Method for making organism deposit-inhibiting pipe

Abstract: The invention provides a method for making an organism deposit-inhibition pipe, which excels in corrosion resistance, dispenses with maintenance work, and offers no toxicity problem. A thin sheet comprising a copper alloy is wound spirally around a round bar and inserted into a resin pipe made up of an electrical insulating material. And the round bar is taken out. The obtained pipe has an inner wall which is covered with the copper thin sheet. The copper alloy has a Be content of 0.2 to 2.8% by weight, and is selected from, e.g., Be-Cu, Be-Co-Cu, Be-Co-Si-Cu and Be-Ni-Cu alloys. With this method, the inner surface of tubes can be easily lined by beryllium-copper thin sheets. The beryllium-copper alloy has a remarkable antifouling effect and provides a continued liberation of copper ions.

Description: The present invention relates to a method effective to inhibit deposition of oceanic organisms such as barnacles, blue mussel, and seaweedhereinafter called the organism deposit-inhibition structure. Offshore or marine structures in contact with seawater are always exposed to contamination by oceanic organisms, resulting in appearance damage or malfunction. For instance, ships suffer a driving force drop when many forms of oceanic organisms are deposited onto their bottoms, etc., and thermoelectric power plants are forced to stop operation when various forms of oceanic organisms are built up on their seawater intake pits, because a serious problem arises in connection with the circulation of a seawater serving as a cooling medium. Among scores of techniques for inhibiting marine deposits studied so far in the art, there is typically now available a method for protecting an offshore structure against contamination, in which the surface of that structure in contact with seawater is coated with a coating material containing cuprous oxide or organotin. Another method is disclosed in JP-A-60-209505 that is directed to an adhesive member for inhibiting oceanic deposits, which comprises a sheet of copper or a copper alloy, a primer layer provided on one surface thereof, and an adhesive material layer formed on the primer layer. A grave problem with the method using a coating material, however, is that the coating material has a service life of as short as one year, since even when applied in a thick layer, it is likely to peel away; there is needed troublesome maintenance work in which the coating material must be renewed per year. The oceanic organism deposit-inhibiting member disclosed in JP-A-60-209505, on the other hand, is found to be less than satisfactory in terms of corrosion resistance and antifouling effect, because of the use of a copper or a copper-nickel (Cu-Ni) alloy. The CH-A-540450 discloses a method for making a pipe, which involves winding a laminate of a metal sheet and a resin layer around a core. Our years of study have now revealed that the application of a beryllium-copper alloy to an offshore structure achieves a much-more excellent antifouling effect. The reason would be that beryllium and copper ions interact synergistically, producing a great effect on inhibiting oceanic organisms from having access to the offshore structure and preventing their propagation. In other words, we have now found that the beryllium-copper alloy has a combined effect both on inhibiting marine deposits and on the continued liberation of copper ions. A main object of the invention is to provide a method for making an organism deposit-inhibiting pipe, which can be easily produced, excel in the capability to inhibit deposition of organisms and durability, dispense with maintenance work, and offer no toxicity problem. According to the present invention, there is provided a method for making an organism deposit-inhibiting pipe, which involves winding a thin strap made up of a beryllium copper alloy, connecting a convex portion and a concave portion of the thin strap, which are adjacent to each other, to prevent the thin strap from moving in the axial direction, and forming a resin layer on an outer surface of the thin strap. According to a preferred embodiment of the invention, the method involves winding spirally a thin sheet made up of a beryllium copper alloy to make an inner pipe, forming a first electrical insulating resin layer on an outer surface of the inner pipe, cutting the obtained pipe into a plurality of members, facing and connecting edge faces of the cut members and forming a second resin layer on an outer surface of the connected members. According to a further aspect of the invention there is provided a method for making an organism deposit-inhibiting pipe, which involves winding a thin sheet made up of a beryllium copper alloy spirally around