Misalignment accommodating composite shaft

Claim 2

In a composite elongate member for use in transmitting torque between juxtaposed elements rotatable about axes that may be misaligned, the member including a series of pairs of overlapped anisotropic layers bonded together circumferentially about a longitudinal axis with each layer pair comprising substantially parallel filaments bonded together by a matrix material, the filaments in each layer pair being disposed at a predetermined lay angle with respect to said longitudinal axis, the lay angle of the filaments in adjacent layers of each pair being substantially equal in magnitude with one another but opposite in direction with respect to said longitudinal axis so that filaments in adjacent layers of each pair cross one another, the improvement wherein said lay angle of at least one of said pairs of layers is preselected with respect to the stiffness of the matrix material so that the strain in the member in the circumferential direction is substantially equal to the strain in the member in the radial direction when the member is subjected to strain in the axial direction, whereby the bending stress in the composite member is at a minimum while the ratio of torsional stiffness to bending stiffness of the member is not adversely affected.

Claim 3

A composite member according to claim 1 wherein the magnitude of said lay angle is directly related to the magnitude of the Young's modulus of the matrix material with the lay angle magnitude being larger at matrix material Young's moduli approaching 500,000 psi. and being smaller at matrix material Young's moduli approaching 5,000 psi.

Claim 4

A composite member according to claim 2 wherein said matrix material Young's modulus is in a range of about 100,000 psi. to about 500,000 psi. and said lay angle is in a range of about 60 degrees to about 65 degrees.

Claim 5

A composite member according to claim 3 wherein said matrix material is an epoxy.

Claim 6

A composite member according to claim 2 wherein said matrix material Young's modulus is in a range of about 5,000 psi. to about 100,000 psi. and said lay angle is in a range of about 55 degrees to about 60 degrees.

Claim 7

A composite member according to claim 5 wherein said matrix material is a polyurethane.

Claim 8

A composite member according to claim 2 wherein said lay angle is in a range of about 55 degrees to about 65 degrees.

Claim 9

A composite member according to claim 1 wherein said filaments are of a high modulus material selected from the group consisting of: carbon, boron, glass, graphite, polyamide and steel.

Claim 10

A composite member according to claim 1 wherein the Poisson's ratio of the member in the radial direction is equal to the Poisson's ratio of the member in the circumferential direction.

Claim 11

A composite member according to claim 1 wherein said lay angle is in a range of about 55 degrees to about 65 degrees.

Claim 12

In a composite elongate member for use in transmitting torque between juxtaposed elements rotatable about axes that may be misaligned, the member including a series of basis of overlapped anisotropic layers bonded together circumferentially about a longitudinal axis with each layer pair comprising substantially parallel filaments bonded together by a matrix material, the filaments in each layer pair being disposed at a predetermined lay angle with respect to said longitudinal axis, the lay angle of the filaments in adjacent layers of each pair being substantially equal in magnitude with one another but opposite in direction with respect to said longitudinal axis so that filaments in adjacent layers of each pair cross one another, the improvement wherein said matrix material is flexible and has a Young's modulus of less than about 100,000 psi., and said filament lay angle of at least one of said pairs of layers is in a range of between about 55 degrees to about 60 degrees and is preselected within said range with respect to the stiffness of the matrix material so that the strain in the member in the circumferential direction is substantially equal to the strain in the member in the radial direction when the member is subjected to strain in the axial direction, whereby the bending stress in the composite member is at a minimum while the ratio of torsional stiffness to bending stiffness of the member is not adversely affected.

Claim 13

In a composite elongate member for use in transmitting torque between juxtaposed elements rotatable about axes that may be misaligned, the member including a series of basis of overlapped anisotropic layers bonded together circumferentially about a longitudinal axis with each layer pair comprising substantially parallel filaments bonded together by a matrix material, the filaments in each layer pair being disposed at a predetermined lay angle with respect to said longitudinal axis, the lay angle of the filaments in adjacent layers of each pair being substantially equal in magnitude with one another but opposite in direction with respect to said longitudinal axis so that filaments in adjacent layers of each pair cross one another, the improvement wherein said matrix material is flexible and has a Young's modulus of less than about 100,000 psi., and said filament lay angle of at least one of said pairs of layers is in a range of between about 55 degrees to about 60 degrees and is preselected within said range with respect to the stiffness of the matrix material so that the strain in the member in the circumferential direction is substantially equal to the strain in the member in the radial direction when the member is subjected to strain in the axial direction, whereby the bending stress in the composite member is at a minimum while the ratio of torsional stiffness to bending stiffness of the member is not adversely affected.

Claim 14

In a composite elongate member for use in transmitting torque between juxtaposed elements rotatable about axes that may be misaligned, the member including a series of basis of layers overlapped anisotropic layers bonded together circumferentially about a longitudinal axis with each layer pair comprising substantially parallel filaments bonded together by a matrix material, the filaments in each layer pair being disposed at a predetermined lay angle with respect to said longitudinal axis, the lay angle of the filaments in adjacent layers being substantially equal in magnitude with one another but opposite in direction with respect to said longitudinal axis so that filaments in adjacent layers of each pair cross one another, the improvement wherein said matrix material is stiff and has a Young's modulus in excess of about 100,000 psi., and said filament lay angle of at least one of said pairs of layers is in a range of between about 60 degrees to about 65 degrees and is preselected in said range with respect to the stiffness of the matrix material so that the strain in the member in the circumferential direction is substantially equal to the strain in the member in the radial direction when the member is subjected to strain in the axial direction, whereby the bending stress in the composite member is at a minimum while the ratio of torsional stiffness to bending stiffness of the member is not adversely affected.

Claim 15

In a composite elongate member for use in transmitting torque between juxtaposed elements rotatable about axes that may be misaligned, the member including a series of basis of layers overlapped anisotropic layers bonded together circumferentially about a longitudinal axis with each layer pair comprising substantially parallel filaments bonded together by a matrix material, the filaments in each layer pair being disposed at a predetermined lay angle with respect to said longitudinal axis, the lay angle of the filaments in adjacent layers being substantially equal in magnitude with one another but opposite in direction with respect to said longitudinal axis so that filaments in adjacent layers of each pair cross one another, the improvement wherein said matrix material is stiff and has a Young's modulus in excess of about 100,000 psi., and said filament lay angle of at least one of said pairs of layers is in a range of between about 60 degrees to about 65 degrees and is preselected in said range with respect to the stiffness of the matrix material so that the strain in the member in the circumferential direction is substantially equal to the strain in the member in the radial direction when the member is subjected to strain in the axial direction, whereby the bending stress in the composite member is at a minimum while the ratio of torsional stiffness to bending stiffness of the member is not adversely affected.