EP-4739478-A1 - METHODS OF PRODUCING A PRESSURE CONTAINING STRUCTURE FROM RECYCLED COMPOSITE PARTS AND PRESSURE CONTAINING PIPE

Abstract

Systems, methods, and devices for providing a low permeability pressure containing structure from high performance recycled composite material, such as polymer carbon fiber composite. One or more recycled scrap composite parts are mechanically processed to form a plurality of fragments based on protected carbon fiber, which are then formed into the pressure containing structure. The distribution of the plurality of fragments and fibers included therein generate a tortuous effect that decreases the permeability of the pressure containing structure, such that the pressure containing structure is suitable for transporting and storing gases and other fluids that may corrode traditional steel pressure structures.

Inventors

• SILVA, GABRIEL
• DO, ANH TUAN

Assignees

• FMC Technologies, Inc.

Dates

Publication Date

20260513

Application Date

20240621

Claims (20)

1. 1. A method of producing a pressure containing structure, the method comprising: receiving one or more recycled parts, the one or more recycled parts comprising a carbon fiber composite material; mechanically processing the one or more recycled parts into a plurality of fragments with a random fiber distribution; and forming, via a forming process, the plurality of fragments into the pressure containing structure thereby producing the pressure containing structure, wherein the random fiber distribution of the plurality of fragments generates a tortuous effect thereby producing a low gas permeability for the pressure containing structure for substantially containing a fluid within the pressure containing structure.
2. 2. The method of claim 1 , wherein the carbon fiber composite material comprises carbon fiber polyether ether ketone, and wherein an initial matrix of the carbon fiber composite material protects a plurality of short fibers disposed therein.
3. 3. The method of claim 1 , wherein the forming process comprises an extrusion process using an extruder device.
4. 4. The method of claim 1 , wherein the forming process comprises an additive manufacturing process using a 3D printer, the method further comprising: processing the plurality of fragments into a powder form comprising a plurality of granules with an average particle diameter of about 10 micrometers to about 100 micrometers; and providing the plurality of granules to the 3D printer.
5. 5. The method of claim 1 , further comprising: selecting a fragment size for the plurality of fragments based on a pressure level associated with the pressure containing structure.
6. 6. The method of claim 1 , wherein the forming process comprises an injection molding process using an injection mold.
7. 7. The method of claim 1 , further comprising: forming a first layer of the pressure containing structure using a first portion of the plurality of fragments; and forming a second layer of the pressure containing structure using a second portion of the plurality of fragments.
8. 8. A method of producing a pressure containing structure, the method comprising: receiving one or more recycled parts, the one or more recycled parts comprising a carbon fiber composite material; mechanically processing the one or more recycled parts to form a plurality of fragments; and forming the pressure containing structure by fusing the plurality of fragments into the pressure containing structure, wherein the plurality of fragments are selectively oriented to generate a tortuous effect thereby producing a low gas permeability for the pressure containing structure for substantially containing a fluid within the pressure containing structure.
9. 9. The method of claim 8, wherein the plurality of fragments are fused into the pressure containing structure via an extrusion process using an extrusion device.
10. 10. The method of claim 8, further comprising: forming a first layer of the pressure containing structure using a first portion of the plurality of fragments selectively oriented in a first selected direction; and forming a second layer of the pressure containing structure using a second portion of the plurality of fragments selectively oriented in a second selected direction distinct from the first selected direction.
11. 11 . The method of claim 10, further comprising: forming a third layer of the pressure containing structure using a third portion of the plurality of fragments selectively oriented in a third selected direction distinct from the second selected direction.
12. 12. The method of claim 8, wherein mechanically processing the one or more recycled parts comprises feeding the one or more recycled parts into a cutting device configured to cut the one or more recycled parts along an axis parallel to a fiber direction of a plurality of fibers of the carbon fiber composite material to thereby form the plurality of fragments while preserving the plurality of fibers.
13. 13. The method of claim 8, further comprising: adding additional carbon fiber material to the plurality of fragments.
14. 14. The method of claim 13, further comprising: adding an additional polymer material to the plurality of fragments prior to forming the pressure containing structure.
15. 15. A pressure containing pipe comprising: a carbon fiber polyether ether ketone (PEEK) material configured to provide a low permeability pressure seal for containing a fluid inside the pressure containing pipe; and a plurality of fused mechanically recycled fragments comprising the carbon fiber PEEK material, wherein the carbon fiber PEEK material has a random fiber distribution that generates a tortuous effect to thereby reduce a permeability of the pressure containing pipe.
16. 16. The pressure containing pipe of claim 15, wherein the pressure containing pipe is configured to contain a pressurized gaseous hydrogen fluid disposed therein, and wherein the carbon fiber PEEK material prevents corrosion of the pressure containing Pipe.
17. 17. The pressure containing pipe of claim 16, wherein the carbon fiber PEEK material comprises a concentration of between 20% to 50% carbon fiber by volume.
18. 18. The pressure containing pipe of claim 15, further comprising: a first layer of the carbon fiber PEEK material including one or more first fibers oriented in a first direction; and a second layer of carbon fiber PEEK material including one or more second fibers oriented in a second direction distinct from the first direction.
19. 19. The pressure containing pipe of claim 15, wherein the pressure containing pipe is configured to contain a pressurized hydrogen fluid.
20. 20. The pressure containing pipe of claim 15, wherein the pressure containing pipe is configured to contain a pressurized carbon dioxide fluid.

