Continuous-Fiber Composite Connector for Hoop Load Resistance
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Solution Overview
Problem
Conventional connectors for fluid transfer conduits, particularly those made from metal, result in significant material waste and are not compatible with composite materials like fiber-reinforced polymers, leading to issues such as galvanic corrosion and unequal thermal expansion, while connectors made from randomly oriented chopped fibers do not fully utilize fiber strength and require excessive material for load resistance.
Innovation Solution
A connector design using continuous fiber-reinforcement, specifically circumferentially oriented in the hub portion and longitudinally oriented in the flange portion, made from fiber-reinforced polymer, which is manufactured via additive processes like resin transfer molding, allowing for tailored fiber orientation and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If connectors are milled from a single block of metal, then the connectors can withstand large circumferential loads and other stresses, but a large amount of material is wasted
Solution Approach 1:
The invention changes the manufacturing method from subtractive machining to additive resin transfer molding, and transitions from metal to fiber-reinforced polymer material. This allows the connector to be formed with continuous fiber reinforcement that follows the load paths, achieving high strength with minimal material waste through tailored fiber orientation in the hub and flange portions.
Solution Approach 2:
The invention uses fiber-reinforced polymer composite materials with continuous circumferential fibers in the hub portion and continuous longitudinal fibers in the flange portion. This composite structure provides the necessary strength to withstand circumferential loads and other stresses while significantly reducing material consumption compared to conventional metal connectors.
2Weight of moving object
If connectors are made from composite materials, then weight is saved and material costs are reduced, but galvanic corrosion and reduced temperature operating window occur due to unequal thermal expansion
Solution Approach 1:
The invention changes the material parameters by using fiber-reinforced polymer composites with specifically oriented continuous fibers. The continuous circumferential fiber reinforcement in the hub portion provides thermal stability that matches composite fluid transfer conduits, eliminating galvanic corrosion issues and expanding the temperature operating window while maintaining weight savings.
3Loss of substance
If connectors are made from chopped-fiber reinforced resin, then material waste is reduced and weight is decreased, but the strength potential of reinforcing fibers is not fully utilized
Solution Approach 1:
The invention applies local quality by using continuous circumferential fiber reinforcement specifically in the hub portion where circumferential loads occur, and continuous longitudinal fiber reinforcement in the flange portion where axial and bending loads occur. This localized continuous fiber orientation fully utilizes the strength potential of the reinforcing fibers in the critical load-bearing regions.
Solution Approach 2:
The invention transitions from randomly oriented chopped fibers to continuously oriented fibers in specific directions (circumferential in hub, longitudinal in flange). This dimensional organization of fibers along the length and circumference maximizes the strength utilization of the reinforcing fibers while maintaining the benefits of composite material manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves significant weight savings, improved hoop strength, and thermal expansion matching, reducing material waste and enhancing the connector's resistance to high pressures and temperatures, while maintaining a reliable seal over a wide temperature range.
Implementation Method 1
a reduced temperature operating window due to unequal thermal expansion
Implementation Method 2
the connector being made from fiber-reinforced polymer and comprising: a hub portion comprising a tube which extends substantially parallel to a central axis; and a flange portion which extends from the hub portion at an angle to the central axis; wherein the hub portion comprises continuous circumferentially oriented fiber reinforcement; and wherein the connector comprises longitudinally oriented fiber reinforcement which runs continuously from the hub portion into the flange portion
Data Source
AI summary
A method of manufacturing a connector for a fluid transfer conduit includes: 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.