U.S. patent application number 16/370489 was filed with the patent office on 2020-10-01 for hybrid composite drive shaft and a method of making.
The applicant listed for this patent is Goodrich Corporation. Invention is credited to Mark R. Gurvich, Michael King, Brayton Reed, Joyel M. Schaefer, Georgios S. Zafiris.
Application Number | 20200309186 16/370489 |
Document ID | / |
Family ID | 1000003992752 |
Filed Date | 2020-10-01 |
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United States Patent
Application |
20200309186 |
Kind Code |
A1 |
Gurvich; Mark R. ; et
al. |
October 1, 2020 |
HYBRID COMPOSITE DRIVE SHAFT AND A METHOD OF MAKING
Abstract
A drive shaft for transferring torque including a tubular insert
extending along an axis and defining a first layer of the drive
shaft including at least one straight portion and at least one
undulation, wherein the tubular insert includes a first material
having a first deformation temperature, and a polymeric tubular
covering defining a second layer of the drive shaft surrounding the
tubular insert including a second material having a deformation
temperature lower than the deformation temperature of the first
material, wherein the covering includes at least one straight
portion adjacent to the straight portion of the tubular insert and
at least one undulation adjacent to the at least one undulation of
the tubular insert.
Inventors: |
Gurvich; Mark R.;
(Middletown, CT) ; Zafiris; Georgios S.;
(Glastonbury, CT) ; Reed; Brayton; (Rome, NY)
; Schaefer; Joyel M.; (Earlville, NY) ; King;
Michael; (Sauquoit, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Goodrich Corporation |
Charlotte |
NC |
US |
|
|
Family ID: |
1000003992752 |
Appl. No.: |
16/370489 |
Filed: |
March 29, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 43/203 20130101;
B32B 27/08 20130101; B29L 2031/75 20130101; B32B 2597/00 20130101;
B29K 2101/10 20130101; B32B 1/08 20130101; B29K 2101/12 20130101;
F16C 3/026 20130101 |
International
Class: |
F16C 3/02 20060101
F16C003/02; B29C 43/20 20060101 B29C043/20; B32B 1/08 20060101
B32B001/08; B32B 27/08 20060101 B32B027/08 |
Claims
1. A drive shaft for transferring torque comprising: a tubular
insert extending along an axis and defining a first layer of the
drive shaft including at least one undulation, wherein the tubular
insert includes a first material having a first deformation
temperature; and a polymeric fiber reinforced composite covering
defining a second layer of the drive shaft surrounding the tubular
insert including a second material having a deformation temperature
lower than the deformation temperature of the first material,
wherein at least one undulation adjacent to the at least one
undulation of the tubular insert.
2. The drive shaft of claim 1, further comprising an adhesive
between the insert and the covering.
3. The drive shaft of claim 1, wherein the insert is thinner than
the covering in a radial direction relative to the axis.
4. The drive shaft of claim 1, wherein the first material includes
a thermoplastic polymer material, or thermoplastic polymer matrix
composite material.
5. The drive shaft of claim 1, wherein the deformation temperature
of the first material is higher than the deformation temperature of
the second material.
6. The drive shaft of claim 1, wherein the insert material includes
fiber reinforcement.
7. The drive shaft of claim 1, wherein the second material includes
a fiber reinforced thermoset polymer composite material, or a fiber
reinforced thermoplastic polymer matrix material.
8. The drive shaft of claim 7, wherein the fiber reinforcement
includes continuous or large discontinuous or short fibers.
9. The drive shaft of claim 7, wherein the fiber includes carbon,
aramid polymer, other organic materials, glass, or other inorganic
materials.
10. The drive shaft of claim 1, wherein the insert includes at
least one straight portion.
11. The drive shaft of claim 10, wherein the covering includes at
least one straight portion adjacent to the straight portion of the
insert.
12. A method of forming a composite drive shaft comprising: forming
a tubular insert to define a first layer of the drive shaft
including forming at least one undulation, wherein the tubular
insert includes a first material having a first deformation
temperature; surrounding the tubular insert with a polymeric
tubular covering defining a second layer of the drive shaft
including a second material having a deformation temperature lower
than the deformation temperature of the first material by
surrounding the tubular insert; and forming at least one undulation
within the polymeric covering radially of the at least one
undulation of the tubular insert.
13. The method of claim 12, wherein the at least one undulation of
the tubular insert is formed by expanding an initial tubular insert
against an external mold.
14. The method of claim 12, wherein the at least one undulation of
the tubular insert is formed by compression from a heated mold.
15. The method of claim 12, further comprising joining the insert
and the covering with an adhesive layer.
16. The method of claim 15, wherein the joining includes applying
the adhesive layer onto the tubular insert.
17. The method of claim 12, further comprising cooling the covering
to solidify the drive shaft.
18. The method of claim 12, further comprising curing the insert
and the covering at temperature below the first deformation
temperature and above the second deformation temperature.
19. The method of claim 12, wherein surrounding includes applying a
non-cured or partially cured thermoset polymer matrix composite
covering and subsequently curing said applied covering at a
temperature below the first deformation temperature.
