PREPARATION METHOD AND USE OF HYBRID COMPOSITE PIPES

• US 20190323634A1
• Filed: 07/03/2019
• Published: 10/24/2019
• Est. Priority Date: 01/03/2017
• Status: Active Application

• Current Assignee: Xiaodong Zhang
• Original Assignee: Xiaodong Zhang
• Inventors: ZHANG, Xiaodong
• Application Number:
  US16/502,824
• Publication Number:
  US 20190323634A1
• Time in Patent Office: Days
• CPC Class Codes: B29C 48/09 Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• CPC Class Codes: B29D 23/00 Producing tubular articles B29D24/00 takes precedence
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: B32B 15/02 Layer formed of wires, e.g. mesh
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 15/085 comprising polyolefins
• CPC Class Codes: B32B 15/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 15/16 next to a particulate layer
• CPC Class Codes: B32B 15/18 comprising iron or steel B32B15/011, B32B15/012 and B32B15/013 take precedence
• CPC Class Codes: B32B 2255/20 Inorganic coating
• CPC Class Codes: B32B 2255/205 Metallic coating
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/025 Particulate layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/0223 Vinyl resin fibres
• CPC Class Codes: B32B 2262/0238 Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 2262/0246 Acrylic resin fibres
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/0261 : Polyamide fibres
• CPC Class Codes: B32B 2262/0269 : Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/0276 : Polyester fibres
• CPC Class Codes: B32B 2262/101 : Glass fibres
• CPC Class Codes: B32B 2262/106 : Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2264/10 : Inorganic particles
• CPC Class Codes: B32B 2264/101 : Glass
• CPC Class Codes: B32B 2264/102 : Oxide or hydroxide
• CPC Class Codes: B32B 2264/107 : Ceramic
• CPC Class Codes: B32B 2264/2031 : Porous particles
• CPC Class Codes: B32B 2307/202 : Conductive
• CPC Class Codes: B32B 2307/304 : Insulating
• CPC Class Codes: B32B 2307/306 : Resistant to heat
• CPC Class Codes: B32B 2307/3065 : Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/402 : Coloured
• CPC Class Codes: B32B 2307/51 : Elastic
• CPC Class Codes: B32B 2307/536 : Hardness
• CPC Class Codes: B32B 2307/54 : Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/554 : Wear resistance
• CPC Class Codes: B32B 2307/558 : Impact strength, toughness
• CPC Class Codes: B32B 2307/71 : Resistive to light or to UV
• CPC Class Codes: B32B 2307/7145 : Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2307/72 : Density
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2307/738 : Thermoformability
• CPC Class Codes: B32B 2307/744 : Non-slip, anti-slip
• CPC Class Codes: B32B 2307/752 : Corrosion inhibitor
• CPC Class Codes: B32B 2597/00 : Tubular articles, e.g. hoses, pipes
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/14 : next to a particulate layer
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/28 : characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 5/16 : characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 5/30 : one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: B32B 9/005 : comprising one layer of ceramic material, e.g. porcelain, ceramic tile layered products with at least two ceramic layers composed mainly of ceramic B32B18/00
• CPC Class Codes: B32B 9/045 : of synthetic resin
• CPC Class Codes: B32B 9/047 : made of fibres or filaments
• CPC Class Codes: C08K 11/005 : Waste materials, e.g. treated or untreated sewage sludge
• CPC Class Codes: C08K 3/34 : Silicon-containing compounds
• CPC Class Codes: C08K 7/14 : Glass
• CPC Class Codes: C08K 7/22 : Expanded, porous or hollow particles
• CPC Class Codes: C08K 9/06 : with silicon-containing compounds
• CPC Class Codes: C08L 2203/10 : used for bottles
• CPC Class Codes: C08L 2205/025 : containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
• CPC Class Codes: C08L 23/06 : Polyethene
• CPC Class Codes: C08L 23/0815 : Copolymers of ethene with aliphatic 1-olefins
• CPC Class Codes: C08L 23/286 : Chlorinated polyethylene
• CPC Class Codes: C08L 67/06 : Unsaturated polyesters
• CPC Class Codes: F16L 11/083 : three or more layers
• CPC Class Codes: F16L 9/14 : Compound tubes, i.e. made of materials not wholly covered by any one of the preceding groups F16L9/16 - F16L9/22 take precedence
• CPC Class Codes: F16L 9/147 : comprising only layers of metal and plastics with or without reinforcement
• CPC Class Codes: F16L 9/22 : Pipes composed of a plurality of segments

Abstract

A preparation method of a hybrid composite pipe and applications thereof. By mixing and curing high polymers as a matrix with one or more types of porous lightweight aggregates or granules, the main body or structural layer of this composite pipe can combine with a variety of non-metal or metal materials as well as various types of metal or non-metal base pipes so as to prepare different hybrid composite pipes. The high polymers include the thermosetting high polymers and thermoplastic high polymers. The pipe can be prepared and molded by one or more processes of rolling, winding, pultrusion, centrifugal casting, extrusion, injection molding, resin transfer, and sandwiching. The pipe described herein can be applied to petroleum, natural gas, heat and gas supply, water supply and drainage, agricultural irrigation, mining, seawater desalination, electric power communication, municipal pipeline corridor and other purposes.

Claims

1. A hybrid composite pipe, comprising an outer layer, an inner layer and a main structural layer;

wherein the outer layer and the inner layer are made from high polymers or base pipes;

the main structural layer is made by combining the high polymers as a matrix with porous lightweight aggregates or granules that have a bulk density of less than 1200 kg/m³ and a porous or uneven surface; and

the high polymers comprise thermosetting high polymers and thermoplastic high polymers.