a round bar, forming a resin layer comprising an electrical insulating material on the thin sheet and taking out the round bar. Preferably, the copper alloy has a beryllium content of 0.2 to 2.8 % by weight, and is an alloy selected from the group consisting of Be-Cu, Be-Co-Cu, Be-Co-Si-Cu and Be-Ni-Cu alloys. The invention will now be explained, more specifically but not exclusively, with reference to the accompanying drawings, in which: FIGURE 1 is an illustration of how a thin sheet made up of a beryllium copper alloy is wound spirally around a round bar, and how a resin layer is formed. FIGURE 2 is a schematic representation of what state an oxide film of the beryllium-copper alloy according to the invention is in, FIGURE 3 is a schematic representation of what state an oxide film of a cupronickel, provided for comparative purposes, is in, FIGURE 4 is a schematic illustration wherein beryllium copper is compared with cupronickel in terms of changes-with-time in the amount of copper ions liberated and the thickness of corrosion product, FIGURE 5 is an illustration of how a thin sheet made up of a beryllium-copper alloy is wound according to the invention, FIGURE 6 is an illustration of how a thin sheet made up of a beryllium-copper alloy is wound according to the invention, FIGURE 7 is an illustration of how an organism deposit-inhibiting pipe is made according to the invention, FIGURE 8 is an enlarged cut-away, perspective view showing the part marked with A in FIGURE 7, and FIGURE 9 is an illustration of how an organism deposit-inhibiting pipe is made according to a particular embodiment of the invention. The copper alloy used in the invention has a beryllium content ranging from 0.2% by weight to 2.8% by weight, and may be selected from the group consisting of Be-Cu, Be-Co-Cu, Be-Co-Si-Cu and Be-Ni-Cu alloys. Typical compositions of the copper alloy used in the invention are: (1) 0.2 to 1.0% by weight of beryllium, 2.4 to 2.7% by weight of cobalt and the balance being copper and inevitable impurities, (2) 0.2 to 1.0% by weight of beryllium, 1.4 to 2.2% by weight of nickel and the balance being copper and inevitable impurities, (3) 1.0 to 2.0% by weight of beryllium, 0.2 to 0.6% by weight of cobalt and the balance being copper and inevitable impurities, and (4) 1.6 to 2.8% by weight of beryllium, 0.4 to 1.0% by weight of cobalt, 0.2 to 0.35% by weight of silicon and the balance being copper and inevitable impurities. Preferably, the contents of beryllium (Be), cobalt (Co), nickel (Ni) and silicon (Si) selectively incorporated in the copper alloy lie in the respective ranges: Beryllium - 0.2 to 2.8% by weight Cobalt - 0.2 to 2.7 % by weight Nickel - 1.4 to 2.2% by weight Silicon - 0.2 to 0.35% by weight Set out below are what purpose the above elements are added for and why the upper and lower limits thereof are set at the above values. Beryllium: 0.2-2.8% by weight Beryllium is used to (1) protect the structure, when immersed in seawater, against contamination by liberating beryllium ions, (2) improve the strength and properties, e.g., corrosion resistance, of the copper alloy, (3) enhance the productivity of the copper alloy as by heat treatment and grain size regulation, and (4) improve the processability and castability of the copper alloy. At below 0.2% by weight the above-described effects (1)-(4) are unachievable. At higher than 2.8% by weight, not only is there some metalleability drop but a cost-effective problem arises as well. Cobalt: 0.2 to 2.7% by weight Cobalt is used to form a fine CoBe compound and disperse it throughout the alloy matrix, thereby improving the mechanical properties and productivity of the copper alloy. At less than 0.2% by weight this effect is not well achievable. At higher than 2.7% by weight, not only is there some material flowability drop but there is little or no improvement in the above-described effect as well. In addition, a cost-effective problem arises. Nickel: 1.4-2.2% by weight Nickel is used to form a fine NiBe compound and disperse it throughout the alloy matrix, thereby improving the mechanical properties and productivity of the copper alloy. At less than 1.4% by weight this effect is not well achievable. At higher than 2.2% by weight, not only is there some material flowability drop but there is little or no improvement in the above-described effect as well. In addition, a cost-effective problem arises. Silicon: 0.2-0.35% by weight Silicon is used to improve the material flowability of the copper alloy. At less than 0.2% by weight this effect is not well achievable. At higher than 0.35% by weight the resulting alloy becomes brittle with a toughness drop. As a result of our years of experimentation and research, it has turned out that the beryllium-copper alloy