Composite drive shaft

Claim 2

A compliant composite drive shaft of a symmetrical lamination comprising: a tubular length having bellows adjacent each end inwardly of connection means for the shaft to be used between driving and driven devices said tubular length and bellows having: an inner layer of a first continuous filament reinforced tape, said inner layer including several of said tapes layed in alternating acute angles to the axis of the shaft; an intermediate layer of a second continuous filament reinforced tape including at least one such tape layed along the longitudinal axis of the shaft about said inner layer; and an outer layer of said first continuous filament reinforced tape, said outer layer including several of said tapes layed in alternating acute angles to the axis of the shaft, which acute angles are a repeat of that of said tapes of said inner layer providing integrated inner, intermediate and outer layers throughout the tubular length including the bellows adjacent each end that is symmetrical about the shaft axis such that said bellows provide an integrated universal for said shaft within the extremities and adjacent the ends of the drive shaft.

Claim 3

The drive shaft of claim 1 wherein said first tape is comprised of continuous fiberglass filaments each parallel to the longitudinal axis of the first tape and to each other within a resin matrix and said second tape is comprised of continuous kevlar filaments each parallel to the longitudinal axis of the second tape and to each other within a resin matrix.

Claim 4

The drive shaft of claim 1 wherein said first tape is comprised of continuous fiberglass filaments each parallel to the longitudinal axis of the first tape and to each other within a resin matrix and said second tape is comprised of continuous graphite filaments each parallel to the longitudinal axis of the second tape and to each other within a resin matrix.

Claim 5

A composite drive shaft having integral misalignment means, said drive shaft being a symmetrical lamination of a finite length tube with bellows areas within the extremities and adjacent the ends, said lamination comprising: inner layers of continuous graphite filaments within a resin matrix providing a reinforced tape, said inner layers being at least two such tapes layed in alternating acute angles to the axis of the shaft from one end to the other between and beyond the spaced bellows areas; an intermediate layer of continuous graphite filaments within a resin matrix providing another reinforced tape, said intermediate layer being at least one such tape layed along the longitudinal axis of the shaft about said inner layers from one end to the other between and beyond the spaced bellows areas; and outer layers of continuous graphite filaments within a resin matrix providing a reinforced tape, said outer layers being at least two such tapes layed in alternating acute angles to the axis of said shaft which acute angles are a repeat of that of said inner layers integrating with said inner and intermediate layers from the ends of said shaft through the bellows areas providing symmetrical construction about the axis of said shaft in integration of a constant velocity universal adjacent but within each end of said shaft.

Claim 6

A composite drive shaft having integral misalignment means, said drive shaft being a symmetrical lamination of a finite length tube with bellows areas within the extremities and adjacent the ends, said lamination comprising: inner layers of continuous graphite filaments within a resin matrix providing a reinforced tape, said inner layers being at least two such tapes layed in alternating acute angles to the axis of the shaft from one end to the other between and beyond the spaced bellows areas; an intermediate layer of continuous graphite filaments within a resin matrix providing another reinforced tape, said intermediate layer being at least one such tape layed along the longitudinal axis of the shaft about said inner layers from one end to the other between and beyond the spaced bellows areas; and outer layers of continuous graphite filaments within a resin matrix providing a reinforced tape, said outer layers being at least two such tapes layed in alternating acute angles to the axis of said shaft which acute angles are a repeat of that of said inner layers integrating with said inner and intermediate layers from the ends of said shaft through the bellows areas providing symmetrical construction about the axis of said shaft in integration of a constant velocity universal adjacent but within each end of said shaft.

Claim 7

A composite drive shaft of a symmetrical lamination according to claim 1 wherein the alternating angles of the inner and outer layers are ±45° from the axis of the shaft.

Claim 8

The composite drive shaft of a symmetrical lamination according to claim 4 wherein the alternating angles of the inner and outer layers are ±45° from the axis of the shaft.

Claim 9

The composite drive shaft of claim 5 and further comprising flange means connected to each end of the shaft just beyond the bellows area for operative connection of the drive shaft.

Claim 10

The composite drive shaft of claim 5 and further comprising flange means connected to each end of the shaft just beyond the bellows area for operative connection of the drive shaft.

Claim 11

The composite drive shaft of claims 1, 4, 5 and 6 wherein the matrix material is a thermosetting resin.

Claim 12

The composite drive shaft of claims 1, 4, 5 and 6 wherein the matrix material is a thermoplastic resin.

Claim 13

A compliant composite construction for a drive shaft, said composite construction including: a tubular section with bellows areas adjacent and within the length of said tubular section, said tubular section comprising a lamination of tapes, said tapes being a composite of continuous, unidirectional filaments parallely arranged within a matrix along the axis of the tapes, said lamination being a plurality of bias inner surface layers, an intermediate axial layer and a plurality of bias outer surface layers from end to end through and beyond each bellows area and flange means attached to each end of the tubular section outwardly of the tubular section bellows area to be a connecting means for the drive shaft between a driving and driven means.

Claim 14

A compliant composite construction for a drive shaft, said composite construction including: a tubular section with bellows areas adjacent and within the length of said tubular section, said tubular section comprising a lamination of tapes, said tapes being a composite of continuous, unidirectional filaments parallely arranged within a matrix along the axis of the tapes, said lamination being a plurality of bias inner surface layers, an intermediate axial layer and a plurality of bias outer surface layers from end to end through and beyond each bellows area and flange means attached to each end of the tubular section outwardly of the tubular section bellows area to be a connecting means for the drive shaft between a driving and driven means.

Claim 15

The structure of claim 11 wherein said bellows area is symmetrical about an axis of the drive shaft.

Claim 16

The structure of claim 11 wherein said tapes for said inner and outer surface layers consist of fiberglass filaments and said tapes of said intermediate axial layers consist of kevlar filaments.

Claim 17

The structure of claim 11 wherein said tapes for said inner and outer surface layers consist of fiberglass filaments and said tapes of said intermediate axial layers consist of graphite filaments.