20. The method of claim 12, wherein forming the at least one
undulation of the covering includes compression by a heated mold.
Description
BACKGROUND
Technological Field
[0001] The present disclosure relates to a hybrid composite drive
shaft, and more particularly to a drive shaft using two different
types of composites.
Description of Related Art
[0002] A variety of devices are known in the making of composite
drive shafts. Major challenge in making composite drive shafts is
to make profiled segments for bending and axial flexibility. The
conventional methods and systems have generally been considered
unsatisfactory for their intended purpose. There is still a need
for new designs where these challenges can be significantly
mitigated or even avoided. There also remains a need in the art for
such shafts and methods that are economically viable. The present
disclosure may provide a solution for at least one of these
remaining challenges.
SUMMARY OF THE INVENTION
[0003] A drive shaft for transferring torque includes a tubular
insert extending along an axis and defining a first layer of the
drive shaft including at least one undulation in the radial
direction, wherein the tubular insert includes a first material
having a first deformation temperature and a polymeric tubular
covering defining a second layer of the drive shaft surrounding the
tubular insert including a second material having a deformation
temperature lower than the melting point of the first material,
wherein the covering includes at least one undulation adjacent to
the at least one undulation of the tubular insert. The at least one
undulation of the insert can include additional multiple
undulations. The insert and the covering can also include straight
portions lined up with each other.
[0004] The insert can include fiber reinforcement. The insert can
be thinner than the covering in a radial direction relative to the
axis. The second material can include a fiber reinforced thermoset
polymer or thermoplastic polymer matrix composite material, with a
deformation temperature lower than the deformation temperature of
the first insert material. The drive shaft can further include an
adhesive layer between the insert and the covering.
[0005] A method of forming a composite drive shaft is also
presented. The method includes forming a tubular insert to define a
first layer of the drive shaft including forming at least one
undulation, wherein the tubular insert includes a first material
having a first deformation temperature, reinforcing the insert with
a polymeric tubular covering defining a second layer of the drive
shaft including a second material having a deformation temperature
lower than the deformation temperature of the first material by
surrounding the tubular insert, and forming at least one straight
portion and at least one undulation within the covering adjacent to
the at least one undulation of the tubular insert.
[0006] The at least one undulation of the tubular insert can be
formed by expanding an initial tubular insert against an external
mold or by compression from a heated mold.
[0007] The method can further include joining the insert and the
covering with an adhesive layer by applying or by spraying or by
using other techniques to place the adhesion layer onto the tubular
insert.
[0008] The method can further include cooling the covering to
solidify the drive shaft for thermoplastic materials or curing the
covering at a temperature below the first deformation temperature
for thermoset materials and above the second deformation
temperature. A non-cured or partially cured thermoset polymer
matrix covering can be applied onto the formed insert and
subsequently cured at a temperature below the insert deformation
temperature of the insert material. Forming the at least one
undulation of the covering can include compression by a heated
mold.
[0009] These and other features of the systems and methods of the
subject disclosure will become more readily apparent to those
skilled in the art from the following detailed description of the
preferred embodiments taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] So that those skilled in the art to which the subject
invention appertains will readily understand how to make and use
the devices and methods of the subject invention without undue
experimentation, preferred embodiments thereof will be described in
detail herein below with reference to certain figures, wherein:
[0011] FIG. 1 is an axial cross-sectional view of a drive shaft
showing layers and undulations;
[0012] FIG. 2 is a diametric cross-sectional view of FIG. 1,
showing the concentricity of the layers;
[0013] FIG. 3a is an axial cross-sectional view of a production
step for forming the undulations of an inner layer of FIG. 1,
showing a pre-formed insert;
[0014] FIG. 3b is an axial cross-sectional view of a production
step for forming the undulations of an inner layer of FIG. 1,
showing an interaction of the insert and a mold;
[0015] FIG. 3c is an axial cross-sectional view of a production
step showing the post-formed undulated insert of an inner layer of
FIG. 1;
[0016] FIG. 3d is an axial cross-sectional view of a production
step for forming the undulations of an inner layer of FIG. 1,
showing a pre-formed insert;
[0017] FIG. 3e is an axial cross-sectional view of a production
step for forming the undulations of an inner layer of FIG. 1,
showing an interaction of the insert and a mold; and
[0018] FIG. 3f is an axial cross-sectional view of a production
step showing the post-formed undulated insert of an inner layer of
FIG. 1.
DETAILED DESCRIPTION
[0019] Reference will now be made to the drawings wherein like
reference numerals identify similar structural features or aspects
of the subject invention. For purposes of explanation and
illustration, and not limitation, a partial view of an exemplary
embodiment of a composite drive shaft in accordance with the
invention is shown in FIG. 1 and is designated generally by
reference character 100. Other embodiments of the drive in
accordance with the invention, or aspects thereof, are provided in
FIGS. 2-3f, as will be described. The methods and systems of the
invention can be used to simplify the production process and to
improve the performance of the drive shaft.
