Composite Drive Shaft Web Structure for Torsional Stiffness and Axial Flex

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Solution Overview

Problem

Conventional drive shafts face a dilemma in needing to be both stiff and strong under torque while also being flexible under axial and bending deformations, often requiring expensive metallic couplings and diaphragms that increase weight and cost, and may not efficiently accommodate lateral and axial movements.

Innovation Solution

An integrated composite drive shaft design featuring a +α/−α mesh-type composite web with radially outward undulations, using spiral composite elements arranged at specific angles and reinforced with axial and hoop elements, made from fiber-reinforced polymer-matrix materials, allowing flexibility under bending and axial loads while maintaining stiffness under rotational loads.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If metallic flexible couplings and diaphragms are used to provide flexibility under axial and bending deformations, then flexibility is improved, but weight and cost increase

Engineering Contradiction:

Improveflexibility under axial and bending deformationsVSAvoidoverall weight of integrated coupling and shaft body systems

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The patent merges the coupling and shaft body into a single integrated composite structure. The composite elements are arranged in a grid pattern forming an integrated coupling-shaft body system that provides both flexibility and torsional load transfer capabilities in one unified structure, eliminating the need for separate metallic coupling components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses composite materials (fiber-reinforced polymers) to create the integrated coupling-shaft body structure. The composite elements provide high strength-to-weight ratio, enabling the structure to achieve the required flexibility under bending and axial loads while maintaining low weight, unlike traditional metallic couplings

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If metallic flexible couplings and diaphragms are used to provide flexibility under axial and bending deformations, then flexibility is improved, but manufacturing cost increases

Engineering Contradiction:

Improveflexibility under axial and bending deformationsVSAvoidmanufacturing cost and labor

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent changes the material parameters from metallic to composite materials, and modifies the structural parameters by using a grid pattern of composite elements. This allows the structure to achieve the required flexibility while simplifying manufacturing processes and reducing costs associated with high-precision fabrication and quality control of metallic couplings

Inventive Principle:

Principle #35Parameter changes

3Strength

If a hollow cylindrical shaft with constant cross-section is used to transfer torsional load, then torsional stiffness is improved, but flexibility under bending and axial loads deteriorates

Engineering Contradiction:

Improvetorsional load transfer capabilityVSAvoidflexibility under bending and axial loads

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent segments the shaft body into a grid pattern of discrete composite elements arranged in circumferential and axial directions. This segmentation allows each element to independently deform under bending and axial loads, providing flexibility, while the collective arrangement maintains torsional load transfer capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #40Composite materials

4Adaptability or versatility

If high-precision fabrication and high-quality control of metallic couplings are implemented, then flexibility and strength are improved, but manufacturing cost and time increase

Engineering Contradiction:

Improveflexibility and strength of couplingVSAvoidmanufacturing cost and labor

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12577977B2Integrated composite drive shafts

Publication Date: 2026.03.17 GOODRICH CORP

AI summary

A composite shaft includes a plurality of composite elements arranged about an axis to form a hollow shaft with at least one undulation. The plurality of composite elements incudes a first group of the composite elements arranged about the axis offset by an angle +α and a second group of the composite elements arranged about the axis offset by an angle −α to form a web with the first group of composite elements. The first and second groups of the plurality of composite elements are configured to cooperate with one another to allow the hollow shaft to be flexible under axial load and stiff under rotational load.