has a combined effect both on preventing contamination and on the continued liberation of copper ions. Detailed explanation will now be made to the antifouling effect and the continued action on liberating copper ions. (1) Antifouling Effect As well known from literature, the order of ionization tendency among beryllium, copper and nickel is expressed by Be>Ni>Cu In other words, beryllium ions are more likely to be liberated than nickel ions, and nickel ions are more likely to be liberated than copper ions. In the case of a beryllium-copper combination, beryllium is first ionized to form a local cell, which has an effect on preventing deposition of oceanic life contaminants due to its current effect, while beryllium ions take on the form of internal oxidation. By this internal oxidation, a BeO film is first formed, as typically shown in FIGURE 2. This BeO film, because of being porous, allows copper ions to be liberated, forming Cu₂O+BeO on the surface. This liberation of copper ions into seawater produces an antifouling effect. (2) Continued Action on Liberating Copper Ions The above-mentioned effect (1) on preventing contamination makes another contribution to providing-a continued liberation of copper ions; that is, the beryllium-copper combination enables the antifouling function to be maintained ceaselessly. While in contact with seawater, the beryllium-copper combination forms on its surface an intimate surface oxide (Cu2O), just below which a porous oxide film of BeO is formed, as can be seen from FIGURE 2. Thus, the liberation of copper ions into seawater is maintained, while this film increases in volume by the oxidation. When the volume increase reaches a certain level, the surface oxide film peels away from the porous oxide or BeO layer. This would enable electrochemical action and the liberation of copper ions to be maintained over an extended period of time. The continued action of the beryllium copper on the liberation of copper ions will now be explained with reference to FIGURE 4 that is a graphic representation showing the results of comparison of beryllium copper with cupronickel. When the corrosion (oxidation) product reaches a certain thickness, it peels away from the beryllium copper (BeCu), as can be best seen from FIGURE 4. Then, the beryllium-copper alloy is again exposed on the surface to seawater, and corroded or oxidized for oxide film growth. When this film grows to a certain thickness level, it peels away from the beryllium copper. This process is repeated over and over. The liberation of copper ions, on the other hand, is likely to be reduced with an increase in the thickness of the oxidation product. As the oxidation product peels away, however, the beryllium-copper alloy is again exposed on the surface to seawater, so that there can be an increase in the amount of the copper ions liberated. Thus, the increase and decrease in the amount of the copper ions liberated occur alternately. The beryllium-copper alloy used in the invention enables copper ions to be continuously liberated by the peeling-off of the oxide film. As a result, the amount of oceanic organisms deposited onto the surface of the beryllium copper is little, if any. This is in contrast to the comparative cupronickel (CuNi), as can be seen from FIGURE 3. With the passing of some years, an intimate nickel oxide (NiO2) or copper oxide (Cu2O) layer is formed on the surface of the cupronickel, reducing the liberation of copper ions, as can be seen from FIGURE 4. According to the order of ionization tendency (Be>Ni>Cu), this would be due to the fact the nickel (Ni) is preferentially ionized to form a local cell and so an intimate oxide is formed on the surface of the cupronickel, as can be seen from FIGURE 3. As can be seen from FIGURE 4, the thickness of the corrosion product on the cupronickel increases with time in an early stage, but its growth rate decreases as time goes by. With this, there is a decrease in the amount of the copper ions liberated. In addition, the corrosion product is less likely to peel away from the cupronickel than from the beryllium copper. Thus, the quantity of the copper ions liberated remains low, making the antifouling effect slender. It is to be noted that the facts that a beryllium-copper alloy has a remarkable antifouling effect and provides a continued liberation of copper ions have been discovered by us for the first time. Insofar as we are concerned, never until now have such facts been referred to or indicated in literature. For practical beryllium alloys, various alloys inclusive of JIS 11 ALLOY having a beryllium content of 0.2 to 0.6% by weight and JIS 25 ALLOY having a beryllium content of 1.8 to 2.0% by weight are now available in the art. In view of the antifouling effect, however, a