Patent Application
20130330553
Fiber rovings have been employed in a wide variety of applications. For example, such ravings have been utilized to form fiber-reinforced composite rods. The rods may be utilized as lightweight structural reinforcements. For example, power umbilicals are often used in the transmission of fluids and/or electric signals between the sea surface and equipment located on the sea bed. To help strengthen such umbilicals, attempts have been made to use pultruded carbon fiber rods as separate load carrying elements.
Present manufacturing techniques have improved such that rods having relatively long lengths, and which still exhibit desirable strength properties, can be manufactured. For example, fiber reinforced thermoplastic rods having lengths of up to approximately 5,000 feet can be manufactured in some instances. However, for many applications, longer lengths of rods are required. Rods for use in, for example, undersea power umbilicals may be required to have lengths exceeding 20,000 feet.
Various methods and apparatus for joining rods to form longer rod assemblies are known. However, such methods and apparatus generally cause weakening of the rods at the connection between the rods. For example, mechanical devices and other various methods and apparatus utilized to join rods together may cause misalignments between the fibers in the rods at the connection between the rods. This can significantly weaken the rods at the connection, which can cause failure of the rods during use in various applications.
As such, a need currently exists for an improved method for forming a rod assembly, and for an improved rod assembly. In particular, a need currently exists for a method that results in a rod assembly, and a rod assembly, having improved strength characteristics at the connections between the various rods of the rod assembly.
In accordance with one embodiment of the present disclosure, a method for forming a fiber reinforced polymer rod assembly is disclosed. The method includes heating a portion of a first fiber reinforced polymer rod and heating a portion of a second fiber reinforced polymer rod. The method further includes intertwining the portions of the first fiber reinforced polymer rod and the second fiber reinforced polymer rod to form a rod connecting section. The method further includes aligning the first fiber reinforced polymer rod and the second fiber reinforced polymer rod along a linear axis. The method further includes cooling the portions of the first fiber reinforced polymer rod and the second fiber reinforced polymer rod.
In accordance with another embodiment of the present disclosure, a fiber reinforced polymer rod assembly is disclosed. The rod assembly includes a first fiber reinforced polymer rod, a second fiber reinforced polymer rod, and a rod connecting section. The rod connecting section includes overlapping portions of the first fiber reinforced polymer rod and the second fiber reinforced polymer rod, the overlapping portions being intertwined and fused together.
In accordance with another embodiment of the present disclosure, a method for forming a fiber reinforced polymer rod assembly is disclosed. The method includes heating a portion of a first fiber reinforced polymer rod and heating a portion of a second fiber reinforced polymer rod. The method further includes aligning the first fiber reinforced polymer rod and the second fiber reinforced polymer rod along a linear axis such that the portions of the first fiber reinforced polymer rod and the second fiber reinforced polymer rod overlap and are in contact along the linear axis. The method further includes surrounding the portions of the first fiber reinforced polymer rod and the second fiber reinforced polymer rod with a fiber reinforced polymer cuff to form a rod connecting section. The method further includes cooling the portions of the first fiber reinforced polymer rod and the second fiber reinforced polymer rod.
In accordance with another embodiment of the present disclosure, a fiber reinforced polymer rod assembly is disclosed. The rod assembly includes a first fiber reinforced polymer rod, a second fiber reinforced polymer rod, and a rod connecting section. The rod connecting section includes overlapping portions of the first fiber reinforced polymer rod and the second fiber reinforced polymer rod, the overlapping portions being surrounded by a cuff, the overlapping portions and cuff being fused together.
In accordance with another embodiment of the present disclosure, a method for forming a fiber reinforced polymer rod assembly is disclosed. The method includes aligning a first fiber reinforced polymer rod and a second fiber reinforced polymer rod such that a portion of the first fiber reinforced polymer rod and a portion of the second fiber reinforced polymer rod overlap. The method further includes heating the overlapping portion of the first fiber reinforced polymer rod and heating the overlapping portion of the second fiber reinforced polymer rod. The method further includes pressing the overlapping portions of the first fiber reinforced polymer rod and the second fiber reinforced polymer rod together. The method further includes cooling the overlapping portions of the first fiber reinforced polymer rod and the second fiber reinforced polymer rod.
