Composite Connector with Circumferential Fibres for Corrosion-Free Joining
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Solution Overview
Problem
Conventional connectors for fluid transfer conduits, especially those made of metal, face issues with material wastage, galvanic corrosion, and thermal expansion mismatch when used with composite materials, leading to inefficiencies in strength, weight, and temperature operating windows.
Innovation Solution
The use of continuous circumferentially-oriented fibre reinforcement in a composite connector system, where the hub portion is manufactured using additive processes, allows for tailored fibre orientation to optimize strength and weight, reducing material waste and thermal expansion mismatch by matching the coefficient of thermal expansion and stiffness of the connector with the fluid transfer conduit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If connectors are machined from a single block of metal, then strength and structural integrity are improved, but material waste increases significantly
Solution Approach 1:
The patent changes the manufacturing parameter from subtractive machining to additive manufacturing, building the connector layer by layer to achieve near-net-shape production. This eliminates material waste while maintaining structural integrity through controlled material deposition and bonding.
Solution Approach 2:
The patent employs composite materials consisting of thermoplastic polymer matrix reinforced with continuous fibres (such as carbon, glass, or aramid fibres). This composite structure provides high strength-to-weight ratio while enabling additive manufacturing, thus resolving the contradiction between strength and material waste.
2Strength
If metallic connectors are used with composite fluid transfer conduits, then connection strength is improved, but galvanic corrosion and thermal expansion mismatch occur
Solution Approach 1:
The patent uses homogeneous material composition for both the connector and the fluid transfer conduit, specifically thermoplastic composite materials with continuous fibre reinforcement. This material compatibility eliminates galvanic corrosion between dissimilar metals and reduces thermal expansion mismatch, while maintaining strong mechanical connection.
3Loss of substance
If chopped-fibre reinforced composite connectors are used, then material waste is reduced compared to metal machining, but strength is not fully optimized
Solution Approach 1:
The patent transitions from randomly oriented chopped fibres to continuously oriented fibres arranged in specific directional patterns. This dimensional organization of fibres along principal stress trajectories maximizes strength utilization while maintaining the benefits of additive manufacturing and reduced material waste.
Data Source
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AI summary
A method of manufacturing a composite (e.g. fibre-reinforced polymer) connector 102 comprises: manufacturing a tubular hub portion 106 which extends substantially parallel to a central axis C, the hub portion 106 comprising a thermoplastic polymer reinforced with continuous, circumferentially-oriented fibre reinforcement 110; placing the hub portion 106 into a mould featuring at least one cavity; and introducing polymer into the mould so as to fill the at least one cavity to form a flange portion 108 around the hub portion 106.