beryllium content of at least 1.6% by weight is preferable. At a beryllium content higher than 2.8% by weight, beryllium does no longer form any further solid solution with copper. In other words, the resulting alloy excels in the antifouling effect but undergoes a gradual decrease in metalleability. Referring now to FIGURE 1, there is shown how a thin sheet made up of a beryllium copper alloy is wound spirally around a round bar. A thin sheet 2 made up of a beryllium-copper alloy is spirally wound around a round bar 1, as illustrated in FIGURE 1(A). A resin layer 3 made up of an electrical insulating material is formed on an outer surface of the beryllium-copper alloy thin sheet 2, as shown in FIGURE 1(B). Then, the round bar is taken out. The obtained pipe 7 has an inner wall made up of the beryllium-copper alloy thin sheet 2. This beryllium-copper alloy has a remarkable antifouling effect and provides a continued liberation of copper ions, as already mentioned. An other way of how a thin strap of a beryllium copper alloy is wound spirally and how a resin layer is formed on an outer surface of the thin strap is illustrated in FIGURE 5. In Figure 5, a thin sheet 2 made up of a beryllium-copper alloy is spirally wound around a round bar 1 with space 5. The wound beryllium-copper alloy thin sheet 2 is inserted into a pipe 7 made up of resin, as illustrated in FIGURE 1(B) and the round bar 1 is taken out. The obtained pipe has an inner wall on which the beryllium-copper alloy thin sheet 2 is partly formed and the resin pipe is exposed in other parts, as shown in FIGURE 1(C). The beryllium-copper alloy of the second embodiment also has a remarkable antifouling effect and its continued effect, thereby preventing deposition and propagation of oceanic organisms. In an embodiment of the invention as illustrated by FIGURE 6, a thin sheet 2 made up of a beryllium-copper alloy is spirally wound around a round bar 1 with space 5. Another beryllium-copper alloy thin sheet 2 is wounded to cover the space 5. A resin layer is formed on the beryllium-copper thin sheet 2 and the round bar 1 is taken out. The obtained pipe has an inner wall which is completely covered with the beryllium-copper alloy. The present invention is further illustrated in FIGURES 7 and 8. In Figures 7 and 8, a thin strap 22 made up of a beryllium-copper alloy is spirally wound. A convex portion 26a and a concave portion 26b of the beryllium-copper alloy thin strap 22, which are adjacent to each other, are engaged to prevent the beryllium-copper alloy thin strap 22 from moving in the axial direction. Then, an electrical insulating resin layer (not shown) is formed on an outer surface of the beryllium-copper thin strap 22 to make a cylindrical pipe. The obtained pipe has an inner wall which is covered with the beryllium-copper thin strap 22. A particular embodiment of the invention will now be explained with reference to FIGURE 9. In this embodiment, a thin strap 32 made up of a beryllium-copper alloy is spirally wound to make an inner pipe, as illustrated in FIGURE 9 (A). An outer casing 33 comprising a first electrical insulating resin layer is formed on an outer surface of the inner pipe to make a cylindrical pipe 35, as shown in FIGURE 9(B). Then, the pipe 35 is cut along inclined cutting plane lines m1, m2, m3, - mm to obtain cut members 30 which are of uniform shape and size, as shown in FIGURE 9(C). End faces 30a and 30b of the cut members 30 are connected to make a curved pipe, as illustrated in FIGURE 9(D). An outer casing 36 comprising a second resin layer is covered on the casing 33, as shown in FIGURE 9(E). On the both sides of the obtained curved pipe 40, flanges 42 and 43 are formed. The beryllium-copper alloy thin sheet is wound to make the cylindrical pipe, and the outer surface of the cylindrical pipe is covered with the resin layer to make the straight pipe 35. The straight pipe 35 is cut along the predetermined inclined cutting plane lines. The end faces of the cut members 30 are connected to each other. With this method, a curved pipe can be easily produced. In addition, a curvature of a pipe can be easily changed by circumferentially shifting a connecting angle between one end face 30a and another end face 30b of the cut members 30. Therefore, it is possible to make a beryllium-copper alloy pipe with desired curvature. In another particular embodiment, the processes shown in FIGURE 1(A), 1(B) and 1(C) are employed in place of the processes shown in FIGURES 9(A) and 9(B). A thin sheet 2 made up of a beryllium-copper alloy is spirally wound around a round bar 1, as illustrated in FIGURE 1(A). An electrical insulating resin layer 3 is covered on an outer surface of the beryllium-copper alloy thin sheet 2, as shown in FIGURE 1(B). Then, the