In accordance with another embodiment of the present disclosure, a fiber reinforced polymer rod assembly is disclosed. The rod assembly includes a first fiber reinforced polymer rod, a second fiber reinforced polymer rod, and a rod connecting section. The rod connecting section includes overlapping portions of the first fiber reinforced polymer rod and the second fiber reinforced polymer rod, the overlapping portions being pressed and fused together.
Other features and aspects of the present invention are set forth in greater detail below.
A full and enabling disclosure of the present invention, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:
Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.
It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention.
Generally speaking, the present disclosure is directed to methods for forming fiber reinforced polymer rod assemblies, and the resulting fiber reinforced polymer rod assemblies. A fiber reinforced polymer rod assembly according to the present disclosure includes multiple fiber reinforced polymer rods. These rods are connected together to form the fiber reinforced polymer rod assembly. In exemplary embodiments, the polymers utilized to form the rods are thermoplastics, such as for example polyphenylene sulfide (“PPS”).
In some exemplary embodiments, the rods of a rod assembly according to the present disclosure are connected by heating, intertwining, and cooling of the rods. For example, portions of the rods may be heated. Heating may be to a temperature generally high enough to soften the polymer material to an extent that the rods can bond, or fuse, together. For example, in some embodiments, portions of the rods may be heated to the melting point for the polymer materials of the rods. These portions may then be intertwined, as discussed herein. The intertwined rods may then be cooled. The resulting rods may be intertwined and fused together to form a rod assembly.
In other exemplary embodiments, the rods of a rod assembly according to the present disclosure are connected by heating, overlapping, surrounding with a fiber reinforced polymer cuff, and cooling. For example, portions of the rods, and the cuff, may be heated. These portions may be overlapped, and the cuff may be positioned surrounding the portions of the rods. The rods, and the cuff, may then be cooled. The resulting rods may be surrounded and fused together, and the cuff may be fused to the rods, to form a rod assembly.
In still other exemplary embodiments, the rods of a rod assembly according to the present disclosure are connected by heating, pressing, and cooling of the rods. For example, portions of the rods may be heating. These portions may then be placed in a die press and pressed together. The pressed together rods may then be cooled. The resulting rods may be pressed and fused together to form a rod assembly.
Connecting of rods to form a rod assembly as disclosed herein may provide improved strength characteristics for the rod assembly. In particular, the present disclosure may provide for improvements in the strength of the rods assembly at the connections between the rods in the rod assemblies. In some exemplary embodiments, these improvements are caused by aligning of the rods along a linear axis during various steps in the forming process, such that the fibers in the rods generally align during the forming process. Tensile forces may additionally be applied to the rods during formation to provide this alignment and resulting improvement in local and overall strength characteristics.
Referring now to
Any of a variety of polymers, such as in exemplary embodiments thermoplastics, may be utilized to form a rod according to the present disclosure. Suitable polymers for use in the present invention may include, for instance, polyolefins (e.g., polypropylene, propylene-ethylene copolymers, etc.), polyesters (e.g., polybutylene terephalate (“PBT”)), polycarbonates, polyamides (e.g., Nylon™), polyether ketones (e.g., polyetherether ketone (“PEEK”)), polyetherimides, polyarylene ketones (e.g., polyphenylene diketone (“PPDK”)), liquid crystal polymers, polyarylene sulfides (e.g., polyphenylene sulfide (“PPS”)), fluoropolymers (e.g., polytetrafluoroethylene-perfluoromethylvinylether polymer, perfluoro-alkoxyalkane polymer, petrafluoroethylene polymer, ethylene-tetrafluoroethylene polymer, etc.), polyacetals, polyurethanes, polycarbonates, styrenic polymers (e.g., acrylonitrile butadiene styrene (“ABS”)), and so forth.
