Abstract
A fiber reinforced polymer composite pipe includes first and second ends and defines a central axis running in a longitudinal direction from the first end to the second end, and the pipe including at least one non-linear portion along the central axis between the first end and the second end. A first material extends continuously from the first end to the second end, the first material being a fiber reinforced polymer material comprising fiber reinforcement in a polymer matrix and having an electrical resistivity determined by an electrically conductive fiber reinforcement and/or an electrically conductive additive in the polymer matrix; and a second material arranged at the at least one non-linear portion and extending discontinuously between the first end and the second end, and has an elastic modulus greater than the elastic modulus of the first material in the longitudinal direction.
Claims
1. A method of making a fiber reinforced polymer composite pipe comprising: providing a mold cavity shaped to form a pipe having a first end, a second end, and at least one non-linear portion between the first end and the second end; placing one or more fiber preforms in the mold cavity to form the fiber reinforcement of a first material extending continuously from the first end to the second end; placing one or more carbon fiber preforms in the mold at the at least one non-linear portion to form the fiber reinforcement of a second material extending discontinuously between the first end and the second end; and filling the mold cavity with a polymer matrix material to form the first material as a fiber reinforced polymer material comprising fiber reinforcement in a polymer matrix and the second material as a carbon fiber reinforced polymer material comprising carbon fiber reinforcement in a polymer matrix.
2. The method of claim 1, wherein the first material has an electrical resistivity determined by an electrically conductive fiber reinforcement or an electrically conductive additive in the polymer matrix.
3. The method of claim 1, wherein an elastic modulus of the second material is greater than an elastic modulus of the first material in the longitudinal direction.
4. The method of claim 1, wherein the first material is formed by automated fiber placement (AFP).
5. The method of claim 1, wherein the first material is formed by filament winding of the fiber reinforcement.
6. The method of claim 1, wherein the first material is formed by resin transfer moulding (RTM), using a braided preform for the fiber reinforcement.
7. The method of claim, further comprising: forming the second material by filament winding of the carbon fiber reinforcement.
8. The method of claim 1, comprising forming the second material by automated fiber placement (AFP).
9. The method of claim 1, comprising forming the second material by braiding continuous carbon fiber reinforcement so as to achieve one or more desired fiber angles.
10. The method of claim 9, further comprising: interweaving groups of continuous carbon fibers into a triaxially braided tube comprising a first group of continuous carbon fibers extending substantially along the central axis of the pipe, a second group of continuous carbon fibers extending at an angle of +50-85 degrees relative to the central axis of the pipe, and a third group of continuous carbon fibers extending at an angle of −50-85 degrees relative to the central axis of the pipe.
11. The method of claim 1, comprising forming the second material at the same time as the first material.
12. The method of claim 11, comprising forming both the first material and the second material in a single RTM process.
13. The method of claim 1, wherein the first material takes the form of an inner pipe or an outer pipe.
14. The method of claim 1, wherein the second material is formed as a layer on the inside or the outside of the first material.
15. The method of claim 1, wherein the mould cavity is shaped to form a pipe with a plurality of non-linear portions between the first end and the second end, and the method comprises placing carbon fiber preforms in the mould at each of the non-linear portions.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0063] One or more non-limiting examples will now be described, by way of example only, and with reference to the accompanying figures, in which:
[0064] FIG. 1 is a schematic cross-sectional view of a composite pipe according to a first example;
[0065] FIG. 2 is a schematic cross-sectional view of a composite pipe according to a second example;
[0066] FIG. 3 is a schematic cross-sectional view of a composite pipe according to a third example;
[0067] FIG. 4 is a schematic cross-sectional view of a composite pipe according to a fourth example;
[0068] FIG. 5 is a schematic cross-sectional view of a composite pipe according to a fifth example; and
[0069] FIG. 6 is a schematic cross-sectional view of a composite pipe according to a sixth example;
[0070] FIG. 7 is a schematic cross-sectional view of a mold used in an exemplary method of making a composite pipe;
[0071] FIG. 8a is a schematic cross-sectional view of a composite pipe with end connectors as known in the prior art; and
[0072] FIG. 8b is a schematic cross-sectional view of a composite pipe with end connectors according to one or more examples of the present disclosure.