2. The hybrid composite pipe of claim 1, wherein at least one of the outer, inner and main structural layers is a metal or a ceramic base pipe structure, or additionally coated with a metal or ceramic base pipe structure.

3. The hybrid composite pipe of claim 1, wherein the porous lightweight aggregates or granules are selected from ceramsite, ceramic sand, expanded perlite, glass microbeads, pumice, volcanic slag, cinder, mineral waste residue, porous sinter, light sand, porous plastic granules and artificial or natural lightweight granules.

4. The hybrid composite pipe of claim 2, wherein the porous lightweight aggregates or granules are selected from ceramsite, ceramic sand, expanded perlite, glass microbeads, pumice, volcanic slag, cinder, mineral waste residue, porous sinter, light sand, porous plastic granules and artificial or natural lightweight granules.

5. The hybrid composite pipe of claim 1, wherein the high polymers are compounds with relative molecular weight of greater than 10,000, comprising thermoplastic plastics selected from PE, PP, PVC, PS, ABS, PEEK, PES, PASU, PPS, XLPE, m-PP and PB-1), thermosetting plastics (selected from phenolics, epoxy, amino, unsaturated polyester, furane, polysiloxane, and PDAP plastics), rubbers (selected from styrene butadiene rubber, butadiene rubber, isoprene rubber, ethylene propylene rubber and neoprene rubber), special rubbers (selected from nitrile rubber, chlorinated rubber, fluororubber, epichlorohydrin rubber, silicone rubber, urethane rubber, polysulfide rubber, and acrylate rubber), and fibers (selected from glass fiber, aramid fiber, carbon fiber, polyester fiber/terylene, polyamide fiber/chinlon/nylon, polyvinyl alcohol fiber/vinyl, polyacrylonitrile fiber/acrylic fiber, polypropylene fiber/PP fiber, polyvinyl chloride fiber/PVC fiber, and synthetic and regenerated fibers).

6. The hybrid composite pipe of claim 2, wherein the high polymers are compounds with relative molecular weight of greater than 10,000, comprising thermoplastic plastics selected from PE, PP, PVC, PS, ABS, PEEK, PES, PASU, PPS, XLPE, m-PP and PB-1, thermosetting plastics selected from phenolics, epoxy, amino, unsaturated polyester, furane, polysiloxane, and PDAP plastics, rubbers selected from styrene butadiene rubber, butadiene rubber, isoprene rubber, ethylene propylene rubber and neoprene rubber, special rubbers selected from nitrile rubber, chlorinated rubber, fluororubber, epichlorohydrin rubber, silicone rubber, urethane rubber, polysulfide rubber, and acrylate rubber, and fibers selected from glass fiber, aramid fiber, carbon fiber, polyester fiber/terylene, polyamide fiber/chinlon/nylon, polyvinyl alcohol fiber/vinyl, polyacrylonitrile fiber/acrylic fiber, polypropylene fiber/PP fiber, polyvinyl chloride fiber/PVC fiber, and synthetic and regenerated fibers.

7. The hybrid composite pipe of claim 1, wherein the main structural layer is produced by mixing the porous lightweight aggregates or granules with other pipe granules and materials comprising short fiber materials and nano materials.

8. The hybrid composite pipe of claim 2, wherein the main structural layer is produced by mixing the porous lightweight aggregates or granules with other pipe granules and materials comprising short fiber materials and nano materials.

9. The hybrid composite pipe of claim 1, wherein the porous lightweight aggregates or granules are modified using a surfactant and coupling agent by a method comprising:

adding the surfactant or the coupling agent to a low-boiling solvent to form a solution with certain concentration, and then uniformly dispersing the porous lightweight aggregates or granules in the solution in a high-speed mixer at a certain temperature;

alternatively, reacting with the atomized surfactant or the coupling agent at a certain temperature;

or, as another option, dispersing a cross-linking agent into a certain solvent, adding the porous lightweight aggregates or granules into the solvent, and treating the solvent by heating and stirring simultaneously.

10. The hybrid composite pipe of claim 1, wherein organic bentonite, thickeners, binders and hot melt adhesives are added to the main structural layer.

11. The hybrid composite pipe of claim 2, wherein organic bentonite, thickeners, binders and hot melt adhesives are added to the main structural layer.

12. The hybrid composite pipe of claim 1, wherein the composite pipe is prepared and molded by one or more processes of rolling, winding, pultrusion, centrifugal casting, extrusion, injection molding, prestressing, resin transfer, and sandwiching.

13. The hybrid composite pipe of claim 2, wherein the composite pipe is prepared and molded by one or more processes of rolling, winding, pultrusion, centrifugal casting, extrusion, injection molding, prestressing, resin transfer, and sandwiching.

14. An application of the hybrid composite pipe of claim 1, comprising:

applying the hybrid composite pipe in petroleum, natural gas, heat and gas supply, water supply and drainage, agricultural irrigation, mining, seawater desalination, electric power communication, municipal pipeline corridor and the other purposes.

15. An application of the hybrid composite pipe of claim 2, comprising:

applying the hybrid composite pipe in petroleum, natural gas, heat and gas supply, water supply and drainage, agricultural irrigation, mining, seawater desalination, electric power communication, municipal pipeline corridor and the other purposes.