US 12,247,614 B2
Hybrid composite drive shaft and a method of making
Mark R. Gurvich, Middletown, CT (US); Georgios S. Zafiris, Glastonbury, CT (US); Brayton Reed, New York Mills, NY (US); Joyel M. Schaefer, Earlville, NY (US); and Michael J. King, Sauquoit, NY (US)
Assigned to Goodrich Corporation, Charlotte, NC (US)
Filed by Goodrich Corporation, Charlotte, NC (US)
Filed on May 24, 2023, as Appl. No. 18/201,683.
Application 18/201,683 is a division of application No. 16/370,489, filed on Mar. 29, 2019, abandoned.
Prior Publication US 2023/0383783 A1, Nov. 30, 2023
Int. Cl. F16C 3/02 (2006.01); B29C 43/20 (2006.01); B32B 1/08 (2006.01); B32B 27/08 (2006.01); B29K 101/10 (2006.01); B29K 101/12 (2006.01); B29L 31/00 (2006.01)
CPC F16C 3/026 (2013.01) [B29C 43/203 (2013.01); B32B 1/08 (2013.01); B32B 27/08 (2013.01); B29K 2101/10 (2013.01); B29K 2101/12 (2013.01); B29L 2031/75 (2013.01); B32B 2597/00 (2013.01)] 10 Claims
OG exemplary drawing
 
1. A method of forming a composite drive shaft comprising:
forming a tubular insert having a first deformation temperature to define an innermost first layer of the drive shaft with a hollow center, the tubular insert formed by expanding the tubular insert against an external mold using a gas, and wherein forming the tubular insert comprises:
forming a first end section with multiple undulations; and
forming a first flat section adjacent the first end section;
surrounding the first layer with a polymeric tubular covering comprising a second material having a second deformation temperature lower than the first deformation temperature; and
forming the covering to define a second layer of the drive shaft, wherein the covering is a main load-bearing part and forming the covering comprises:
forming a second end section with multiple undulations on an exterior and an interior surface, the second end section of the second layer conforming to the first end section of the first layer; and
forming a second flat section between adjacent the second end section such that the second flat section of the second layer conforms to the first flat section of the first layer.