Composite Connector Hub With Circumferential Fibers for High Pressure
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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 materials, and do not effectively utilize the strength of reinforcing fibers.
Innovation Solution
A composite connector with a hub portion reinforced by continuous circumferentially-oriented fibers and a flange portion made from a thermoplastic polymer, where the flange is overmoulded onto the hub, allowing for adjustable design and reduced material usage, enhancing hoop strength and thermal expansion matching.
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 wastage increases significantly
Solution Approach 1:
The connector is divided into two distinct portions: a hub portion made from metal and a flange portion made from composite material. This segmentation allows each portion to be optimized for its specific function while reducing overall material usage compared to a solid metal connector.
Solution Approach 2:
The flange portion is constructed from composite material (such as carbon fiber reinforced polymer) which provides high strength-to-weight ratio and sufficient structural integrity with less material than metal, thereby reducing material wastage while maintaining connector strength.
2Strength
If metallic connectors are used with composite fluid transfer conduits, then connection strength is improved, but galvanic corrosion and thermal expansion issues occur
Solution Approach 1:
Different materials are used for different portions of the connector: the hub portion (in contact with the composite conduit) is made from metal to provide strong mechanical connection, while the flange portion is made from composite material to match the thermal and electrical properties of the composite conduit, eliminating galvanic corrosion and thermal expansion mismatches.
Solution Approach 2:
The flange portion uses composite material that is electrically non-conductive and has thermal expansion properties matching the composite conduit, thereby preventing galvanic corrosion and reducing thermal expansion differential between the connector and the conduit.
3Weight of moving object
If chopped-fibre reinforced composite connectors are used, then weight is reduced and material waste decreases, but strength utilization of fibres is insufficient
Solution Approach 1:
The connector is segmented such that the hub portion uses metal for high strength requirements, while the flange portion uses composite material where continuous fibres can be optimally oriented to exploit their full strength potential in the primary load direction, achieving better fibre strength utilization than chopped-fibre composites.
Solution Approach 2:
Continuous fibres in the flange portion are oriented to align with the primary stress directions specific to each region, maximizing the strength contribution of the fibres where needed while maintaining lightweight composite construction.
Data Source
AI summary
A method of manufacturing a composite (e.g. fibre-reinforced polymer) connector comprises: manufacturing a tubular hub portion which extends substantially parallel to a central axis C, the hub portion comprising a thermoplastic polymer reinforced with continuous, circumferentially-oriented fibre reinforcement; placing the hub portion 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 around the hub portion.