Universal Joint Assembly Embedding Pivots in Composite Shaft

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Solution Overview

Problem

Existing universal joint assemblies made from fibre-reinforced polymer (FRP) shafts require numerous manufacturing and assembly steps, are heavy, and prone to misalignment and rotational backlash.

Innovation Solution

A method of producing universal joint assemblies by creating a single fibre-reinforced polymer structure with a joining member embedded within, which is then split into two coupled FRP shafts, improving alignment and reducing assembly steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If metal end fittings are attached to composite shafts and coupled with a joining member, then universal joint assembly is achieved, but the assembly requires numerous manufacturing and assembly steps

Engineering Contradiction:

Improvemanufacturing and assembly stepsVSAvoidassembly process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the composite shaft and metal end fitting into a single integrated component by embedding the joining member directly within the fibre-reinforced polymer structure during manufacturing. This eliminates the separate attachment step and reduces assembly complexity while maintaining the functional benefits of combining composite and metal materials.

Inventive Principle:

Principle #5Merging (Combining)

2Weight of moving object

If metal end fittings are attached to composite shafts, then universal joint assembly is achieved, but the assembly becomes heavy

Engineering Contradiction:

Improveuniversal joint assembly weightVSAvoidmanufacturing approach

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The patent uses fibre-reinforced polymer composite materials for the shaft portion that integrates with the metal joining member. The composite material provides high strength-to-weight ratio, reducing overall assembly weight while maintaining structural integrity and enabling the embedded joining member configuration.

Inventive Principle:

Principle #40Composite materials

3Manufacturing precision

If separate attachment of metal end fittings to composite shafts is used, then universal joint assembly is achieved, but misalignment and rotational backlash occur

Engineering Contradiction:

Improvealignment precisionVSAvoidattachment process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The joining member is positioned and embedded within the composite shaft structure during the manufacturing process itself, before final assembly. This preliminary positioning ensures precise alignment is built into the structure, eliminating alignment issues that would arise from separate attachment operations and reducing rotational backlash.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP4253016B1Method of producing a universal joint assembly and universal joint assembly

Publication Date: 2025.06.11 CROMPTON TECH GROUP

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AI summary

A method of producing a universal joint assembly (100) is provided. The method comprises providing a joining member (106) for forming a universal joint, said joining member (106) comprising a first pivot (110) and a second pivot (112); applying continuous fibre reinforcement (206) and a polymer matrix (210) to a form (205) including said joining member (106) to create a single fibre-reinforced polymer structure (212) in which the joining member (106) is embedded; and splitting said single fibre-reinforced structure (212) into a first fibre-reinforced polymer shaft (102) and a second fibre-reinforced polymer shaft (104) that are coupled together by the joining member (106) to form a universal joint.