Inside-Out Flexible Coupling Assembly for Lower Weight Manufacturing

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Solution Overview

Problem

Conventional flexible couplings are heavy and costly, necessitating a design that is lighter and more cost-effective.

Innovation Solution

A flexible coupling assembly with U-shaped radial cross-section disks that are welded together, featuring a smooth outer surface and venting holes, ensuring protection and reduced size, weight, and manufacturing complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If conventional flexible coupling designs are used with end protrusions and adapters attaching to the inner diameter, then the coupling provides adequate functionality, but the weight and manufacturing cost increase

Engineering Contradiction:

Improvecoupling weightVSAvoidmanufacturing complexity

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The patent inverts the conventional attachment approach by moving from inner-diameter attachment to outer-diameter attachment. The flexible members now have adapters attached to their outer diameters rather than inner diameters, fundamentally changing the structural arrangement to reduce weight and simplify manufacturing while maintaining coupling functionality

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The coupling assembly is divided into distinct modular components: flexible members with outer-diameter adapters, end protrusions, and a coupling body. This segmentation allows each component to be manufactured separately with optimized geometry, reducing overall complexity and enabling lighter weight construction compared to conventional integrated designs

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

Engineering Contradiction:

Improvemanufacturing costVSAvoidcoupling reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

By inverting the attachment location from inner to outer diameter, the patent creates a more manufacturable structure that reduces cost. The outer-diameter attachment method allows for simpler adapter geometry and easier assembly processes while the distributed adapter arrangement across multiple flexible members maintains or enhances coupling reliability

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent merges the adapter function directly into the flexible member structure by attaching adapters to the outer diameters of the flexible members themselves. This integration eliminates separate inner-diameter attachment components and simplifies the overall assembly process, reducing manufacturing cost while maintaining reliable power transmission

Inventive Principle:

Principle #5Merging (Combining)

3Volume of moving object

If the outer diameter of the flexible coupling is reduced, then the size and weight decrease, but the structural integrity and strength may be compromised

Engineering Contradiction:

Improvecoupling volumeVSAvoidstructural strength

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The patent employs composite construction with flexible members made from materials exhibiting both flexibility and high strength-to-weight ratio. The combination of flexible material properties with the optimized outer-diameter adapter structure allows the coupling to maintain structural integrity and strength while achieving reduced overall volume and weight

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality optimization by concentrating structural reinforcement at critical locations such as the adapter attachment points on the outer diameters. This localized strengthening allows the overall coupling volume to be reduced while maintaining necessary strength at load-bearing locations through optimized material distribution

Inventive Principle:

Principle #3Local quality

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 provides enhanced manufacturability, reliability, and protection while reducing size, weight, and cost.

Implementation Method 1

a first circular disk 102 defining a u-shaped radial cross-section 104 including a first leg 106 and a second leg 108 connected at an inner diameter D1

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentEP3726082B1Inside out flexible coupling assembly

Publication Date: 2025.11.12 GOODRICH CORP

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AI summary

A flexible coupling assembly for a power transmission system includes a first circular disk (102) defining a u-shaped radial cross-section (104) including a first leg (106) and a second leg (108) connected at an inner diameter thereof circumscribing an axial bore (110) of the flexible coupling and disconnected at an outer diameter of the first circular disk configured to connect to a first rotating member interface (112) and a second circular disk (103) defining a u-shaped radial cross-section (105) including a first leg (107) and a second leg (109) connected at an inner diameter thereof circumscribing the axial bore of the flexible coupling and disconnected at an outer diameter of the first circular disk configured to connect to a first rotating member interface.