DETAILED DESCRIPTION
[0073] In the first to sixth examples disclosed herein, there is seen a composite pipe that is hollow and may carry a pressurised fluid, for example in use as a fuel pipe. As is seen in FIGS. 8a and 8b, a composite fuel pipe is typically connected into the fuel system by floating seals at its first and second ends. This means that any axial displacement, resulting from bends in the pipe undergoing deformation as a result of the pressurised flow, can result in the pipe coming loose. It is therefore desirable to stiffen the non-linear portions of the pipe to prevent deformations.
[0074] In the first example seen in FIG. 1, a composite pipe 1 has a first end 1a and a second end 1b with a central axis (dashed line) running between the two ends 1a, 1b in a longitudinal direction. The pipe 1 is made of a first material 2 extending continuously from the first end 1a to the second end 1b. As disclosed herein, the first material 2 is a fiber reinforced polymer material having a predetermined electrical resistivity. The pipe 1 also includes a second material 4 arranged at the two non-linear portions 6. In this example, the second material 4 is localised at the two non-linear portions 6 and does not extend from the first end 1a to the second end 1b. As disclosed herein, the second material 4 is a carbon fiber reinforced polymer material having a greater elastic modulus than the first material 2 in the longitudinal direction. The second material 4 therefore provides additional axial stiffness/strength at the bends in the pipe 1.
[0075] In the second example seen in FIG. 2, the composite pipe 11 is again made of the first material 2 extending continuously from the first end 1a to the second end 1b. The second material 14 is arranged at the two non-linear portions 6 and extends between the two non-linear portions 6, but does not extend continuously from the first end 1a to the second end 1b.
[0076] In the third example seen in FIG. 3, the composite pipe 21 is again made of the first material 2 extending continuously from the first end 1a to the second end 1b. The second material 24 is arranged at the two non-linear portions 6 and extends from each non-linear portion 6 to the nearest end 1a, 1b, but does not extend continuously from the first end 1a to the second end 1b.
[0077] In the examples of FIGS. 1-3, the second material 4 is formed as a layer on the outside of the first material 2. The first material 2 forms an inner pipe.
[0078] In the following examples of FIGS. 4-6, the second material is formed as a layer on the inside of the first material. The first material forms an outer pipe.
[0079] In the fourth example seen in FIG. 4, a composite pipe 100 has a first end 100a and a second end 100b with a central axis (dashed line) running between the two ends 100a, 100b in a longitudinal direction. The pipe 100 is made of a first material 102 extending continuously from the first end 100a to the second end 100b. As disclosed herein, the first material 102 is a fiber reinforced polymer material having a predetermined electrical resistivity. The pipe 100 also includes a second material 104 arranged at the two non-linear portions 106. In this example, the second material 104 is localised at the two non-linear portions 106 and does not extend continuously from the first end 100a to the second end 100b. As disclosed herein, the second material 104 is a carbon fiber reinforced polymer material having a greater elastic modulus than the first material 102 in the longitudinal direction. The second material 104 therefore provides additional stiffness/strength at the bends in the pipe 100.
[0080] In the fifth example seen in FIG. 5, the composite pipe 111 is again made of the first material 102 extending continuously from the first end 100a to the second end 100b. The second material 114 is arranged at the two non-linear portions 106 and extends between the two non-linear portions 106, but does not extend continuously from the first end 100a to the second end 100b.
[0081] In the sixth example seen in FIG. 6, the composite pipe 121 is again made of the first material 102 extending continuously from the first end 100a to the second end 100b. The second material 124 is arranged at the two non-linear portions 106 and extends from each non-linear portion 106 to the nearest end 100a, 100b, but does not extend continuously from the first end 100a to the second end 100b.
