Flexible pipe and method of manufacturing same

Abstract

A flexible pipe and a method of manufacturing same according to which the pipe is formed by multiple layers of different materials and suitable for use in subsea and land-based applications. (It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure; and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims under 37 CFR § 1.72.)

1 . A method of manufacturing a pipe from coils of wires having a substantially circular cross section, the method comprising: 
 unwinding the wires from their respective coils;    passing the unwound wires through rollers to flatten each circular cross section to a substantially rectangular cross section as the wires unwind from the coil; and    passing the wires from the rollers and wrapping them around a tubular member.    
   
   
       2 . The method of  claim 1  wherein the act of wrapping comprises: 
 wrapping a plurality of the wires around the exterior of the tubular member to form a first tensile layer; and    wrapping a plurality of the wires around the exterior of the first tensile layer to form a second tensile layer.    
   
   
       3 . The method of  claim 2  wherein the wires of the first tensile layer are wrapped helically around the exterior of the tubular member and the wires of the second tensile layer are wrapped helically around the first tensile layer in an opposite direction to the wires of the first tensile layer.  
   
   
       4 . The method of  claim 2  further comprising extruding an outer sheath over the second tensile layer.  
   
   
       5 . The method of  claim 4  further comprising wrapping at least one layer of tape over the second tensile layer and between the second tensile layer and the outer sheath.  
   
   
       6 . The method of  claim 1  wherein the tubular member is a plastic sheath.  
   
   
       7 . The method of  claim 1  wherein the tubular member is a carbon steel strip.  
   
   
       8 . The method of  claim 7  further comprising providing a plastic sheath over which the carbon steel strip extends.  
   
   
       9 . The method of  claim 8  wherein the carbon steel strip is helically wound over the plastic sheath.  
   
   
       10 . The method of  claim 9  further comprising providing a collapse resistant, inner helical strip within the plastic sheath.  
   
   
       11 . A method of manufacturing a pipe from a coiled sheet, the method comprising: 
 unwinding the sheet from the coil;    disposing a plurality of spaced cutters in the path of the sheet as the sheet unwinds from the coil to cut the sheet into a plurality of wires each having a substantially rectangular cross section; and    wrapping the wires around a tubular member.    
   
   
       12 . The method of  claim 11  wherein the act of wrapping comprises: 
 wrapping a plurality of the wires around the exterior of the tubular member to form a first tensile layer; and    wrapping a plurality of the wires around the exterior of the first tensile layer to form a second tensile layer.    
   
   
       13 . The method of  claim 12  wherein the wires of the first tensile layer are wrapped helically around the exterior of the tubular member and the wires of the second tensile layer are wrapped helically around the first tensile layer in an opposite direction to the wires of the first tensile layer.  
   
   
       14 . The method of  claim 12  further comprising extruding an outer sheath over the second tensile layer.  
   
   
       15 . The method of  claim 14  further comprising wrapping at least one layer of tape over the second tensile layer and between the second tensile layer and the outer sheath.  
   
   
       16 . The method of  claim 11  wherein the tubular member is a plastic sheath.  
   
   
       17 . The method of  claim 11  wherein the tubular member is a carbon steel strip.  
   
   
       18 . The method of  claim 17  further comprising providing a plastic sheath over which the carbon steel strip extends.  
   
   
       19 . The method of  claim 18  wherein the carbon steel strip is helically wound over the plastic sheath.  
   
   
       20 . The method of  claim 19  further comprising providing a collapse-resistant, inner helical strip within the plastic sheath.