COMPOSITE DRIVE SHAFTS

• US 20200132109A1
• Filed: 10/29/2018
• Published: 04/30/2020
• Est. Priority Date: 10/29/2018
• Status: Active Grant

• Current Assignee: Hamilton Sundstrand Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Original Assignee: Hamilton Sundstrand Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Schaefer, Joyel M., King, Michael, Reed, Brayton, Gurvich, Mark R.
• Granted Patent: US 11,396,904 B2
• Time in Patent Office: Days
• CPC Class Codes: F16C 2208/02 comprising fillers, fibres
• CPC Class Codes: F16C 2226/36 by welding
• CPC Class Codes: F16C 2326/06 Drive shafts in general B60K
• CPC Class Codes: F16C 2326/43 Aeroplanes; Helicopters in general B64C
• CPC Class Codes: F16C 3/023 made of several parts, e.g. by welding
• CPC Class Codes: F16C 3/026 Shafts made of fibre reinforced resin
• CPC Class Codes: F16D 1/027 non-disconnectable, e.g. involving gluing, welding or the like
• CPC Class Codes: F16D 1/068 involving gluing, welding or the like
• CPC Class Codes: F16D 1/0894 with other than axial keys, e.g. diametral pins, cotter pins and no other radial clamping
• CPC Class Codes: F16D 2200/006 containing fibres or particles
• CPC Class Codes: F16D 2250/0076 Welding, brazing
• CPC Class Codes: F16D 3/725 with an intermediate member made of fibre-reinforced resin made of rubber-like material F16D3/74; shafts made of fibre-reinforced resin F16C3/026
• CPC Class Codes: Y10S 138/02 Glass fiber
• CPC Class Codes: Y10S 285/919 Resinous

Abstract

A drive shaft is for selectively connecting a drive input to an output. The drive shaft has a tubular portion, a first diaphragm member, and a second diaphragm member displaced axially along the shaft from the first diaphragm member. The first and second diaphragm members each are formed with two axial ends. At least one undulation extends radially of the ends. The tubular portion connects the first and second diaphragm members. The first and second diaphragm members and the tubular portion are formed of fiber-reinforced polymer matrix composites. The first and second diaphragm members are connected to first and second axial ends of the tubular portion through a mechanical connection at joints. A method of forming a drive shaft is also disclosed.

Claims

1. A drive shaft for selectively connecting a drive input to an output, said drive shaft comprising:

a tubular portion;

a first diaphragm member; and

a second diaphragm member displaced axially along the shaft from the first diaphragm member, said first and second diaphragm members each being formed with two axial ends and at least one undulation extending radially of said ends, and the tubular portion connecting said first and second diaphragm members, said first and second diaphragm members and said tubular portion being formed of fiber-reinforced polymer matrix composites, and said first and second diaphragm members connected to first and second axial ends of said tubular portion through a mechanical connection at joints.

2. The drive shaft as set forth in claim 1, wherein said mechanical connection includes welding of said axial ends of each of said first and second diaphragms to said tubular portion.

3. The drive shaft as set forth in claim 1, wherein said mechanical connection receives reinforcement.

4. The drive shaft as set forth in claim 3, wherein said reinforcement is provided by the axial end of one of said tubular portion and said first and second diaphragms being radially within the axial end of the other of said tubular portion and one of said first and second diaphragms.

5. The drive shaft as set forth in claim 3, wherein a separate fiber-reinforced polymer matrix composite sleeve provides said reinforcement.

6. The drive shaft as set forth in claim 5, wherein said sleeve provides a radially extending step such that said sleeve has reinforcement portions at distinct radial positions.

7. The drive shaft as set forth in claim 5, wherein said sleeve is radially inward of said joints.

8. The drive shaft as set forth in claim 7, wherein a second sleeve is provided at a radially outer surface of said joints.

9. The drive shaft as set forth in claim 5, wherein said sleeve is provided on a radially surface of said joint.

10. The drive shaft as set forth in claim 3, wherein a mechanical radial fastener is provided to further secure said first and second diaphragms to said tubular portion.

11. The drive shaft as set forth in claim 3, wherein said reinforcement includes teeth on said first and second diaphragms interfitting with teeth at said axial ends of said tubular portion.

12. The drive shaft as set forth in claim 11, wherein said teeth on said first and second diaphragms are radially spaced with said teeth at said ends of said tubular portion.

13. The drive shaft as set forth in claim 11, wherein said teeth on said first and second diaphragms are circumferentially spaced with said teeth at said ends of said tubular portion.

14. The drive shaft as set forth in claim 1, wherein said at least one undulation extends radially outwardly of said ends.

15. The drive shaft as set forth in claim 1, wherein said at least one undulation extends radially inwardly of said ends.

16. A mechanical system for an aerospace application comprising:

a drive input connected to a first axial end of a first diaphragm member, and a drive output connected to a second axial end of a second diaphragm member, and said drive output is an aerospace component; and

said first and second diaphragm members being formed with two axial ends and at least one undulation extending radially of said axial ends, and a tubular portion connecting said first and second diaphragm members, said first and second diaphragm members and said tubular member being formed of fiber reinforced polymer matrix composites, and said first and second diaphragm members being connected to axial ends of said tubular member through a mechanical connection of joints.

17. The mechanical connection as set forth in claim 16, wherein said mechanical connection includes welding of said axial ends of said tubular portion to one of said inner ends of each of said first and second diaphragms.

18. The mechanical connection as set forth in claim 16, wherein reinforcement is provided by the axial end of one of said tubular portion and said first and second diaphragms being radially within the axial end of the other of said tubular portion and one of said first and second diaphragms.

19. The mechanical connection as set forth in claim 18, wherein a separate reinforcement sleeve provides reinforcement.

20. A method of forming a drive shaft comprising the steps of:

(a) forming a first and a second diaphragm member, and separately forming a tubular member said first and second diaphragm members and said tubular member being formed of a fiber reinforced polymer matrix composite; and

(b) mechanically connecting one end of each of said first and second diaphragm members to first and second ends of said tubular member.