass of the nucleus, it is fully utverjdayut on this thread, then on the resulting thread rigid structure is applied polymer binder, which is used as thermoplastic binder weight equal to 30 - 45% weight yarn patterns sheath-core, and the winding lead thread of the new structure with the subsequent formation of them bearing layer pipe coating.

2. A method of manufacturing a high-strength pipe shells made of composite materials, including wound on a mandrel unidirectional yarns, impregnated with a polymeric binder, forming the bearing layer, followed by curing, characterized in that the unidirectional yarns in the form impregnation in the form of a rigid structure, the sheath-core, the core of which impose high modulus is awn her utverjdayut on this thread, then on the resulting thread rigid structure is applied polymer binder, which is used as an elastic binder type rubber, polyurethane mass, equal to 30 - 45% of the mass of thread patterns sheath-core, and the winding lead thread of the new structure with the subsequent formation of them bearing layer pipe coating.

 

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