Composite Fluid Connector With Oriented Fibres for Thermal Match
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Solution Overview
Problem
Conventional connectors for fluid transfer conduits, particularly those made from metal, face issues such as material wastage, galvanic corrosion, and mismatched thermal expansion with composite conduits, leading to inefficiencies and increased weight.
Innovation Solution
The use of continuous fibre-reinforced polymer connectors, manufactured through additive processes like resin transfer moulding, allows for tailored fibre orientation to enhance strength and match thermal expansion, reducing material waste and weight while maintaining a secure seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If connectors are milled from a single block of metal, then strength and structural integrity are improved, but material wastage increases significantly
Solution Approach 1:
The invention changes the manufacturing parameter from subtractive machining to additive moulding, transforming how the connector is created. This allows the connector to be built up layer by layer or formed directly in the mould, dramatically reducing material removal and waste while maintaining structural integrity
Solution Approach 2:
The invention transitions from homogeneous metal material to composite materials (such as fibre-reinforced polymers). These composite materials provide comparable or superior strength-to-weight ratios while enabling additive manufacturing processes that minimize material wastage
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 invention applies homogeneity by using composite materials for both the fluid transfer conduit and the connector. This material compatibility eliminates galvanic corrosion between dissimilar metals and reduces thermal expansion mismatch, as both components respond similarly to temperature changes
Solution Approach 2:
The invention uses composite materials (e.g., fibre-reinforced polymers) for the connector to match the composite fluid transfer conduit. This material compatibility prevents galvanic corrosion and minimizes thermal expansion differences, eliminating the harmful effects of material mismatch
3Weight of moving object
If connectors are made from composite materials, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The invention segments the connector into distinct functional zones with different fibre orientations and material properties. This allows each zone to be optimized for its specific function while being manufactured as an integrated component, reducing overall complexity
Solution Approach 2:
The invention applies local quality by varying the fibre orientation, density, and material composition in different regions of the connector. This enables each local area to have the precise properties needed for its function, optimizing performance while managing manufacturing complexity through targeted material placement
4Ease of manufacture
If randomly oriented chopped fibres are used in injection-moulded connectors, then manufacturing simplicity is improved, but strength potential is not fully exploited
Solution Approach 1:
The invention transitions from randomly oriented fibres to locally oriented fibres, where the fibre direction is controlled to align with principal stress trajectories in different regions of the connector. This maximizes the strength contribution of each fibre while maintaining manufacturability
Solution Approach 2:
The invention changes the fibre orientation parameter from random to controlled directional alignment. This can be achieved through specialised moulding techniques or pre-forming fibres in the desired orientation before moulding, significantly enhancing strength while keeping the process relatively simple
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 solution provides stronger, lighter connectors with improved hoop strength and thermal expansion matching, reducing material costs and ensuring reliable connections over a wider temperature range.
Implementation Method 1
a reduced temperature operating window due to unequal thermal expansion
Implementation Method 2
an alternative manufacturing technique has been developed whereby connectors are produced by injection-moulding a resin matrix reinforced with randomly oriented chopped fibres
Data Source
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AI summary
A method of manufacturing a connector for a fluid transfer conduit comprises: providing a first mould section comprising a hub-moulding portion 410 which extends substantially parallel to a central axis C and a flange-moulding portion 410 which extends from the hub-moulding portion 410 at an angle to the central axis C; introducing fibre-reinforcement to the first mould section such that continuous circumferentially-oriented fibre-reinforcement lies in the hub-moulding portion 404, and continuous longitudinally-oriented fibre reinforcement extends from the hub-moulding portion 404 into the flange-moulding portion 410; applying a second mould section 420 over the first mould section to form a complete mould 422 in which the fibre-reinforcement is confined; and introducing a polymer 428 to the complete mould such that it permeates through the fibre-reinforcement to form a fibre-reinforced polymer connector; and extracting the connector from the mould 422.