Composite Fluid Connector Fiber Layout for Hoop and Axial Loads
Find Innovative SolutionsGenerate Solutions
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 conduits, leading to inefficiencies in strength, weight, and temperature tolerance.
Innovation Solution
A connector made from fiber-reinforced polymer with continuous circumferentially oriented fiber reinforcement in the hub portion and longitudinally oriented fibers in the flange portion, manufactured using additive processes like resin transfer molding, which optimizes material usage, enhances strength-to-weight ratio, and matches thermal expansion coefficients with the conduit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If connectors are milled from a single block of metal, then strength and structural integrity are improved, but material wastage increases significantly
Solution Approach 1:
The invention changes the manufacturing parameter from subtractive machining to additive molding processes. Connectors are molded from fiber-reinforced polymer materials in their final shape, eliminating material removal and achieving near 100% material utilization while maintaining structural integrity
Solution Approach 2:
The invention uses composite materials (fiber-reinforced polymers) instead of solid metal. The fibers provide structural strength while the polymer matrix binds them, creating a material that offers comparable strength to metal with significantly reduced density and material wastage
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 invention uses homogeneous polymer-based materials for both the connector and the fluid transfer conduit. This material compatibility eliminates galvanic corrosion between dissimilar metals and composites, and reduces thermal expansion mismatch, allowing both components to expand and contract uniformly with temperature changes
Solution Approach 2:
The connector is made from fiber-reinforced polymer composite materials that match the composite fluid transfer conduit. This composite-to-composite interface eliminates the harmful electrochemical and thermal effects associated with metal-composite connections while maintaining structural strength
3Loss of substance
If chopped-fiber reinforced resin connectors are used, then material waste is reduced and weight is decreased, but fiber strength potential is not fully exploited
Solution Approach 1:
The invention changes the fiber configuration parameter from chopped/discontinuous fibers to continuous fibers. Continuous fibers maintain their full length and load-bearing capacity throughout the connector structure, fully exploiting the high tensile strength of the fiber reinforcement while still using additive molding processes
Solution Approach 2:
The invention segments the fiber reinforcement into different orientations within the connector: circumferential fibers in the hub portion for hoop strength, and longitudinal fibers in the flange portion for axial strength. This segmented fiber arrangement optimizes strength utilization while maintaining the benefits of additive manufacturing
4Strength
If continuous fiber reinforcement is used, then strength-to-weight ratio is improved, but manufacturing complexity increases
Solution Approach 1:
The invention segments the continuous fiber reinforcement into functionally distinct zones: circumferential fiber layers in the hub portion for hoop strength, and longitudinal fiber layers in the flange portion for axial strength. This segmentation allows each zone to be optimized for its specific load requirements while simplifying the manufacturing process through standardized molding techniques
Data Source
AI summary
A method of manufacturing a connector for a fluid transfer conduit comprises: providing a first mould section comprising a hub-moulding portion which extends substantially parallel to a central axis C and a flange-moulding portion which extends from the hub-moulding portion at an angle to the central axis C; introducing fiber-reinforcement to the first mould section such that continuous circumferentially-oriented fiber-reinforcement lies in the hub-moulding portion, and continuous longitudinally-oriented fiber reinforcement extends from the hub-moulding portion into the flange-moulding portion; applying a second mould section over the first mould section to form a complete mould in which the fiber-reinforcement is confined; and introducing a polymer to the complete mould such that it permeates through the fiber-reinforcement to form a fiber-reinforced polymer connector; and extracting the connector from the mould.