Composite connectors and methods of manufacturing the same

Patent metadata

Field	Value
Publication number	US-11859739-B2
Application number	US-201916536345-A
Country	US
Kind code	B2
Filing date	Aug 9, 2019
Priority date	Aug 10, 2018
Publication date	Jan 2, 2024
Grant date	Jan 2, 2024

Abstract

A method of manufacturing a composite (e.g. fiber-reinforced polymer) connector for a fluid transfer conduit comprises: manufacturing a tubular pre-form which extends substantially parallel to a central axis C, the tubular pre-form comprising continuous circumferentially-oriented fiber reinforcement; manufacturing a continuous fiber pre-form net, the pre-form net comprising a support layer and continuous fiber reinforcement, the continuous fiber reinforcement being secured by being stitched to the support layer; placing the tubular pre-form and the pre-form net together into a mould to form a tubular hub portion from the tubular pre-form and a flange portion from the pre-form net, the flange portion extending from the hub portion at an angle to the central axis C; and introducing polymer into the mould so as to form a composite connector comprising the flange portion and the hub portion.

First claim

The invention claimed is:

1. A connection system comprising a composite connector and fiber-reinforced polymer fluid transfer conduit, the composite connector comprising:
a hub portion comprising a tube which extends substantially parallel to a central axis; and
a flange portion which extends from the hub portion at an angle to the central axis;
wherein the hub portion comprises a polymer reinforced with continuous circumferentially-oriented fiber reinforcement;
wherein the flange portion comprises the same polymer reinforced with continuous fiber reinforcement and a support layer to which the continuous fiber reinforcement is secured by being stitched thereto;
wherein the flange portion comprises at least one fixing point for securing the composite connector to another structure, and the continuous fiber reinforcement at least partially encircles the at least one fixing point;
wherein the fluid transfer conduit is connected to the hub portion; and
wherein the composition and orientation of the continuous fiber reinforcement at least within the hub portion is selected such that the coefficient of thermal expansion and/or the stiffness of the hub portion substantially matches that of the fluid transfer conduit;
the connection system further comprising an elastomeric O-ring positioned between an outer surface of the fluid transfer conduit and an inner surface of the hub portion.

2. The connection system as claimed in claim 1 , wherein the continuous fiber reinforcement comprises multiple layers stitched to the common support layer.

3. The connection system as claimed in claim 1 , wherein the flange portion is substantially perpendicular to the central axis of the hub portion.

4. The connection system as claimed in claim 1 , wherein the flange portion comprises one or more tabs which extend along a surface of the hub portion.

5. The connection system as claimed in claim 1 , wherein the polymer comprises a thermosetting polymer.

6. The connection system as claimed in claim 1 ,
wherein the elastomeric O-ring is seated between a pair of retaining ridges that allow for axial movement between the fluid transfer conduit and the hub portion.

7. The connection system as claimed in claim 1 , wherein the at least one fixing point is a through-hole.

8. The connection system as claimed in claim 1 , wherein the at least one fixing point is surrounded by unbroken fiber reinforcement.

9. The connection system as claimed in claim 1 , wherein the flange portion comprises a plurality of fixing points and the continuous fiber reinforcement is arranged to encircle an adjacent pair of fixing points.

Assignees

• Crompton Technology Group Ltd

Inventors

• Chase Ian Thomas
• Pollitt Will
• Giannakopoulos Ioannis

Classifications

• F16L23/032 Primary

  characterised by the shape or composition of the flanges · CPC title

• B29B11/16

  comprising fillers or reinforcement {(non-woven fabrics per se D04H1/00, D04H3/00)} · CPC title

• B29C70/48 Primary

  and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM] {, e.g. by vacuum} · CPC title

• F16L23/22

  made exclusively of a material other than metal · CPC title

• B29L2031/24

  Pipe joints or couplings (B29L2031/26 takes precedence) · CPC title