Further, a plurality of fibers are dispersed in the polymer material forming the rod. Thus, the material is a fiber reinforced polymer material. The fibers are in exemplary embodiments continuous fibers, although in other embodiments the fibers may be long fibers. As used therein, the term “long fibers” generally refers to fibers, filaments, yarns, or rovings that are not continuous, and as opposed to “continuous fibers” which generally refer to fibers, filaments, yarns, or ravings having a length that is generally limited only by the length of a part.
The fibers dispersed in the polymer material to form a rod may be formed from any conventional material known in the art, such as metal fibers, glass fibers (e.g., E-glass, A-glass, C-glass, D-glass, AR-glass, R-glass, S1-glass, S2-glass), carbon fibers (e.g., graphite), boron fibers, ceramic fibers (e.g., alumina or silica), aramid fibers (e.g., Kevlar® marketed by E. I. duPont de Nemours, Wilmington, Del.), synthetic organic fibers (e.g., polyamide, polyethylene, paraphenylene, terephthalamide, polyethylene terephthalate and polyphenylene sulfide), and various other natural or synthetic inorganic or organic fibrous materials known for reinforcing polymer compositions. Glass fibers and carbon fibers are particularly desirable for use in the fibers.
Such fibers often have a nominal diameter of about 4 to about 35 micrometers, and in some embodiments, from about 9 to about 35 micrometers. The fibers may be twisted or straight. If desired, the fibers may be in the form of rovings (e.g., bundle of fibers) that contain a single fiber type or different types of fibers. Different fibers may be contained in individual rovings or, alternatively, each roving may contain a different fiber type. For example, in one embodiment, certain rovings may contain carbon fibers, while other rovings may contain glass fibers. The number of fibers contained in each roving can be constant or vary from roving to roving. Typically, a roving may contain from about 1,000 fibers to about 50,000 individual fibers, and in some embodiments, from about 2,000 to about 40,000 fibers.
In some embodiments, an extrusion device may be employed to embed the fibers into the polymer material, in order to minimize the void fraction and ensure good impregnation. Among other things, the extrusion device may facilitate the ability of the polymer to be applied to the entire surface of the fibers. The extrusion device may include, for example, an extruder containing a screw shaft mounted inside a barrel. A heater (e.g., electrical resistance heater) may be mounted outside the barrel. During use, a polymer feedstock, which may be a thermoplastic or a thermoset, is supplied to the extruder through a hopper. The feedstock is conveyed inside the barrel by the screw shaft and heated by frictional forces inside the barrel and by the heater. Upon being heated, the feedstock exits the barrel through a barrel flange and enters a die flange of an impregnation die. Fibers may be supplied to the impregnation die, wherein the fibers are impregnated with polymer material. When processed in this manner, the fiber rovings become embedded in the polymer material, which may be a resin processed from the feedstock. The mixture may then be extruded from the impregnation die to create an extrudate.
The extrusion system may be included in a pultrusion system that is utilized to form a rod according to the present disclosure. For example, the extrudate exiting the impregnation die may be directly supplied to other various components of the pultrusion system. A tension-regulating device may be employed to help control the degree of tension in the extrudate as it is drawn through the pultrusion system. An oven may be supplied in the device for heating the extrudate. The extrudate may then be provided to a consolidation die, which may operate to compress the extrudate together into a preform, and to align and form the initial shape of the desired product. In other words, the consolidation die may shape and form the extrudate into the rod. If desired, a second die (e.g., calibration die) may also be employed that compresses the preform into a final shape of the die. Cooling systems may additionally be incorporated between the dies and/or after either die to cool the rod. A downstream pulling device may be positioned to size the final product and pull the product through the system.
