Composite Shaft Coupling Living Hinge Structure for Axial 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, grooves, or recesses, allowing for axial misalignment while transmitting torque.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional flexible couplings use metal tubes with circumferential slots to reduce bending stiffness, then the tube can flex to accommodate misalignment, but the structural integrity and torque transmission capability are compromised

Engineering Contradiction:

Improveflexibility to accommodate misalignmentVSAvoidstructural integrity

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent employs continuous-fibre-reinforced composite material to create a flexible coupling that maintains high strength while achieving flexibility. The composite structure with fibres oriented at specific angles (e.g., 0°, 45°, 90°) provides both structural integrity and controlled flexibility, resolving the contradiction between strength and adaptability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The coupling is divided into distinct segments including rigid sections and flexible sections with reduced wall thickness. This segmentation allows different parts of the coupling to serve different functions - rigid sections for strength and torque transmission, while flexible sections accommodate misalignment through controlled deformation.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If additional components like universal joints or disc type couplings are used to accommodate axial misalignment, then misalignment is addressed, but the device complexity increases

Engineering Contradiction:

Improveaccommodation of axial misalignmentVSAvoidnumber of components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into a single integrated flexible coupling component. The coupling simultaneously provides torque transmission, accommodates axial misalignment, and maintains structural integrity without requiring separate universal joints or disc type couplings, thereby reducing overall system complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible coupling is designed as a multi-functional component that can accommodate various types of misalignment (axial, angular, and lateral) while also transmitting torque effectively. This universal capability replaces the need for multiple specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If the tubular section is made from continuous-fibre-reinforced composite material with living hinge sections, then flexibility and torque transmission are improved, but the manufacturing complexity increases

Engineering Contradiction:

Improveflexibility under loadVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent achieves flexibility by changing the wall thickness parameter in specific regions to create living hinge sections. This parameter modification allows the composite material to flex under load while maintaining its structural advantages, balancing manufacturing feasibility with performance requirements.

Inventive Principle:

Principle #35Parameter changes

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 flexible coupling effectively accommodates axial misalignment between transmission shaft system parts, offering improved flexibility and torque transmission capabilities, potentially replacing traditional solutions like universal joints, while maintaining structural integrity.

Implementation Method 1

The flexible coupling 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

Methodology Applied

Scientific EffectTorque transmission: Torque

Implementation Method 2

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

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS20230228299A1Composite flexible coupling

Publication Date: 2023.07.20 CROMPTON TECH GROUP

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.