Composite Fluid Connector with Oriented Fibres for Thermal Stability
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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 compatibility.
Innovation Solution
A fibre-reinforced polymer connector with continuous circumferentially oriented fibre reinforcement in the hub portion and longitudinally oriented fibre reinforcement in the flange portion, manufactured using additive processes, which optimizes material usage, strength, and thermal expansion matching.
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 waste increases significantly
Solution Approach 1:
The invention changes the manufacturing parameter from subtractive machining to additive injection-moulding, transforming how the connector is formed. This allows the same structural integrity to be achieved with minimal material waste, as the connector is built up layer by layer in its final shape rather than being carved from a solid block.
Solution Approach 2:
The invention replaces traditional metal materials with composite materials (polymer matrix with chopped fibre reinforcement). This substitution maintains the required strength and structural integrity while dramatically reducing material waste, as composites can be formed directly into complex shapes through injection-moulding without the need for extensive 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 invention applies homogeneity by using composite material for both the fluid transfer conduit and the connector. This material matching eliminates galvanic corrosion between dissimilar metals and composites, and reduces thermal expansion mismatch by ensuring both components have similar thermal properties, allowing them to expand and contract together temperature-wise.
Solution Approach 2:
The invention uses composite materials for the connector to match the composite fluid transfer conduit. This material compatibility eliminates galvanic corrosion issues that arise with metal-composite interfaces and reduces differential thermal expansion, as both components now have similar thermal expansion characteristics.
3Loss of substance
If chopped-fibre reinforced resin connectors are used, then material waste is reduced and weight is decreased, but strength is not fully optimized
Solution Approach 1:
The invention applies local quality by varying the fibre orientation and concentration in different regions of the connector. The hub portion has circumferentially oriented fibres to resist hoop stresses from internal pressure, while the flange portion has longitudinally oriented fibres to resist axial loads and bending moments. This localized optimization ensures maximum strength where needed while maintaining the benefits of additive manufacturing.
Data Source
AI summary
A method of manufacturing a connector for a fluid transfer conduit comprises: manufacturing a tube which runs parallel to a central axis C from fibre-reinforced polymer, said tube comprising a hub portion 206 and a flange-forming portion 208 located adjacent to the hub portion 206, wherein the hub portion 206 comprises continuous circumferentially oriented fibre-reinforcement 210; and the hub portion 206 and the flange-forming portion 208 comprise longitudinally oriented fibre-reinforcement 212 which runs continuously from the hub portion 206 into the flange-forming portion 208; and bending the flange-forming portion 208 away from the central axis C such that it extends from the hub portion 206 at an angle to the central axis C.