It should be understood, however, that the above disclosed method for forming a rod according to the present disclosure is merely one example of a suitable method, and that any suitable methods and/or apparatus for forming such a rod are within the scope and spirit of the present disclosure.
Thus, the rods of a fiber reinforced polymer rod assembly 10 according to the present disclosure are each formed from a suitable polymer material, which in exemplary embodiments is a thermoplastic, with a plurality of fibers dispersed within the polymer material. To form a rod assembly 10, the rods, such as first rod 12 and second rod 14, are heated. As shown in
The temperature to which the portions 16, 18 of the rods 12, 14 are heated is generally high enough to soften the polymer materials of the rods 12, 14 to an extent that the rods 12, 14, and portions 16, 18 thereof, can bond, or fuse, together. However, the temperature is not so high as to destroy the integrity of the material. The temperature may, for example, range from about 100° C. to about 500° C., in some embodiments from about 200° C. to about 400° C., and in some embodiments, from about 250° C. to about 350° C. Further, in some embodiments, the rods 12, 14, such as the portions 16, 18 thereof, are heated to or above the melting points of the polymer materials thereof. In one particular embodiment, for example, polyphenyiene sulfide (“PPS”) is used as the polymer material, and the portions 16, 18 of the rods 12, 14 are heated to or above the melting point of PPS, which is about 285° C.
It should be understood that the entire portions 16, 18 of the rods 12, 14 need not be heated. Areas of the portions 16, 18 that will be in contact with each other should be heated, such that these areas can fuse together to join the rods 12, 14 and form the rod assembly 10.
Before or after heating of the portions 16, 18 of the rods 12, 14, the rods 12, 14 may in some embodiments be aligned in various specific manners. For example, in some embodiments as shown in
In some embodiments, as shown in
In some embodiments, as shown in
In some embodiments, the third rod 40 may be intertwined with the portions 16, 18 during intertwining of the portions 16, 18. The resulting rod connecting section 30 may thus include the third rod 40 intertwined within the portions 16, 18, as shown in
In some embodiments, the third rod 40 is heated prior to, during, or after intertwining with the portions 16, 18 of the rods 12, 14. Heating may in some embodiments be to the melting point for the polymer material of the third rod 40, or may to another suitable temperature as discussed above with respect to heating of rods.
In some embodiments, as shown in
The resulting heated and intertwined rods 12, 14, along with optional third rod 40, may thus be in contact, and may thus fuse together. It should be noted that after heating and intertwining of the rods 12, 14, the rods 12, 14 may be cooled. Cooling may solidify the portions 16, 18, and optional third rod 40, thus solidifying the intertwined and fused connections therebetween. Thus, the resulting rod connecting section 30 includes portions 16, 18, and optional third rod 40, that are intertwined and fused together. Intertwining and fusing together of the rods 12, 14 as disclosed herein provides a rod connecting section 30 and a rod assembly 10 with improved strength characteristics. Thus, the method and rod assembly 10 disclosed herein can be utilized with relatively long rods to form relatively long rod assemblies 10 as desired or required.
In some embodiments, as shown in
As shown, a cuff 60 according to the present disclosure may be provided surrounding the portions 16, 18 of the rods 12, 14. In some embodiments, the portions 16, 18 may be interweaved, as shown in
In some embodiments, the cuff 60 is heated prior to, during, or after surrounding of the portions 16, 18 of the rods 12, 14. Heating may in some embodiments be to the melting point for the polymer material of the cuff 60, or may to another suitable temperature as discussed above with respect to heating of rods.