Description

METHODS OF PRODUCING A PRESSURE CONTAINING STRUCTURE FROM RECYCLED COMPOSITE PARTS AND PRESSURE CONTAINING PIPE BACKGROUND 1. FIELD [0001] Embodiments of the present disclosure relate to low permeation structures. More specifically, embodiments of the present disclosure relate to forming low permeation structures from recycled composite material. 2. RELATED ART [0002] Pressure containing structures such as tubing, valves, and connectors associated therewith have been used to contain pressurized fluids. However, the typical steel pipe liners included within pressurized piping fortransporting fluids such as gaseous hydrogen and carbon dioxide are prone to corrosion and fragmentation, for example, due to reaction with hydrogen. Accordingly, composite materials have been used in place of metals within hydrogen transport pressure containing structures. However, the cost of said composite materials is prohibitive and the manufacturing processes to produce said composite materials are energy intensive. SUMMARY [0003] Embodiments of the present disclosure solve the above-mentioned problems by providing a non-corrosive, low permeability pressure containing structure produced from recycled composite material. Scrap parts comprising composite material are recycled via mechanical recycling to produce a plurality of fragments such that fibers within the fragments are preserved. The fragments are then formed into a final structure, such as a pressure containing tube or other pressure containing structure in which the preserved fibers aid in generating a tortuous path to thereby decrease a permeability of the final structure. [0004] In some aspects, the techniques described herein relate to a method of producing a pressure containing structure, the method including: receiving one or more recycled parts, the one or more recycled parts including a carbon fiber composite material; mechanically processing the one or more recycled parts into a plurality of fragments with a random fiber distribution; and forming, via a forming process, the plurality of fragments into the pressure containing structure thereby producing the pressure containing structure, wherein the random fiber distribution of the plurality of fragments generates a tortuous effect thereby producing a low gas permeability for the pressure containing structure for substantially containing a fluid within the pressure containing structure. [0005] In some aspects, the techniques described herein relate to a method, wherein the carbon fiber composite material includes carbon fiber polyether ether ketone, and wherein an initial matrix of the carbon fiber composite material protects a plurality of short fibers disposed therein. [0006] In some aspects, the techniques described herein relate to a method, wherein the forming process includes an extrusion process using an extruder device. [0007] In some aspects, the techniques described herein relate to a method, wherein the forming process includes an additive manufacturing process using a 3D printer, the method further including: processing the plurality of fragments into a powder form including a plurality of granules with an average particle diameter of about 10 micrometers to about 100 micrometers; and providing the plurality of granules to the 3D printer. [0008] In some aspects, the techniques described herein relate to a method, further including: selecting a fragment size for the plurality of fragments based on a pressure level associated with the pressure containing structure. [0009] In some aspects, the techniques described herein relate to a method, wherein the forming process includes an injection molding process using an injection mold. [0010] In some aspects, the techniques described herein relate to a method, further including: forming a first layer of the pressure containing structure using a first portion of the plurality of fragments; and forming a second layer of the pressure containing structure using a second portion of the plurality of fragments. [0011] In some aspects, the techniques described herein relate to a method of producing a pressure containing structure, the method including: receiving one or more recycled parts, the one or more recycled parts including a carbon fiber composite material; mechanically processing the one or more recycled parts to form a plurality of fragments; and forming the pressure containing structure by fusing the plurality of fragments into the pressure containing structure, wherein the plurality of fragments are selectively oriented to generate a tortuous effect thereby producing a low gas permeability for the pressure containing structure for substantially containing a fluid within the pressure containing structure. [0012] In some aspects, the techniques described herein relate to a method, wherein the plurality of fragments are fused into the pressure containing structure via an extrusion process using an extrusion device. [0013] In some aspects, the techniques