[0020] Referring to FIG. 1, the shaft 100 is disclosed with two
different composite materials with distinctively different
properties and functions. The first material serves as an insert
and works as a mandrel. The second composite material works as a
main load-bearing part (LBP), while its complex shape is achieved
upon fabrication overlying upon the insert. A drive shaft 100 for
transferring torque to another component by mating with the
component using and adhesive or mechanical fastener. The shaft
includes a tubular insert 102 extending along an axis 104 and
defining a first layer of the drive shaft 100 including at least
one straight portion 106 and at least one undulation 108, wherein
the tubular insert 102 includes a first material having a first
deformation temperature and a polymeric tubular covering 110
defining a second layer of the drive shaft 100 surrounding the
tubular insert 102 including a second material having a deformation
temperature lower than the deformation point of the first material,
wherein the covering 110 includes at least one straight portion 112
adjacent to the straight portion 106 of the tubular insert and at
least one undulation 114 adjacent to the at least one undulation
108 of the tubular insert. Deformation temperature is the
temperature at or above which (and below the degradation
temperature) a polymer can be formed or shaped upon application of
mechanical force via a shaping tooling or a mold, or through an
extrusion or injection process. The ASTM HDT (heat deflection
temperature) is the temperature at which a standard sized polymer
sample strip is deflected by a fixed distance upon application of a
given load via a "pushing" rod. For both semi-crystalline as well
as amorphous polymers, glass transition temperature, below which
the polymer chains motions are, and above that the polymer chains
motions are activated and polymers become rubbery and viscous, and
eventually will flow. Only semi-crystalline polymers have a
thermodynamically defined melt temperature (Tm) first order
transition; amorphous ones do not. The deformation temperature or
HDT of a polymer relates to its characteristic Tg temperature. The
insert 102 and the covering 110 are concentric in at least one
portion of the shaft, as shown in FIG. 2. The undulations 114 and
108 can include multiple undulations. The number of undulations and
of the pitch can be determined based on the load conditions.
[0021] The insert 102 can include fiber reinforcement. The insert
can be thinner than the covering 110 in a radial direction relative
to the axis 104. The insert 102 material can include a
thermoplastic polymer material, with or without fillers and fibers.
The covering 110 material can include fiber reinforced
thermoplastic polymer composite material, as well as fiber
reinforced thermoset polymer matrix composite material. The drive
shaft 100 can further include an adhesive layer 116 between the
insert 102 and the covering 110 to provide or improve bonding
between the insert 102 and covering 110 layers. The fiber
reinforcement can include continuous or/and large discontinuous
or/and short fibers. They can be applied, for example, as
pre-pregs, fabric, or mats or their combination. The fiber
reinforcement can include fibers made of carbon, or aramid polymer
or other organic material, or glass or other inorganic material or
their combination.
[0022] A method of forming a composite drive shaft 100 is also
presented. The method includes forming a tubular insert 102 to
define a first layer of the drive shaft 100 including forming at
least one straight portion 106 and at least one undulation 108,
wherein the tubular insert 102 includes a first material having a
first deformation temperature, overlaying the insert 102 by a
polymeric tubular covering 110 defining a second layer of the drive
shaft including a second material having a deformation temperature
lower than that of the first material by surrounding the tubular
insert 102, and forming at least one straight portion 112 adjacent
to the at least one straight portion 106 of the tubular insert and
at least one undulation 114 within the covering adjacent to the at
least one undulation 108 of the tubular insert. Overlaying can
include applying a fiber reinforced non-cured or partially cured
thermoset polymer matrix composite onto the insert 102 to form the
undulated covering 110, which subsequently can be cured at a
temperature below the deformation temperature of the insert layer,
optionally utilizing a clamshell mold, to produce the composite
gear shaft 100. Overlaying can also include applying a fiber
reinforced thermoplastic polymer matrix composite layer and
compression molding it to form the undulated covering 110.
Overlaying can further include over-molding a discontinuous fiber
reinforced thermoplastic polymer matrix composite to form the
undulated covering 110. It is also contemplated that the shaft 100
could include more layers, in various arrangements in order to meet
the requirements of the system.
[0023] As shown in FIGS. 3a-c, the at least one undulation 108 of
the tubular insert 102 is formed by expanding an initial tubular
insert against an external mold. It is also considered, and shown
in FIGS. 3d-3f, that the undulation(s) 108 are formed by
compression from a heated mold.
[0024] The method further includes joining the insert 102 and the
covering 110 with an adhesion layer 116 by either overlaying or
spraying the adhesive layer onto the tubular insert. The adhesive
layer can also be coated on, or placed between the layers as
film.
[0025] In summary, proposed designs maximize benefits of composites
(e.g., lightweight, lack of corrosion, cost) and, at the same time,
minimize their disadvantages associated with complexity of
fabrication of composite components with internal cavities, such
as, for example, drive shafts. The methods and systems of the
present disclosure, as described above and shown in the drawings,
provide for torque transmission systems and gear shafts that can
accommodate bending and flexing requirements, as well as vibration
dampening with superior properties including increased reliability
and stability, and reduced size, weight, and/or cost. While the
apparatus and methods of the subject disclosure have been showing
and described with reference to embodiments, those skilled in the
art will readily appreciate that changes and/or modifications may
be made thereto without departing from the spirit and score of the
subject disclosure.
* * * * *