CA1232146A - Manufacture of filamentary composites - Google Patents
Manufacture of filamentary compositesInfo
- Publication number
- CA1232146A CA1232146A CA000514910A CA514910A CA1232146A CA 1232146 A CA1232146 A CA 1232146A CA 000514910 A CA000514910 A CA 000514910A CA 514910 A CA514910 A CA 514910A CA 1232146 A CA1232146 A CA 1232146A
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- tube
- mandrel
- composite tube
- filament wound
- resin
- Prior art date
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Abstract
MANUFACTURE OF FILAHENTARY COMPOSITES
Abstract of Disclosure This invention relates to industrial manufacture of corn-posite tubes in a continuous fashion. The invention utilizes a segmented mandrel which proceeds as a train of endwise joined segments through a composite tube forming machine.
Segments are added to and subtracted from the mandrel during manufacture of the tubes.
Abstract of Disclosure This invention relates to industrial manufacture of corn-posite tubes in a continuous fashion. The invention utilizes a segmented mandrel which proceeds as a train of endwise joined segments through a composite tube forming machine.
Segments are added to and subtracted from the mandrel during manufacture of the tubes.
Description
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This application is a division of Canadian Patent Application No. ~30,871, filed June 21, 1983.
Lucy invention relates to manufacture of hollow, file-Monterey composite tubes that can be used, for example, to transmit torque in the drive train of motor vehicles. Fife-Monterey composite tubes have been proposed for reduced weight S shafts in the drive train of motor vehicles. See, for exam-pie, US. Patents 4,17l,626; 4,236,3~6; 4,238,539; 4,238,540 and 4,289,557. See, also, "Development of an Advanced Come posit Tail Rotor Drive shaft" by Zinberg et Al presented at the Thea annual National Forum of the American Helicopter lo Society, Washington, DO June l970.
Fabrication of composite tubes by applying fiber to a cylindrical mandrel is known. See, for example, US. Patents 4,248,062; 4,532,579 and 3,407,101. This invention differs from these prior art techniques in that it provides for suck cessive production of suitably reinforced composite tubes using a continuous tubular mandrel of joined mandrel segments.
US. Patents: 2,714,414 (Gunwale et at.); 3,723,705 Collins); 4,125,423 (Golds worthy); 4,309,865 (Brunch et at.) disclose tube making yrocPsses in which a segmented man-duel body is in relative motion with respect to composite tube forming devices operatively engaging such segmented man-duel body. The present invention is characterized by in pro-cuss aspect as passing a tube-shaped, segmented mandrel come prosing endues joined segments lengthwise through a series of tube fabricating devices for (it forming a resin and fiber tube comprising continuous filamentary reinforcements about said segmented mandrel passing there through (ii) hardening said rosin and fiber tube around said segmented mandrel after said forming; and (iii) s~vertng adjacent the juncture be-tweet adj~c4ntly joined segments of said segmented mandrel the tubular product of said resin and fiber tube that has hardened sufficiently for said severing; as this passage . . . . _ . .
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through said series continues, disconnecting from segmented mandrel the leading segment thereof that carries a composite tube that has been severed from said tubular product in conjunction with connecting a fresh mandrel segment -to the other end of said segmented mandrel as a replacement for such disconnected leading segment; separating the composite -tubes from said mandrel segments that are disconnected from said segmented mandrel to provide said hollow composite tube members.
The above cited patents also disclose machines for implementing each of -the disclosed methods. The machine of the present invention is characterized by; support for passing a segmented mandrel lengthwise through a plurality of longitudinally spaced tube fabricating devices; longitudinally spaced filament applicators -for applying diversely angled continuous filamentary plies to said segmented mandrel atop each other; a reciprocating wrench for periodically joining segments to an end of said segmented mandrel that is upstream Eros said tube fabricating devices; a reciprocating wrench for periodically disconnecting joined segments from an end of said segmented mandrel that is downstream from said tube fabricating stations; a saw for severing a composite tube circumferential, said saw located between the other tube fabricating devices and said downstream wrench.
