Composite Flexible Coupling With Living Hinges for Shaft Misalignment
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Solution Overview
Problem
Conventional flexible couplings for transmission shaft systems face limitations in accommodating axial misalignment effectively, as they often require additional components like universal joints or disc type couplings, and there is a need for improved materials that can flex under load while maintaining torque transmission.
Innovation Solution
A flexible coupling made from continuous-fibre-reinforced composite material with modified tubular sections featuring living hinge sections created by reducing bending stiffness through patterns of apertures, recesses, or grooves, allowing for axial misalignment while transmitting torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional metal flexible couplings with circumferential slots are used, then bending stiffness is reduced to allow flexion, but weight increases and manufacturing complexity increases
Solution Approach 1:
The patent applies composite materials by constructing the coupling from multiple layers of fibrous material (e.g., carbon fiber, glass fiber, or aramid fiber) wound or laid in specific patterns. This composite structure provides both the necessary flexion capability through controlled fiber orientation and layering, and significant weight reduction compared to conventional metal couplings. The fibrous layers can be designed to bend at specific locations while maintaining overall structural integrity and torque transmission capability.
2Adaptability or versatility
If circumferential slots are cut through metal tube wall, then bending stiffness is reduced, but manufacturing precision requirements increase and structural strength decreases
Solution Approach 1:
The patent segments the continuous fibrous structure into controlled layers with different orientations and properties. By winding or laying fibers in specific patterns across multiple layers, the coupling achieves flexion capability without requiring precise cutting operations. The segmentation of fibers into discrete layers allows controlled bending zones to form naturally at intended hinge locations, eliminating the need for high-precision slot cutting while maintaining structural integrity.
3Adaptability or versatility
If metal tube with flexible section is used, then axial misalignment is accommodated, but device complexity increases compared to rigid couplings
Solution Approach 1:
The patent merges multiple functions into a single integrated fibrous coupling structure. The coupling simultaneously provides torque transmission, flexion for misalignment accommodation, and structural strength without requiring separate components like universal joints or disc couplings. The multi-layer fibrous construction integrates the flexible hinge sections and rigid coupling sections into one unified component, reducing overall device complexity while achieving the desired adaptability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables flexible couplings to accommodate axial misalignment and transmit torque efficiently, offering improved flexibility and reduced weight compared to metal couplings, with the ability to handle misalignment up to ±15 degrees, making it suitable for applications like aircraft shaft systems.
Implementation Method 1
a first layer of continuous fibres having a first winding angle; and a second layer of continuous fibres having a second winding angle
Data Source
AI summary
A flexible coupling for transmitting torque between parts of a transmission shaft system comprises a tubular section of continuous-fibre-reinforced composite material which has been modified to form a living hinge section with reduced bending stiffness to allow flexion of the tubular section. The tubular section may be modified through the provision of a pattern of formations within the living hinge section. The formations may be in the form of apertures and/or recesses in the continuous-fibre-reinforced composite material to create a plurality of living hinges in the material between, in particular slots and/or grooves.