Hybrid metal-composite drive shaft unit and method of manufacturing same

• Main Authors: Juergens, Michael, Remer, Niklas, Bortolotto, Laurent, Ehard, Stefan
• Format: Patent
• Language: English
• Published: 07.05.2019
• Subjects: AEROPLANES; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING; AIRCRAFT; AVIATION; BEARINGS; BLASTING; COSMONAUTICS; ELEMENTS OR CRANKSHAFT MECHANISMS; ENGINEERING ELEMENTS AND UNITS; FLEXIBLE SHAFTS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVEFUNCTIONING OF MACHINES OR INSTALLATIONS; HEATING; HELICOPTERS; INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULARARTICLES; LIGHTING; MECHANICAL ENGINEERING; PERFORMING OPERATIONS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; SHAFTS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDEDFOR; SHAPING OR JOINING OF PLASTICS; THERMAL INSULATION IN GENERAL; TRANSPORTING; WEAPONS; WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL

A hybrid metal-composite drive shaft unit, which comprises at least one metal drive shaft connector that is at least partly embedded into a composite drive shaft, the composite drive shaft comprising a thermoplastic polymer and being connected to the at least one metal drive shaft connector by means of a welded connection that defines a first load path for transmission of loads between the at least one metal drive shaft connector and the composite drive shaft, the at least one metal drive shaft connector and the composite drive shaft comprising, in the region of the welded connection, at least partly a polygonal cross-sectional shape for forming a form-fit connection that defines a second load path for transmission of loads between the composite drive shaft and the at least one metal drive shaft connector.