Fiber reinforced composite shaft with metallic connector sleeves mounted by connector ring interlock

A method of forming a tubular reinforced composite drive shaft comprising the steps of:

• providing a metal sleeve having longitudinally extending, circumferentially spaced grooves and ribs on an outer periphery thereof, each of said ribs and grooves being inclined in a direction extending longitudinally inwardly and radially outwardly along a longitudinally outer extent of said sleeve, and inclined in a direction extending longitudinally and radially inwardly along a longitudinally inner extent of said sleeve;
• positioning said sleeve upon a segment of a mandrel;
• applying fibrous material bearing a non-solidified resinous material upon said mandrel and over said grooves in said sleeve along said inner and outer extents of said sleeve;
• providing an annular lock ring having longitudinally extending, circumferentially spaced ridges and recesses on an inside periphery thereof, each of said ridges and recesses being inclined in a direction extending longitudinally inwardly and radially outwardly;
• inserting said lock ring over said outer extent of said sleeve and over said fibrous material applied thereto, with said ridges overlying said grooves in said sleeve to press portions of said fibrous material into said grooves;
• solidifying said resinous material with portions of said previously applied resinous material positioned in said grooves to create a torsiontransmitting connection with said metal sleeve;
• and
• removing said mandrel.

A method of forming a tubular reinforced composite shaft comprising the steps of:

• providing a metal sleeve having longitudinally extending, circumferentially spaced grooves on an outer periphery thereof;
• positioning said sleeve upon a segment of a mandrel;
• applying fibrous material bearing a non-solidified resinous material upon said mandrel and over said grooves in said sleeve;
• providing an annular lock ring having longitudinally extending, circumferentially spaced ridge means on an inside periphery thereof;
• inserting said lock ring over said sleeve and fibrous material applied thereto, with said ridge means overlying said grooves in said sleeve to press portions of said fibrous material into said grooves;
• solidifying said resinous material with portions of said previously applied resinous material being positioned in said grooves to create a torsion-transmitting connection with said metal sleeve;
• and
• removing said mandrel.

A tubular reinforced composite shaft comprising:

• a shaft body comprising a plurality of integrally bonded circumferential plies of solidified fiber reinforced resinous material;
• a metal sleeve mounted in at least one end of said shaft body, said sleeve including a plurality of circumferentially spaced, longitudinally extending grooves on an outer periphery of said sleeve;
• an annular lock ring positioned upon said sleeve and upon said plies of fibrous material disposed therearound, said lock ring including a plurality of circumferentially spaced, longitudinally extending ridge means on an inside periphery thereof;
• said ridge means being disposed in overlying relation to said grooves in said sleeves to press portions of said fibrous material into said grooves thereby forming a torsion-transmitting connection therebetween.

A hollow tubular reinforced composite shaft comprising:

• a shaft body comprising a plurality of integrally bonded circumferential plies of solidified fiber reinforced resinous material;
• a metal sleeve mounted in at least one end of said shaft body, said sleeve including a plurality of circumferentially spaced, longitudinally extending grooves on an outer periphery of said sleeve;
• said grooves each being inclined in a direction extending longitudinally inwardly and radially outwardly;
• an annular lock ring positioned upon said sleeve and upon said plies of fibrous material disposed therearound, said lock ring including a plurality of circumferentially spaced, longitudinally extending ridges on an inside periphery thereof;
• said ridges each being inclined in a direction extending longitudinally inwardly and radially outwardly, and being disposed in overlying relation to said grooves in said sleeves to press portions of said fibrous material into said grooves thereby forming a torsion-transmitting connection therebetween.

A hollow tubular reinforced composite drive shaft comprising:

• a shaft body comprising a plurality of integrally bonded circumferential plies of solidified fiber reinforced resinous material;
• a metal sleeve mounted in at least one end of said shaft body, said sleeve including a plurality of circumferentially spaced, longitudinally extending grooves and ribs on an outer periphery thereof;
• said grooves and ribs each being inclined in a direction extending longitudinally inwardly and radially outwardly along a longitudinally outer extent of said sleeve, and inclined in a direction extending longitudinally and radially inwardly along a longitudinally inner extent of said sleeve;
• an annular lock ring positioned upon said outer extent of said sleeve and upon said plies of fibrous material disposed therearound, said lock ring including a plurality of circumferentially spaced, longitudinally extending ridges and recesses on an inside periphery thereof;
• said ridges and recesses each being inclined in a direction extending longitudinally inwardly and radially outwardly and being disposed in overlying relation to said grooves and ribs, respectively, to press portions of said fibrous material into said grooves, thereby forming a torsion-transmitting connection therebetween.