Method of forming composite tubular structure

• US 4,930,204 A
• Filed: 09/18/1989
• Issued: 06/05/1990
• Est. Priority Date: 02/01/1989
• Status: Expired due to Fees

• Current Assignee: A. O. Smith Corporation
• Original Assignee: A. O. Smith Corporation
• Inventors: Schurter, Robert M.
• Primary Examiner(s): Moon, Charlie T.
• Application Number:
  US07/409,265
• Time in Patent Office: 260 Days
• Field of Search: 29/419.2, 29/507, 29/525, 29/516, 29/469.5, 464/181, 464/182, 464/183, 228/136, 285/382, 403/278
• US Class Current: 29/419.2
• CPC Class Codes: B29C 37/0085 by means of openings in the layers joining through openings B29C66/304
• CPC Class Codes: B29C 65/56 using mechanical means or mechanical connections, e.g. form-fits
• CPC Class Codes: B29C 66/1222 comprising at least a lapped joint-segment
• CPC Class Codes: B29C 66/1224 comprising at least a butt joint-segment
• CPC Class Codes: B29C 66/534 Joining single elements to open ends of tubular or hollow articles or to the ends of bars
• CPC Class Codes: B29C 66/5344 said single elements being substantially annular, i.e. of finite length, e.g. joining flanges to tube ends B29C66/5346 takes precedence
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/721 Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/7212 characterised by the composition of the fibres
• CPC Class Codes: B29C 66/73755 the to-be-joined area of at least one of the parts to be joined being fully cured, i.e. fully cross-linked, fully vulcanized
• CPC Class Codes: B29C 66/7394 characterised by the material of at least one of the parts being a thermoset
• CPC Class Codes: B29C 66/74 Joining plastics material to non-plastics material
• CPC Class Codes: B29C 66/742 to metals or their alloys
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/06 containing reinforcements, fillers or inserts
• CPC Class Codes: B29K 2307/04 Carbon
• CPC Class Codes: B29K 2309/08 Glass
• CPC Class Codes: B29K 2705/00 Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
• CPC Class Codes: B29L 2031/75 Shafts
• CPC Class Codes: F16C 2326/06 : Drive shafts
• CPC Class Codes: F16C 3/026 : Shafts made of fibre reinforced resin
• CPC Class Codes: F16D 1/068 : involving gluing, welding or the like
• CPC Class Codes: F16D 3/387 : Fork construction; Mounting of fork on shaft; Adapting shaft for mounting of fork
• CPC Class Codes: Y10T 29/49803 : Magnetically shaping
• CPC Class Codes: Y10T 29/49906 : Metal deforming with nonmetallic bonding
• CPC Class Codes: Y10T 29/49911 : by expanding inner annulus
• CPC Class Codes: Y10T 29/49927 : Hollow body is axially joined cup or tube
• CPC Class Codes: Y10T 29/49945 : by driven force fit
• CPC Class Codes: Y10T 403/4933 : by separate, deformable element

Abstract

A composite tubular structure, such as a vehicle drive shaft. The ends of a fiber reinforced resin tubular member are formed with a plurality of longitudinal slots and each slotted end of the tubular member is positioned in overlapping relation with a cylindrical sleeve portion of a metal yoke. A cylindrical metal collar is disposed around the overlapping joint and spaced portions of the collar are deformed inwardly by electromagnetic energy into contact with the sleeve of the yoke. The deformed portions can be mechanically interlocked with the sleeve by welding or the like. With this construction, the torsional load is transmitted through the deformed portions of the collar and the edges of the tubular member bordering the slots to provide an improved mechanical connection between the fiber reinforced tubular member and the yokes.

Claims

1. A method of forming a composite shaft construction, comprising the steps of forming a tubular member of fibrous material bonded with a cured thermosetting resin, forming a plurality of spaced openings in an end of said tubular member, positioning said end in overlapping contacting relation to a cylindrical sleeve portion of a metal yoke to provide an overlapping joint, positioned a continuous cylindrical metal collar around said joint, and applying electromagnetic energy to said collar of sufficient intensity to deform spaced portions of said collar through said openings and into contact with said sleeve portion.

2. The method of claim 1, and including the step of securing said deformed portions to said sleeve portion.

3. The method of claim 2, wherein said step of securing said deformed portions of said sleeve portion comprising welding.

4. The method of claim 1, wherein said tubular member is formed of substantially continuous fibrous strands.

5. The method of claim 1, wherein the step of forming said openings comprises forming a plurality of generally parallel longitudinally extending slots in said end.

6. A method of forming a composite shaft construction, comprising the steps of forming a tubular member of fibrous material bonded with a cured thermosetting resin, forming a plurality of generally parallel longitudinally extending slots in an end portion of said tubular member, positioning said end portion in overlapping contacting relation to a cylindrical sleeve portion of a metal yoke to provide an overlapping joint, positioning a continuous cylindrical metal collar around said joint, applying electromagnetic energy to said collar of sufficient intensity to deform spaced portions of said collar through said openings and into contact with said sleeve portion, and securing said deformed portions to said sleeve portion.

7. A method of forming a composite shaft construction, comprising the steps of forming a tubular member of fibrous material bonded with a cured thermosetting resin, forming a plurality of longitudinally elongated slots through an end of said tubular member, positioning said end in overlapping contacting relation to a cylindrical sleeve portion of a metal yoke to provide an overlapping joint, said sleeve portion being exposed through said slots, positioning a continuous uninterrupted metal ring around said joint, and deforming spaced portions of said ring through said slots to provide inwardly deformed longitudinally elongated circumferentially spaced sections offset radially inward and disposed in contact with said sleeve portion.

8. The method of claim 7, and including the step of securing said deformed sections to said sleeve portion.