Composite Connector Hub and Overmoulded Flange for Hoop Strength
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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 tolerance.
Innovation Solution
A composite connector with a hub portion reinforced by continuous circumferentially-oriented fibres and a flange portion made from thermoplastic polymer, where the flange is overmoulded onto the hub, allowing for tailored fibre orientation 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 parts: a hub portion made from metal and a flange portion made from composite material. This segmentation allows each part to be optimized for its specific function while reducing overall material usage compared to machining a single metal block.
Solution Approach 2:
The flange portion is constructed from composite material (such as fibre-reinforced polymer) instead of metal, providing sufficient strength while significantly reducing material wastage. The composite material is formed through additive processes like injection moulding rather than subtractive machining.
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 flange portion is made from composite material that can be selected to match the thermal expansion properties of the composite fluid transfer conduit. This eliminates galvanic corrosion and thermal expansion mismatch issues that occur with metal connectors.
Solution Approach 2:
Different materials are used for different portions of the connector: metal for the hub portion requiring high strength and stiffness, and composite for the flange portion requiring thermal compatibility with the conduit. This local optimization resolves the contradiction between connection strength and thermal compatibility.
3Weight of moving object
If chopped-fibre reinforced composite connectors are used, then weight is reduced and material waste is minimized, but strength is insufficient compared to metal connectors
Solution Approach 1:
The connector is segmented into a metal hub portion providing high strength for withstanding circumferential loads, and a composite flange portion providing weight reduction. This segmentation allows each material to be used where it is most effective.
Solution Approach 2:
While the flange portion uses composite material for weight reduction, the hub portion uses metal to provide the necessary strength. This hybrid approach maintains connection strength while achieving weight reduction and minimizing material waste through additive manufacturing of the composite portion.
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.