Composite Fluid Connector Seal Section for Thermal Expansion Matching
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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 sealing problems when used with composite materials, and they struggle to maintain a consistent seal across varying temperatures due to unequal thermal expansion.
Innovation Solution
The method involves manufacturing composite connectors using continuous fibre reinforcement oriented circumferentially and pre-impregnated with thermoplastic polymer, combined with injection moulding for the rest of the connector, which reduces material waste, enhances sealing reliability, and matches the thermal expansion of the conduit, allowing for complex shapes and reduced weight.
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 waste increases significantly
Solution Approach 1:
The invention changes the manufacturing approach from subtractive (machining) to additive (injection moulding), fundamentally altering how the connector is created. This allows the same structural integrity to be achieved with minimal material waste by building the part from molten material that conforms exactly to the required shape.
Solution Approach 2:
The invention uses composite materials (thermoplastic polymer matrix with randomly oriented chopped fibres) instead of solid metal. This composite structure provides sufficient strength for connector applications while being inherently lighter and more suitable for additive manufacturing processes, thereby reducing material waste.
2Weight of moving object
If connectors are made from composite materials, then weight is reduced and material cost decreases, but galvanic corrosion and thermal expansion issues arise when used with metallic connectors
Solution Approach 1:
The invention makes both the connector and the fluid transfer conduit homogeneous in material composition (both made from composite materials with similar thermal expansion properties). This eliminates the galvanic corrosion and thermal expansion mismatch problems that occur when dissimilar materials (metal connectors with composite conduits) are joined together.
3Loss of substance
If injection moulding is used to manufacture composite connectors, then material waste is reduced and weight is decreased, but sealing quality deteriorates due to required taper in inner surface
Solution Approach 1:
The invention applies local quality by using a straight inner surface geometry specifically in the sealing region of the connector. This localized design choice maintains the benefits of injection moulding (minimal material waste) while ensuring high sealing quality, as the straight surface allows for proper O-ring sealing without the degradation caused by tapered surfaces.
4Ease of manufacture
If a tapered inner surface is added to injection moulded connectors for extraction, then manufacturability is improved, but seal integrity is significantly diminished
Solution Approach 1:
The invention inverts the conventional approach by using a straight (non-tapered) inner surface instead of a tapered one. This reversal maintains extractability through proper mould design while preserving seal integrity, as the straight surface provides a uniform sealing interface that is not compromised by angular deviations.
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
This approach results in connectors that are lightweight, cost-effective, provide high hoop strength, maintain a consistent seal across temperature variations, and reduce material waste, while ensuring reliable sealing and structural integrity.
Implementation Method 1
injecting a thermoplastic polymer into the mould to form a connector with a tubular hub portion and a flange portion
Implementation Method 2
applying continuous fibre reinforcement, oriented at least partially circumferentially and pre-impregnated with a thermoplastic polymer
Data Source
AI summary
A method of manufacturing a composite connector for a fluid transfer conduit is provided which comprises applying continuous fibre reinforcement, oriented at least partially circumferentially and pre-impregnated with a thermoplastic polymer to a tubular mould portion which extends substantially parallel to a central axis C; applying at least one further mould portion to form a complete mould in which the continuous fibre reinforcement is enclosed and injecting a thermoplastic polymer into the mould to form a connector with a tubular hub portion and a flange portion which extends from the hub portion at an angle to the central axis C. The tubular hub portion comprises a tubular seal section with an inner layer and an outer wherein the inner layer comprises the continuous fibre reinforcement and the outer layer comprises the injected thermoplastic polymer.