[0082] In the examples seen in FIGS. 1-6, the linear portions of the pipes, i.e. those portions that are not the non-linear portions 6, 106, are referred to as “tailored conductivity regions” because only the first material is present. As is disclosed herein, the first material 2, 102 has an electrical resistivity determined by an electrically conductive fiber reinforcement and/or an electrically conductive additive in the polymer matrix, and this electrical resistivity can be tailored so as to achieve a desired overall resistance per unit length for the composite pipe.
[0083] In the examples illustrated herein, the pipes 1, 11, 21, 100, 111, 121 are not linear and instead have a more complex shape, shown as including two bends or non-linear portions 6, 106. However, it will be appreciated that the present disclosure can be applied to complex pipe shapes includes any number of bends.
[0084] FIG. 7 schematically illustrates an exemplary manufacturing process for a pipe 1 such as that seen in FIG. 1. In a Resin Transfer Molding (RTM) process, a two-part mold 200a, 200b includes a core 202 and a molding cavity 204. In this example, one or more fiber preforms 206 for the first material are placed over the core 202 in the cavity 204 so as to create a material layer extending continuously from one end of the core 202 to the other end. One or more carbon fiber preforms 208 for the second material are placed in the cavity 204 at the non-linear portions i.e. bends. The two parts 200a, 200b of the mold are then clamped shut and a vacuum is applied while a resin such as epoxy resin is injected under pressure into the cavity 204. The combination of injection under pressure and the applied vacuum should draw the resin through the fiber preforms 206, 208. Heat is then applied to the mold 200 to cure the resin. This causes the fiber reinforcement and the resin to set in the form of a solid fiber-reinforced composite pipe. The mold 200 may then be unclamped and opened so that the pipe including the second material at the non-linear portion(s) can be removed. In this example, a single shared RTM process is used to form the pipe 1.
[0085] There is seen in FIG. 8a a schematic cross-sectional view of a straight composite pipe 300 with end connectors 30 as known in the prior art. The connectors each comprise a cylindrical hub 32, extending parallel to the central axis C of the pipe 300, and a flange 34, which extends in a direction perpendicular to the central axis C. The flange 34 may be used to secure the connector 30 to another structure, e.g. an aircraft wing.
[0086] Where the hub 32 encircles the pipe 300, an elastomeric O-ring 36 is located between the hub 32 and the pipe 300, retained between an inner wall of the hub 32 and an outer wall of the pipe 300. The O-ring 36 is confined between a pair of retaining ridges 38 which extend radially outwards from the pipe 300 at its ends. The 36 provides a seal between the connector 30 and the pipe 300, such that fluid may flow along the pipe 300 and into the connector 30 without escaping. In addition, the configuration of the O-ring 36 allows the pipe 300 to move a small distance in the longitudinal direction of the central axis C relative to the connectors 30 without compromising the seal. This enables a structure to which the connector 30 is secured to move or flex a small amount without imparting large stresses on the pipe 300 (as would be the case if the connector 30 were rigidly attached to the pipe 300). Instead, the pipe 300 “floats” on the O-ring 36 such that it can slide longitudinally a small distance without breaking the seal. For example, the structure to which the connector 30 is attached may be an aircraft wing spar, which is designed to move a small amount during flight as the wing flexes due to aerodynamic load and/or temperature fluctuations. The pipe 300 may comprise a fuel pipe located within the wing which must therefore be able to cope with wing flex during flight.
[0087] There is seen in FIG. 8b a schematic cross-sectional view of a complex-shaped composite pipe 300′ with the same standard end connectors 30. The more complex geometry of the pipe 300′ introduces extra demands as there may be a tendency for the pipe 300′ to deform at its non-linear portions (i.e. bends) 306. Deflections in the composite pipe 300′ can cause the ends of the pipe 300′ to move larger distances in the longitudinal direction of the central axis C relative to the connectors 30, causing the pipe 300′ to come loose from its end connectors 30. However, this problem is addressed by using a composite pipe that has its non-linear portions strengthened by a second material according to any of the examples disclosed herein.
[0088] Although the present disclosure has been described with reference to various examples, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the scope of the disclosure as set forth in the accompanying claims.