In one broad aspect, the present invention relates to a hollow, mass produced, filament wound composite tube suited for transmitting -torque in a motor vehicle as par-t of the drive train thereof, said tube in absence of end fittings joining I
said tube to said drive train consisting essentially of continuous filaments in a thermoses resin matrix said continuous filaments disposed in resin and fiber zones integrated together in the wall of said tube by said thermoses resin matrix substantially along lines parallel to -the central longitudinal axis of said tube wherein said resin and fiber zones, proceeding radially from closest to farthest from said center longitudinal axis consist essentially of said thermoses resin matrix and: (a) inner glass filaments disposed (i) in one or more inner glass layers and (ii) at angles, with respect to a line drawn parallel to said longitudinal axis, between about ~30 and +55 and -30 and -55 in respective plies of said one or more inner glass layers; (b) intermediate glass filaments disposed (i) in a single intermediate glass ply, (ii) radially between, and adjacent to, said inner glass layers and a single graphite or carbon ply and (iii) substantially circumferential in the wall around said tube; (c) graphite or carbon filaments disposed (i) in said single graphite or carbon ply, (ii) radially between, and adjacent to, said single intermediate glass ply and a single outer glass ply and (iii) at an angle, with respect to a line parallel to said longitudinal axis, of zero degrees; (d) outer glass filaments disposed (i) in said single outer glass ply and (ii) substantially circumferential in the wall around said tube.
Also disclosed are: a method of manufacturing a hollow composite tube, the subject matter or parent Canadian Patent application No. 430,871, which matured to patent on October 14, 1986 as Canadian Patent Jo. 1,212,529; a machine that manufactures composite tubes, the subject matter of Canadian ~32~
Patent application Jo. 514,909, a division of Canadian patent application Jo. 430,871 filed contemporaneously with the present application; and a segmented mandrel, -the subject matter of Canadian Patent No. 51~,911, a division of Canadian patent application No. 430,871, filed contemporaneously with -the present application.
In the following description of -this invention:
"Process mandrel" means a continuous tubular mandrel formed of discrete mandrel segments joined to each other along their central longitudinal axes and around which a tubular composite can be formed. "Mandrel segment" means a tubular segment that can be connected to and disconnected from the process mandrel.
"Composite tubular member for a light truck" means a fiber and resin tubular body having continuous filaments in thermoses resin, the structural properties of which tubular body are exemplified by critical frequency not to exceed 9~.23Hz, shear torque 56,000 in-lb, buckling torque 56,000 in-lb. "Process mandrel portion" means a longitudinal portion of the process mandrel which includes any number or portion of its joined segments. "Layer" means a pair of filamentary plies, a first of which it disposed a-t a plus or minus first angle relative to a line parallel to an axis and the second of which is disposed a-t a second ankle of about the same magnitude as the first angle but the negative /
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thereof relative to such line. ply" means a group of fife-mints disposed at the substantially same angle in a geometric plane concentric with a mandrel portion which plural is nor-molly cylindrical or substantially cylindrical in this invention.
Figure 1 outlines diagrammatically a process sequence that utilizes this invention in producing composite tubes thereof, Figure 2 schematically depicts a cross section of end portions of two joined mandrel segments used in practicing this invention. The end portions are depicted with the come posit tubes they carry after the cutting operation in the sequence of Figure 1.
Figure 3 schematically depicts in perspective an apply-actor for applying helically disposed fibers to a process mandrel portion passing through the applicator.
Figure PA is a detail of the annular deposition ring as-symbol of a wheel depicted in Figure 3.
Figure 4 schematically depicts in perspective an apply-actor for applying longitudinally disposed fibers to a pro-cuss mandrel portion passing through the applicator down stream from the portion of Figure 3.
Figure assay a detail of fiber application ring of an applicator in Figure 4.
Figure 5 schematically depicts in perspective an apply-actor for applying circumferential disposed fibers to a process mandrel portion passing through the applicator down-stream from the portion of Figure 4 or Figure 3.
Figure 6 schematically depicts a cross section of a resin applicator chamber for impregnating fiber carried by a process mandrel portion passing through the chamber down-stream from the portion of Figure 5.
Figure 7 schematically depicts in perspective a bank of induction coils used to cure a resin and fiber tube carried by a process mandrel portion passing through the coils down-sternly from the portion of Figure 6.
Figure 8 schematically depicts in perspective a two blade rotating cutting wheel for cutting a moving tube of I
hardened resin and fiber produced in accordance with this in-mention arid carried by a process mandrel portion downstream from the portion of Figure 7.
Figure g schematically depicts in perspective an into-grated device that disconnects mandrel segments and subset quaintly draws a composite tube from each of the disconnected mandrel segments. The mandrel segment being disconnected is downstrearll of the process mandrel portion of Figure 8.
Figure 10 is a view of a drive shaft member of this in-mention in elevation, including end fittings.
Figure lo is a diagrammatic depiction of a wall portion of the coïnposite of Figure 10.
Figure 1 shows the fabrication steps which result in composite drive shaft tubes for light trucks in accordance with this invention. The fabrication sequence is illustrated in Figure l as a series of steps set forth in the order in which the tubes asp made.
In general, endues joined segments of a process mandrel sequentially proceed lengthwise through the tube fabricating stations identified in the fabrication sequence of Figure 1.