In some embodiments, as shown in
The resulting heated and surrounded rods 12, 14, and cuff 60, along with optional third rod 40, may thus be in contact, and may thus fuse together. It should be noted that after heating and surrounding of the rods 12, 14 with the cuff 60, the rods 12, 14 may be cooled. Cooling may solidify the portions 16, 18, the cuff 60, and the optional third rod 40, thus solidifying the surrounded and fused connections therebetween. Thus, the resulting rod connecting section 30 includes portions 16, 18, and cuff 60, and optional third rod 40, that are surrounded and fused together. Surrounding and fusing together of the rods 12, 14 as disclosed herein provides a rod connecting section 30 and a rod assembly 10 with improved strength characteristics. Thus, the method and rod assembly 10 disclosed herein can be utilized with relatively long rods to form relatively long rod assemblies 10 as desired or required.
In some embodiments, as shown in
In some embodiments, the die 70 may be a hot die. Thus, one or both of the die segments 72, 74 may be heated, and may thus heat the portions 16, 18, during pressing. As such, heating of the portions 16, 18 is performed during pressing of the portions 16, 18. In other embodiments, the portions 16, 18 are heated separately from the die 70. In these embodiments, heating of the portions 16, 18 is performed before pressing of the portions 16, 18.
In some embodiments, as shown in
In some embodiments, as shown in
It should further be understood that, in some embodiments, the portions 16, 18 may be intertwined and/or surrounded by a cuff 60, as discussed above, before pressing. Still further, in some embodiments, a third rod 40 may be intertwined with the portions 16, 18 before or after pressing. For example, the third rod 40 may be intertwined with the intertwined portions 16, 18, or may be intertwined around the portions 16, 18 that are not themselves intertwined. The portions 16, 18 and third rod 40 may be heated as discussed above to facilitate contact and fusing thereof.
The resulting heated and pressed rods 12, 14 may thus be in contact, and may thus fuse together. It should be noted that after heating and pressing of the rods 12, 14, the rods 12, 14 may be cooled. Cooling may solidify the portions 16, 18, thus solidifying the pressed and fused connections therebetween. Thus, the resulting rod connecting section 30 includes portions 16, 18 that are pressed and fused together. Pressing and fusing together of the rods 12, 14 as disclosed herein provides a rod connecting section 30 and a rod assembly 10 with improved strength characteristics. Thus, the method and rod assembly 10 disclosed herein can be utilized with relatively long rods to form relatively long rod assemblies 10 as desired or required.
It should be understood that any suitable apparatus may be utilized to perform the various steps disclosed herein for forming a rod assembly 10. For example, any suitable heat source 80 may be utilized to heat the rods 12, 14. Examples of suitable heat sources include open flames, infrared heat sources, laser heat sources, convection heat sources, and induction heat sources. Further, in some embodiments as discussed above wherein a die 70 is utilized, the die 70 may be a heated die, and thus may itself be the heat source.
Suitable apparatus may additionally be utilized to intertwine the rods 12, 14 and/or surround the rods 12, 14 with a cuff 60. For example, the rods 12, 14 may be clamped or otherwise held in a machine, and a component of the machine may twist or otherwise manipulate the portions 16, 18 of the rods 12, 14 to intertwine them, and/or may provide a cuff 60 surrounding the portions 16, 18. Alternatively, intertwining may for example be performed manually.
Suitable apparatus may additionally be utilized to apply tension to the rods 12, 14. For example, the rods 12, 14 may be clamped or otherwise held in a machine, and a component of the machine may pull or otherwise manipulate the rods 12, 14 to apply tension. Alternatively, tensioning may for example be performed manually.
Suitable apparatus may additionally be utilized to cool the rods 12, 14. For example, the rods 12, 14 may be placed in a refrigeration machine or other suitable cooling chamber, or cooling fluid may be applied to the rods 12, 14 by a cooling apparatus. Alternatively, cooling may be performed by otherwise exposing the rods 12, 14 to relatively lower temperatures, such as by simply exposing the rods 12, 14 to ambient temperatures.
These and other modifications and variations of the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims.
The present application claims filing benefit of U.S. Provisional Patent Application Ser. No. 61/658,551 having a filing date of Jun. 12, 2012, which is incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61658551 | Jun 2012 | US |
