Composite Shaft Flange Lug Design for Fiber Integrity
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Solution Overview
Problem
Existing methods for attaching a flange to a composite shaft often result in damage to the fibers due to drilling holes or require additional pressure to wind filaments around axial lugs during curing, compromising the strength of the composite shaft.
Innovation Solution
A composite shaft assembly design featuring a flange with angularly disposed lugs that allow direct winding of filaments into channels, eliminating the need for hole drilling and additional pressure, with an overwrap layer compacting the filaments during curing to secure the shaft to the flange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If holes are drilled radially through the bonded interface to secure the flange to the shaft, then the flange is secured to the shaft, but the fibers are damaged and the overall strength of the composite shaft is reduced
Solution Approach 1:
The invention removes the harmful drilling operation entirely from the attachment process. Instead of drilling holes through the bonded interface, the flange is secured through friction and normal contact forces generated during the filament winding process itself, extracting the damaging step while preserving the attachment function
Solution Approach 2:
The invention replaces the mechanical drilling and pinning system with a friction-based attachment mechanism. The filament winding process generates sufficient normal force and friction to secure the flange without requiring holes or pins, substituting a damaging mechanical system with a non-invasive friction-based system
2Manufacturing precision
If pressure is applied to force the filament into the channels between the axial lugs during curing, then the filament is properly positioned, but additional complexity and force requirements are introduced
Solution Approach 1:
The invention performs preliminary positioning of the filament by winding it around the axial lugs before curing occurs. The filament is pre-positioned in the correct location and orientation during the winding process, eliminating the need for additional pressure or complex positioning mechanisms during curing
Solution Approach 2:
Instead of forcing the filament into channels using external pressure, the invention inverts the approach by having the filament naturally conform to the lug geometry during winding. The lugs are designed to guide and hold the filament in place through their geometric configuration rather than requiring forced insertion
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
This design enhances the strength and reliability of the composite shaft assembly by maintaining fiber integrity and simplifying the attachment process, ensuring precise and repeatable torque transfer without damaging the fibers or requiring additional pressure.
Implementation Method 1
an uncured composite shaft formed from filaments (comprised of a carrier and an uncured binder) may have these filaments wrapped around axially extending lugs on the barrel of a flange
Data Source
AI summary
A composite shaft assembly may include a shaft body and a flange. The shaft body may include a filament and the flange may include an external surface having a plurality of lugs extending therefrom. A first and second of the plurality of lugs may have an axial spacing therebetween. The filament may be wound between the first and second lugs.