Composite Tubeshaft Metallic Interface via Serrated Locking
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Solution Overview
Problem
Conventional composite tubeshafts require metallic adapters for interfacing other shaft components, leading to limitations in structural integrity, weight, and manufacturing costs due to complex designs such as notched, press-fit, lugged, and bonded joints.
Innovation Solution
An integrally fabricated encapsulated connection is developed using a composite substrate and a serrated metallic substrate, where the composite substrate is woven between serrated teeth of the metallic substrate, creating a locking interface and applying a securing agent before rolling and curing to form a lightweight, high-strength tubeshaft assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metallic adapters (notched, press-fit, lugged, bonded joints) are used to interface composite tubeshafts with other shaft components, then the composite tubeshaft can transmit torque, but the structural integrity is limited and manufacturing complexity increases
Solution Approach 1:
The patent merges the composite tubeshaft and metallic adapter into a single integrated structure where the metallic adapter is embedded within the composite material during manufacturing. This eliminates the need for separate adapter components and complex assembly processes, directly resolving the contradiction between structural integrity and manufacturing complexity.
Solution Approach 2:
The patent utilizes composite materials by embedding metallic elements (adapters, joints) within the composite tubeshaft structure. This composite construction provides both the strength benefits of metallic components and the weight reduction of composite materials, while simplifying manufacturing by creating a unified structure during the composite curing process.
2Weight of moving object
If conventional metallic adapters are used for composite tubeshafts, then torque transmission is enabled, but weight increases
Solution Approach 1:
The patent applies local quality by using metallic materials only in specific locations where torque transmission and structural support are required (at the adapter and joint areas), while the remaining portions of the tubeshaft utilize lightweight composite materials. This localized material distribution maintains torque transmission capability while minimizing overall weight.
Solution Approach 2:
The patent employs composite materials with embedded metallic elements to create a hybrid structure that combines the advantages of both material types. The composite portions provide weight reduction while the embedded metallic adapters and joints ensure reliable torque transmission, effectively resolving the weight-reliability contradiction.
3Ease of manufacture
If multiple types of composite-adapter joint end systems are employed (notched, press-fit, lugged, bonded), then various shaft components can be interfaced, but manufacturing costs and complexity increase
Solution Approach 1:
The patent creates a universal adapter design that can interface with multiple types of shaft components through standardized connection features. The embedded metallic adapter includes universal mounting features that accommodate various joint types, eliminating the need for multiple specialized adapter designs and reducing manufacturing costs while maintaining 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
This method provides a low-cost, lightweight, and high-strength composite tubeshaft assembly with improved structural integrity by bonding the composite and metallic substrates, reducing the need for additional adapters and simplifying the manufacturing process.
Implementation Method 1
bonding the composite and metallic substrates
Implementation Method 2
applying a securing agent before rolling and curing to form a lightweight, high-strength tubeshaft assembly
Implementation Method 3
the composite substrate is woven between serrated teeth of the metallic substrate, creating a locking interface
Data Source
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AI summary
A composite tubeshaft comprising a composite substrate defined by a first surface and a second surface and a metallic substrate having at least two teeth. The teeth of the metallic substrate engage the composite substrate such that at least one tooth is positioned over the first surface and at least one tooth is positioned over the second surface.