Reinforcing Matrix for Spoolable Pipe

Abstract

A spoolable pipe is disclosed, the spoolable pipe having an internal pressure barrier formed about a longitudinal axis, and a reinforcing layer(s) enclosing the internal pressure barrier that includes a solid hydrocarbon matrix. The pipe can also include an energy conductor(s) integrated with and/or located between the internal pressure barrier and/or the reinforcing layer(s).

1 . A spoolable pipe, comprising:
 an internal pressure barrier formed about a longitudinal axis;   at least one reinforcing layer enclosing the internal pressure barrier and comprising fibers and a solid hydrocarbon matrix, wherein said solid hydrocarbon matrix is solid at about 25° C. and said matrix comprises hydrocarbons having an average molecular weight of less than about 20,000 grams/mole; and   an external layer enclosing the at least one reinforcing layer.   
     
     
         2 .- 19 . (canceled) 
     
     
         20 . A spoolable pipe, comprising:
 an internal pressure barrier formed about a longitudinal axis;   at least one reinforcing layer enclosing the internal pressure barrier and comprising fibers and a solid matrix wherein said solid matrix has a tensile modulus between about 10 and 90,000 psi, and wherein said reinforcing layer is formed at least by applying to said fibers a substantially liquid matrix composition having a viscosity between about 10 and about 10,000 cPs at 25° C.   
     
     
         21 . The spoolable pipe of  claim 20 , wherein the at least one reinforcing layer comprises at least two plies of fibers. 
     
     
         22 . The spoolable pipe of  claim 21 , wherein the two plies of fibers have at least a partial helical orientation relative to the longitudinal axis. 
     
     
         23 . The spoolable pipe of  claim 20 , wherein said substantially liquid matrix composition is capable of flowing between said fibers. 
     
     
         24 . The spoolable pipe of  claim 20 , wherein said substantially liquid matrix composition has a viscosity between about 100 and about 5000 cPs. 
     
     
         25 . The spoolable pipe of  claim 20 , wherein said substantially liquid matrix composition is an emulsion, a suspension, a colloid, a immiscible fluid blend, or two-phase system. 
     
     
         26 . (canceled) 
     
     
         27 . The spoolable pipe of  claim 26 , wherein said substantially liquid matrix composition comprises at least one of: an emulsifier, tackifier, binder and a surfactant. 
     
     
         28 . The spoolable pipe of  claim 26 , wherein said substantially liquid matrix composition comprises at least one of: polyethylene, polyethylene oligomers, polypropylene, polypropylene oligomers, polyolefins, polyolefin oligomers, paraffin waxes, or a grease. 
     
     
         29 . The spoolable pipe of  claim 20 , wherein said substantially liquid matrix composition comprises polymer particles. 
     
     
         30 . The spoolable pipe of  claim 29 , wherein said polymer particles have an average diameter between about 10 nm and about 10 μm. 
     
     
         31 . The spoolable pipe of  claim 20 , wherein said substantially liquid matrix composition comprises anionic or cationic moities that are capable of forming a solid upon evaporation, drying, curing or gelling. 
     
     
         32 . The spoolable pipe of  claim 31 , wherein said substantially liquid matrix composition comprises a compound comprising an amine or an ammonium moiety. 
     
     
         33 . The spoolable pipe of  claim 20 , wherein said substantially liquid matrix composition comprises inorganic solids. 
     
     
         34 . The spoolable pipe of  claim 20 , wherein said substantially liquid matrix composition comprises a water-based dispersion. 
     
     
         35 . The spoolable pipe of  claim 20 , wherein said internal pressure barrier comprises at least one of: a metal, polyethylene, cross-linked polyethylene, polyvinylidene fluoride, polybutylene, polyamide, polypropylene, polyethylene terphthalate, or polyphenylene sulfide. 
     
     
         36 . (canceled) 
     
     
         37 . The spoolable pipe of  claim 35 , wherein the permeability of said reinforcing layer is higher than the permeability of said internal pressure barrier. 
     
     
         38 . The spoolable pipe of  claim 20 , further comprising an external layer. 
     
     
         39 . The spoolable pipe of  claim 38 , wherein said external layer wherein the permeability of said external layer is higher than the permeability of said solid matrix. 
     
     
         40 . The spoolable pipe of  claim 38 , wherein said external layer comprises at least one of: polyethylene, cross-linked polyethylene, polybutylene, polyvinylidene fluoride, polyamide, polypropylene, polyethylene terphthalate, or polyphenylene sulfide. 
     
     
         41 . The spoolable pipe of  claim 38 , wherein said external layer comprises a foam. 
     
     
         42 . The spoolable pipe of  claim 41 , wherein said foam comprises at least one of: a thermoset polymer, a thermoplastic polymer, an elastomer, a rubber, closed cells and open cells. 
     
     
         43 . The spoolable pipe of  claim 20 , wherein said fibers comprise a glass, an aramid, a carbon, a ceramic, a metal, a mineral, or a polymer, or combinations thereof. 
     
     
         44 . The spoolable pipe of  claim 20 , further comprising an energy conductor. 
     
     
         45 . The spoolable pipe of  claim 20 , wherein said spoolable pipe further comprises at least one of: afire retardant, a UV stabilizer, an oxidative stabilizer, and a thermal stabilizer. 
     
     
         46 . The spoolable pipe of  claim 20 , wherein said spoolable pipe further comprises a pigment. 
     
     
         47 . The spoolable pipe of  claim 20 , wherein said solid matrix is formed by further drying, curing and/or crosslinking said substantially liquid matrix composition. 
     
     
         48 . A method for producing a spoolable tube comprising: providing an inner layer of said spoolable tube;
 applying a substantially liquid matrix composition comprising at least one of:   polyethylene, polyethylene oligomers, polypropylene, polypropylene oligomers, polyolefins, polyolefin oligomers, a wax, and/or a grease to fibers at a temperature between about 20° C. and about 40° C.;   drying said fibers so that a solid matrix composition between the fibers is formed; and   winding said fibers around said inner layer.   
     
     
         49 .- 54 . (canceled)