Composite Fluid Connector Flange for Corrosion-Free Load Transfer
Find Innovative SolutionsGenerate Solutions
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 and increased costs.
Innovation Solution
A composite connector with a hub portion and flange portion made from a thermosetting polymer reinforced with continuous circumferentially-oriented fibre reinforcement, which reduces material waste, enhances strength-to-weight ratio, and matches thermal expansion characteristics of composite conduits, allowing for efficient load distribution and sealing.
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 manufactured as a composite part using injection moulding with short-fibre reinforced thermoplastic material, replacing conventional metal machining. This achieves the required strength while dramatically reducing material wastage through an additive manufacturing process that uses only the necessary amount of material.
Solution Approach 2:
The invention changes the material parameters from metal to composite (thermoplastic with short fibres), and changes the manufacturing process from subtractive (machining) to additive (injection moulding). This parameter transformation resolves the contradiction by achieving comparable strength with minimal material waste.
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 connector is made from the same thermoplastic material family as the composite fluid transfer conduit, creating material homogeneity. This eliminates galvanic corrosion by removing dissimilar metal-composite interfaces and reduces thermal expansion mismatch by using materials with compatible thermal properties.
Solution Approach 2:
The invention uses composite materials (short-fibre reinforced thermoplastic) for the connector that are compatible with composite fluid transfer conduits. This composite-composite interface eliminates the harmful effects of metal-composite interfaces while maintaining connection strength.
3Weight of moving object
If chopped-fibre reinforced composite connectors are used, then weight is reduced and material waste is minimized, but strength potential is not fully exploited
Solution Approach 1:
The invention optimizes the fibre parameters by using short fibres (3-12 mm length) with appropriate aspect ratios and orientations within the thermoplastic matrix. This parameter optimization during injection moulding maximizes the strength potential of the composite material while maintaining lightweight characteristics.
Solution Approach 2:
The use of short-fibre reinforced thermoplastic composite material provides an optimal balance between weight and strength. The composite structure achieves sufficient mechanical properties for connector applications while being significantly lighter than metal alternatives and using minimal material through injection moulding.
Data Source
AI summary
A method of manufacturing a composite (e.g. fibre-reinforced polymer) connector for a fluid transfer conduit includes: providing a tubular mandrel which extends substantially parallel to a central axis C; providing a former on the tubular mandrel which extends substantially perpendicular to the central axis C; and winding continuous fibre reinforcement, impregnated with a thermosetting polymer, around the mandrel to form a tubular hub portion which extends substantially parallel to the central axis C and over the former to form a flange portion 308 which extends from the hub portion at an angle to the central axis C. Winding the continuous fibre reinforcement over the former includes passing the continuous fibre reinforcement across a first surface of the former that is substantially perpendicular to the central axis C and across a second surface of the former such that the former is encapsulated as a core for the flange portion.