Composite Fluid Connector with Continuous-Fiber Hub and Flange
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Solution Overview
Problem
Existing connectors for fluid transfer conduits face challenges such as high material wastage, galvanic corrosion, and reduced temperature operating windows when using metallic connectors with composite conduits. Additionally, they struggle to efficiently manage relative movement and stresses between conduits and structures.
Innovation Solution
A composite connector featuring a hub portion and a flange portion, both reinforced with continuous fibre reinforcement secured by stitching to a common support layer. This design allows for improved strength, reduced material usage, and tailored fibre orientation to manage loads and thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If connectors are machined from a single block of metal, then the connectors can withstand large circumferential loads and provide requisite strength, but a large amount of material is wasted
Solution Approach 1:
The patent applies composite materials by combining continuous fibre reinforcement (such as carbon, glass, or aramid fibres) with a thermoplastic matrix material to create a connector that maintains high strength while reducing material usage. The composite structure allows load-bearing fibres to be strategically oriented, providing the necessary mechanical strength without requiring excessive material that would be wasted in conventional metal machining.
Solution Approach 2:
The patent implements local quality by orienting continuous fibres in specific directions within the connector structure to match the stress distribution patterns. fibres are concentrated in regions experiencing high circumferential loads while being absent or reduced in low-stress areas, creating a non-uniform but optimally distributed reinforcement pattern that minimizes material usage while maintaining strength.
2Strength
If metallic connectors are used with composite fluid transfer conduits, then connectors can provide structural support, but galvanic corrosion and reduced temperature operating window occur
Solution Approach 1:
The patent applies homogeneity by using a thermoplastic matrix material in the composite connector that is chemically compatible with composite fluid transfer conduits, eliminating the dissimilar metal-contact interface that causes galvanic corrosion. The thermoplastic material provides structural support while being electrochemically homogeneous with the conduit materials, preventing corrosive electrochemical reactions.
Solution Approach 2:
The patent changes the material parameter from metal to composite (thermoplastic matrix with fibre reinforcement), which fundamentally alters the thermal expansion characteristics to match those of composite conduits. This parameter change eliminates the thermal expansion mismatch that limits the operating temperature window when using metallic connectors with composite conduits.
3Loss of substance
If chopped-fibre reinforced composite connectors are produced by injection moulding, then material wastage is reduced and parts are lighter, but the strength potential of reinforcing fibres is not fully exploited
Solution Approach 1:
The patent applies continuity of useful action by using continuous fibres that extend throughout the connector structure rather than discontinuous chopped fibres. These continuous fibres maintain their load-bearing capacity across the entire component, allowing stresses to be transmitted along the full length of each fibre without interruption, thereby fully exploiting the strength potential of the reinforcing fibres while maintaining the benefits of additive manufacturing.
Data Source
AI summary
A method of manufacturing a composite (e.g. fibre-reinforced polymer) connector for a fluid transfer conduit includes: manufacturing a continuous fibre pre-form net that is shaped to comprise a hub-forming portion 156 and a flange-forming portion, the continuous fibre pre-form net comprising continuous fibre reinforcement and a common support layer to which the continuous fibre reinforcement is secured by being stitched thereto; placing the continuous fibre pre-form net into a mould, the mould being shaped such that the hub-forming portion forms a tubular hub portion which extends along a central axis and the flange-forming portion forms a flange portion which extends from the hub portion at an angle to the central axis; and introducing polymer into the mould so as to form a composite connector comprising the flange portion and the hub portion.