Drive shafts made of composite materials and methods of making such shafts

Abstract

A drive shaft has a tubular member extending between axial ends and being hollow. The tubular member is formed of a thermoplastic matrix with embedded fibers. At least one ring member is positioned radially of the tubular member. A method is also disclosed.

1 . A method of forming a drive shaft providing steps of:
 forming a tubular member extending along an axis, and having an inner peripheral surface and an outer peripheral surface;   forming at least one ring member by placing a material on one of said inner peripheral surface and said outer peripheral surface;   heating the material;   applying radial pressure to the material in a sequentially moved fashion; and   adhering the material to said one of inner and outer peripheral surface.   
     
     
         2 . The method as set forth in  claim 1 , wherein said ring member is formed in a circumferential direction about a central axis of said tubular member. 
     
     
         3 . The method as set forth in  claim 2 , wherein said ring member is formed for 360° in the circumferential direction about the central axis of said tubular member. 
     
     
         4 . The method as set forth in  claim 3 , wherein the placing step is performed by a feeding mechanism. 
     
     
         5 . The method as set forth in  claim 3 , wherein a consolidation roller performs part of the placing step. 
     
     
         6 . The method as set forth in  claim 3 , wherein a cutter cuts the material at an end. 
     
     
         7 . The method as set forth in  claim 2 , wherein said ring member includes a plurality of ring portions and each of said ring portions extending for less than 360° in the circumferential direction about the central axis of said tubular member. 
     
     
         8 . The method as set forth in  claim 7 , wherein the placing step is performed by a feeding mechanism. 
     
     
         9 . The method as set forth in  claim 7 , wherein a consolidation roller performs part of the placing step. 
     
     
         10 . The method as set forth in  claim 7 , wherein a cutter cuts the material at an end. 
     
     
         11 . The method as set forth in  claim 1 , wherein said ring member is formed in an axial direction along a central axis of said tubular member. 
     
     
         12 . The method as set forth in  claim 11 , wherein the placing step is performed by a feeding mechanism. 
     
     
         13 . The method as set forth in  claim 11 , wherein a consolidation roller performs part of the placing step. 
     
     
         14 . The method as set forth in  claim 11 , wherein a cutter cuts the material at an end. 
     
     
         15 . The method as set forth in  claim 1 , wherein the forming steps, the heating step and the applying radial pressure and the adhering steps are all performed repeatedly to fabricate a ring member with multi-directional laminated layups. 
     
     
         16 . The method as set forth in  claim 1 , wherein the placing step is performed by a feeding mechanism. 
     
     
         17 . The method as set forth in  claim 1 , wherein a consolidation roller performs part of the placing step. 
     
     
         18 . The method as set forth in  claim 1 , wherein a cutter cuts the material at an end. 
     
     
         19 . The method as set forth in  claim 1 , wherein automated fiber placement is utilized to perform the method. 
     
     
         20 . The method as set forth in  claim 1 , wherein automated tape laying is provided to form the ring member.