US 10,344,794 B2Granted

Open composite shaft

AssigneeDana Automotive Systems Group, LLC

InventorsSteven G. Slesinski, Eve Steigerwalt, Harry W. Trost

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Abstract

A composite shaft assembly including a core structure formed by weaving fiber(s) into an open composite structure. The assembly further includes a first end piece and a second end piece having helically shaped groove(s) and/or axially groove(s) on an outer surface of an end portion of the first and second end piece. Woven into the helical and/or axial groove(s) on the first end piece and at least partially within through hole(s) disposed at an end of the groove(s) is the fiber(s) at a first end portion of the of the core structure. Woven into the helical and/or axial groove(s) on the second end piece and at least partially within through hole(s) disposed at an end of the groove(s) is the fiber(s) at a second end portion of the of the core structure. Structural adhesive(s) are applied over the fiber(s) and allowed to cure to form the composite drive shaft.

Claims27

Dependent claims

A method of making a composite shaft comprising:

providing a first end piece, wherein said first end piece comprises one or more helically shaped grooves and/or one or more axial grooves on an outer surface of an end portion of said first end piece and one or more through holes disposed at an end of said one or more helically shaped grooves and/or disposed at an end of said one or more axial grooves, wherein said one or more through holes extend from an inner surface to said outer surface of said first end piece;
providing a second end piece, wherein said second end piece comprises one or more helically shaped grooves and/or one or more axial grooves on an outer surface of an end portion of said second end piece and one or more through holes disposed at an end of said one or more helically shaped grooves and/or disposed at an end of said one or more axial grooves, wherein said one or more through holes extend from an inner surface to said outer surface of said second end piece;
weaving one or more fibres into an open composite structure to form a core structure;
weaving a first end portion of said one or more fibres of said core structure into said one or more helically shaped grooves and/or said one or more axial grooves on said outer surface of said first end piece and at least partially into said one or more through holes of said first end piece;
weaving a second end portion of said one or more fibres of said core structure into said one or more helically shaped grooves and/or said one or more axial grooves on said outer surface of said second end piece and at least partially into said one or more through holes of said second end piece;
applying one or more structural adhesives to said one or more woven fibres;
and
curing said one or more structural adhesives to form an open structure composite shaft.

5 more elements

A composite shaft assembly, comprising:

a first end piece having a first end portion and a second end portion;
wherein said second end portion of said first end piece has an inner surface and an outer surface defining a hollow portion therein;
one or more helically shaped grooves and/or one or more axial grooves extend along at least a portion of said outer surface of said second end portion of said first end piece;
wherein said one or more helically shaped grooves and/or said one or more axial grooves on said second end portion on said first end piece have a first end and a second end;
one or more through holes extend from said inner surface to said outer surface of said second end portion of said first end piece;
wherein said one or more through holes in said second end portion of said first end piece are disposed at said second end of said one or more helically shaped grooves and/or at said second end of said one or more axial grooves;
a second end piece having a first end portion and a second end portion;
wherein said second end portion of said second end piece has an inner surface and an outer surface defining a hollow portion therein;
one or more helically shaped grooves and/or one or more axial grooves extend along at least a portion of said outer surface of said second end portion of said second end piece;
wherein said one or more helically shaped grooves and/or said one or more axial grooves on said second end portion of said second end piece have a first end and a second end;
one or more through holes extend from said inner surface to said outer surface of said second end portion of said second end piece;
wherein said one or more through holes in said second end portion of said second end piece are disposed at said second end of said one or more helically shaped grooves and/or at said second end of said one or more axial grooves;
a composite core structure having one or more helically oriented fibres and/or one or more axially oriented fibres;
wherein said composite core structure has a first end portion and a second end portion;
wherein at least a portion of said one or more helically oriented fibres and/or said one or more axially oriented fibres at said first end portion of said composite core structure are disposed within said one or more helically shaped grooves and/or said one or more axial grooves on said outer surface of said second end portion of said first end piece;
wherein at least a portion of said one or more helically oriented fibres and/or said one or more axially oriented fibres at said first end portion of said composite core structure are disposed within said one or more through holes in said second end portion of said first end piece;
wherein at least a portion of said one or more helically oriented fibres and/or said one or more axially oriented fibres at said second end portion of said composite core structure are disposed within said one or more helically shaped grooves and/or said one or more axial grooves on said outer surface of said second end portion of said second end piece;
wherein at least a portion of said one or more helically oriented fibres and/or said one or more axially oriented fibres at said second end portion of said composite core structure are disposed within said one or more through holes in said second end portion of said second end piece;
and
one or more structural adhesives encapsulate at least a portion of said one or more helically oriented fibres, at least a portion of said one or more axially oriented fibres, at least a portion of said one or more helically shaped grooves of said first end piece, at least a portion of said one or more helically shaped grooves of said second end piece, at least a portion of said one or more axial grooves of said first end piece, at least a portion of said one or more axial grooves of said second end piece, at least a portion of said one or more through holes in said first end piece and/or at least a portion of said one or more through holes in said second end piece.

17 more elements

Dependencies are inferred from the claim text.

Facts

Application: 15/355,957Filed 18 Nov 2016
Published: US 2018/0142726 A124 May 2018
Granted: 9 Jul 2019
Term ends: Not estimatedThe source records don’t support an estimate.

Classification17 codes

F16C 3/026
Shafts; Axles: shafts made of fibre reinforced resin
B29C 53/58
Winding and joining, e.g. winding spirally: helically
B29C 70/222
Oriented in at least two directions forming a two-dimensional [2D] structure: the structure being shaped to form a three dimensional configuration
B29C 70/302
Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould,…:…