Composite Fluid Connector With Continuous Fibre Winding
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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 unequal thermal expansion when used with composite conduits, and do not efficiently utilize the strength potential of reinforcing fibers.
Innovation Solution
The use of continuous circumferentially-oriented fibre reinforcement in composite connectors, manufactured through additive processes like filament winding, allows for tailored strength properties, reduced material usage, and improved resistance to radial loads and thermal expansion, eliminating the need for additional assembly or jointing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If connectors are machined from a single block of metal, then the requisite strength to withstand large circumferential loads is achieved, but a large amount of material is wasted
Solution Approach 1:
The patent applies composite materials by manufacturing connectors using injection moulding with thermoplastic matrix reinforced with chopped fibres (carbon/glass/aramid). This composite approach provides the requisite strength to withstand circumferential loads while significantly reducing material waste compared to conventional metal machining techniques.
Solution Approach 2:
The patent changes the manufacturing parameters from subtractive metal machining to additive injection moulding process. This parameter change enables material efficiency by building the connector layer by layer with only the necessary material, eliminating the high material waste associated with machining metal blocks.
2Strength
If connectors are made from metal, then the requisite strength is achieved, but galvanic corrosion occurs when used with composite conduits
Solution Approach 1:
The patent applies homogeneity by making both the connector and the fluid transfer conduit from composite materials (thermoplastic matrix reinforced with chopped fibres). This material compatibility eliminates galvanic corrosion by removing the dissimilar metal-composite interface that causes electrochemical degradation.
3Strength
If connectors are made from metal, then the requisite strength is achieved, but the temperature operating window is reduced due to unequal thermal expansion
Solution Approach 1:
The patent uses homogeneous composite material construction for both the connector and conduit, ensuring matched thermal expansion characteristics. This eliminates the differential thermal expansion problems that limit the temperature operating window when dissimilar metal and composite materials are joined.
Solution Approach 2:
The patent employs composite materials with tailored thermal properties that match those of composite fluid transfer conduits. This material selection expands the temperature operating window by eliminating thermal incompatibility issues inherent in metal-composite joints.
4Loss of substance
If chopped-fibre reinforced composite connectors are used, then material waste is reduced and weight is decreased, but the strength potential of reinforcing fibres is not fully exploited
Solution Approach 1:
The patent changes the fibre configuration parameter from chopped/discontinuous fibres to continuous fibres in the composite reinforcement. This parameter change fully exploits the strength potential of the reinforcing fibres while maintaining the advantages of additive manufacturing and material efficiency.
Solution Approach 2:
The patent employs advanced composite materials with continuous fibre reinforcement instead of chopped fibres. This material enhancement maximizes the structural efficiency and strength-to-weight ratio by ensuring continuous load transfer along the fibre length, fully utilizing the high strength potential of the reinforcing fibres.
Data Source
Figure 1
Figure 2A~2B
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AI summary
A method of manufacturing a composite (e.g. fibre-reinforced polymer) connector 309 for a fluid transfer conduit comprises: providing a tubular mandrel 304 which extends substantially parallel to a central axis C; providing a former 302 on the tubular mandrel 304 which extends substantially perpendicular to the central axis C; and winding continuous fibre reinforcement, impregnated with a thermosetting polymer, around the mandrel 304 to form a tubular hub portion 306 which extends substantially parallel to the central axis C and over the former 302 to form a flange portion 308 which extends from the hub portion 306 at an angle to the central axis C. Winding the continuous fibre reinforcement over the former 302 comprises passing the continuous fibre reinforcement across a first surface of the former 302 that is substantially perpendicular to the central axis C and across a second surface of the former 302 such that the former 302 is encapsulated as a core for the flange portion 308.