Reinforced thermoplastic pipe manufacture

• US 6,773,773 B2
• Filed: 06/14/1999
• Issued: 08/10/2004
• Est. Priority Date: 06/14/1999
• Status: Expired due to Term

• Current Assignee: ADC Acquisition Company (Trelleborg AB)
• Original Assignee: ADC Acquisition Company (Trelleborg AB)
• Inventors: Hauber, David Edgar
• Primary Examiner(s): Nolan, Sandra M.
• Assistant Examiner(s): CHEVALIER, ALICIA ANN
• Application Number:
  US09/332,420
• Publication Number:
  US 20020054968A1
• Time in Patent Office: 1,884 Days
• Field of Search: 428/34.1, 428/34.4, 428/34.5, 428/34.6, 428/34.7, 428/36.3, 428/36.9, 428/36.91, 138/172, 138/174, 156/166, 156/172, 156/173
• US Class Current: 428/34.4
• CPC Class Codes: B29C 53/64 and moving axially
• CPC Class Codes: B29C 53/68 with rotatable winding feed member
• CPC Class Codes: B32B 1/08 Tubular products
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: Y10T 428/131 Glass, ceramic, or sintered, fused, fired, or calcined metal oxide or metal carbide containing [e.g., porcelain, brick, cement, etc.]
• CPC Class Codes: Y10T 428/1314 Contains fabric, fiber particle, or filament made of glass, ceramic, or sintered, fused, fired, or calcined metal oxide, or metal carbide or other inorganic compound [e.g., fiber glass, mineral fiber, sand, etc.]
• CPC Class Codes: Y10T 428/1317 Multilayer [continuous layer]
• CPC Class Codes: Y10T 428/1321 Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1352 Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1369 Fiber or fibers wound around each other or into a self-sustaining shape [e.g., yarn, braid, fibers shaped around a core, etc.]
• CPC Class Codes: Y10T 428/139 Open-ended, self-supporting conduit, cylinder, or tube-type article
• CPC Class Codes: Y10T 428/1393 Multilayer [continuous layer]

Abstract

A fiber reinforced thermoplastic pipe member is obtained by a novel continuous process in which the reinforcement fibers are wrapped about the outer pipe surface in an unbonded condition while the pipe member continuously moves in a linear direction and which is followed by sufficient heating of the moving fiber wrapped pipe member to cause thermal bonding between the applied fibers and the pipe member. Automated apparatus for carrying out the continuous process is also disclosed.

Claims

1. A fiber reinforced pipe member comprising an already formed solid thermoplastic pipe length having an outer wall surface enclosing an inner hollow cavity which includes multiple applied layers of continuous juxtapositioned reinforcement fibers formed with a solid material composition selected from the group consisting of ceramics, metals, carbon, glass compositions and organic polymers which further includes a thermoplastic resin binder, each of said multiple applied layers having been applied successively at a predetermined spatial angle with respect thereto which differs from the spatial angle employed for the immediately preceding applied layer, said reinforcement fibers having been continuously wrapped about the outer surface of the unheated hollow pipe length in an unbonded condition while said pipe length continuously moves without rotation in a linear travel direction with respected thereto, followed by sufficient external heating of the fiber wrapped pipe length thereafter while continuously moving in the same linear travel direction to cause thermal bonding of all applied fibers to the outer wall surface of the underlying hollow pipe length without further melting of said underlying hollow pipe length.

2. The fiber reinforced pipe length of claim 1 wherein the pipe reinforcement fibers are wrapped in the hoop direction.

3. The fiber reinforced pipe length of claim 1 wherein the pipe length has a cylindrical configuration.

4. A plurality of identical fiber reinforced pipe lengths joined together prior to reinforcement at the ends and each comprising a solid thermoplastic organic polymer member having an outer wall surface enclosing an inner hollow cavity which includes multiple applied layers of continuous juxtapositioned reinforcement fibers formed with a solid material composition selected from the group consisting of ceramics, metals, carbon, glass compositions and organic polymers which further includes a thermoplastic resin binder, each of said multiple applied layers having been applied successively at a predetermined spatial angle with respect thereto which differs from the spatial angle employed for the immediately preceding applied layer, said reinforcement fibers having been continuously wrapped about the outer surface of the unheated hollow pipe lengths in an unbonded condition while said joined pipe lengths continuously move without rotation in a linear travel direction with respect thereto, followed by sufficient external heating of the fiber wrapped pipe lengths thereafter while continuously moving in the sane linear travel direction to cause thermal bonding of all applied fibers to the outer wall surface of the underlying joined pipe lengths without further melting of said underlying hollow pipe lengths.

5. The fiber reinforced pipe lengths of claim 4 wherein the individual fiber wraps are aligned in the hoop direction.