round bar is taken out. The obtained pipe 7 has an inner wall which is covered with the beryllium-copper alloy thin sheet 2, as illustrated in FIGURE 1(C). The processes shown in FIGURES 9(C), (D) and (E) follow this process. The beryllium-copper alloy of this embodiment also has a remarkable antifouling effect and its continued effect, thereby preventing deposition and propagation of oceanic organisms. In a further specific embodiment, the processes shown in FIGURE 5 is employed in place of the process shown in FIGURE 9(A). A thin sheet 2 made up of a beryllium-copper alloy is spirally wound around a round bar 1 with space 5. This wound beryllium-copper alloy thin sheet is inserted into a resin pipe, and the round bar is taken out. The obtained pipe has an inner wall on which the beryllium-copper alloy is partly formed and the resin pipe is exposed in other parts. Then, the processes shown in FIGURES 9(c), 9(D) and 9(E) follow this process. The beryllium-copper alloy of this embodiment also has a remarkable antifouling effect and its continued effect, thereby preventing deposition and propagation of oceanic organisms. In a still further embodiment, the process shown in FIGURE 6 is employed in place of the process shown in FIGURE 9(A). A thin sheet 2 made up of a beryllium-copper alloy is spirally wound around a round bar 1 with space 5. Another beryllium-copper alloy thin sheet 2 is wound to cover the space 5. A resin layer is formed on the beryllium-copper thin sheet 2 and the round bar 1 is taken out. The obtained pipe has an inner wall which is completely covered with the beryllium-copper alloy. The processes shown in FIGURES 9(C), (D) and (E) follow this process. A still other embodiment of the invention will now be explained with reference to FIGURES 7 and 8. In this embodiment, a thin strap 22 made up of a beryllium-copper alloy is spirally wound. A convex portion 26a and a concave portion 26b of the beryllium-copper alloy thin strap 22, which are adjacent to each other, are engaged to prevent the beryllium-copper alloy thin strap 22 from moving in the axial direction. Then, a first electrical insulating resin layer, which is not shown in the FIGURES, is formed on an outer surface of the beryllium-copper thin strap 22 to make a cylindrical pipe. The obtained pipe has an inner wall which is covered with the beryllium-copper thin strap 22. The processes shown in FIGURES 1(C), 1(D) and 1(E) follow this process. With the method for making an organism deposit-inhibiting pipe according to the invention, it is possible to make the antifouling pipe for inhibiting deposition of oceanic organisms in relatively simple operation. The antifouling structure provided by this method excels in corrosion resistance, can be maintained in less troublesome operation, presents no toxicity problem, and can effectively inhibit deposition of oceanic organisms.

Claims: A method for making an organism deposit-inhibiting pipe, which involves winding spirally a thin strap made up of a beryllium copper alloy, connecting a convex portion and a concave portion of the thin strap, which are adjacent to each other, to prevent the thin strap from moving in the axial direction, and forming a resin layer on an outer surface of the thin strap. A method according to Claim 1, wherein the beryllium copper alloy has a beryllium content of 0.2 to 2.8% by weight, and is an alloy selected from the group consisting of Be-Cu, Be-Co-Cu, Be-Co-Si-Cu and Be-Ni-Cu alloys. A method according to Claim 1 or 2, which involves winding spirally a thin sheet made up of a beryllium copper alloy to make an inner pipe, forming a first electrical insulating resin layer on an outer surface of the inner pipe, cutting the pipe into a plurality of members, facing and connecting edge faces of the cut members, and forming a second resin layer on the outer surface of the connected members. A method according to Claim 3, wherein the pipe is cut into a plurality of members along inclined cutting plane lines, and wherein the cut members are faced and connected by their edge faces to make a curved pipe. A method for making an organism deposit-inhibiting pipe, which involves winding a thin sheet made up of a beryllium copper alloy spirally around a round bar, forming a resin layer comprising an electrical insulating material on the thin sheet and taking out the round bar. A method according to claim 5, wherein the beryllium copper alloy has a beryllium content of 0.2 to 2.8 % by weight, and is an alloy selected from the group consisting of Be-Cu, Be-Co-Cu, Be-Co-Si-Cu and Be-Ni-Cu alloys.

Inventors: INOUE SHUNJI, INOUE, SHUNJI
Applicants: NGK INSULATORS LTD, NGK INSULATORS, LTD.
Application year: 1993
Main classification: F16L58
IPC codes: A01N59, E02B17, B63B59, C23F15