In the final tube forming;operatiorl, however, individual man duel segment ox the process mandrel are disconnected and a completed composite tube is extracted from each disconnected segment, the latter occurring off line from steps that pro-cede it. Also, in the beginning of this process sequence afresh mandrel segment is periodically joined to the rear man-duel segment of the process mandrel. The fresh mandrel sex-merit being joined to the process mandrel may have a cylinder-eel metal sleeve around either or both of its ends whereby the metal sleeve becomes integrated into the composite tube produced by the sequence of Figure 1.
t the beginning of the tube fabricating process so-quince depicted in Figure 1, a mandrel segment, as mentioned, is joined to the rear of a previously assembled process man duel at joining station A. The process mandrel comprises number of connected segments which together have a common central longitudir,~l axis. (See Figure 2 for a cross-section of two joined mandrel segments). Hand over hand clamps at I
station R continually pull the process mandrel away from joining station A and through the other tube fabricating stations that art downstream thereof.
A moving grip jaw at station prevents rotation of the moving process mandrel. The grip jaw holds the process man-duel while thy unconnected, fresh mandrel segment is spun into locking engagement with, and becomes the rear segment of, the process mandrel proceedinc3 as a train of seglnents through downstream tube fabricating operations. An upstream ball rail mounted wrench rotates in spinning this unconnected mandrel segment into the locking relation at station A. The rotating wrench translates in a downstream direction long-tudinally along the upstream extension of the process mandrel central longitudinal axis in joining the new mandrel segment to the process mandrel. A bed of rollers carry the end of the process mandrel and the mandrel segment being joined thereto during the joining operation. The rollers are rota able in the directiorl that the process mandrel proceeds.
At station B dry fiber is deposited around the portion of the process mandrel that proceeds there through. Station B
comprises a helical applicator. The helical applicator de-posits a ply or plies of continuous filaments either at an angle between about +35 and +55 or between about -35 and -55 relative to a line parallel to the central longitudinal axis of thy process mandrel. There are four helical applique-ions in the fabrication sequence of Figure 1, labeled B, D, F
and Al, each of which applicators deposits a ply or pair of plies at an angle within the above ranges.
Helical applicators of station B, D, F and H each come prose a wheel having a plurality of fiber carrying spools spaced about its periphery. The wheels of adjacent stations rotate at similar rates (but opposite each other in spinning the continuous filaments about the process mandrel from these spools see Figure 3 for a view of the two counter rotating wheels). AS a result of passage of the process mandrel through fiber deposition at these wheels, segments of the process mandrel are covered with a layer or layers of con-tenuous foments, as desired. For example, two layers of continuous filamerlt can be deposited by stations B, Do F and H. Unmaking light truck drive shaft tubes, each pair of the stations deposits a layer of filament. The layer has a +45 ply and a -~5 ply where these ankles are each relative to a line parallel to the central longitudinal of the process mandrel.
In making these truck drive shaft tubes, each of stay lions B, D, F and H deposits between about .02~ and .334 lobs of fiber per linear foot of the process mandrel. Each of these station B, DO and H can utilize up to 80 rovings with yields of 113 and 1~00 yards. per lb. where the rovings each comprise E-glass filaments.
Stations C, E, G, I, K, M and o in the sequence of Fig-use l provide for impregnation of the fiber deposited on the process mandrel. Station C like the other of these stations (except station o) includes a resin impregnation coralberry. (A
cross-section of a typical resin impregnation chamber appears in Figure 6.) Station o utilizes a tubular conduit communicating with, and suspended from, a resin supply tank for direct applique-lion of resin. The resin passes through the conduit and onto the passing fiber and resin tube proceeding from station N.
The resin is worked into the passing fiber at station O by a downstream roller such as a paint roller that continuously circles the segmented mandrel. A rotating elastomers wiper blaze downstream of this roller wipes resin from the fiber.
Impregnation alternatively, however, can occur by means of impregnation chamber or such direct application at any or all of stations C, E, G, I, K, M and O. For example, station M could be omitted.
The process mandrel proceeds through the impregnation chamber of stations C, E, G, I, K, I and o (and the other stations) at any desired rate preferably between 1.5 and 6 feet per minute in the sequence being described. it these rates, the fiber absorbs about an equal volume of thermoses-table resin. Fiber wetting reaches an equilibrium at about 50 percent of the total composite volume. Additional impreg-nation stations do not significantly affect the fiber to resin ratio.
Station J in the sequence of Figure 1 deposits dry fiber around the process mandrel over the impregnated fixers there-of as it proceeds from the impregnation at station I. Stay lion J comprises a rotating hoop applicator wheel that no-tats to wind a band of continuous fiber as it spins around the moving process mandrel. (See Figure 5 for a view of this wheel). The hoop applicator applies a ply of continuous lit-amens to the moving process mandrel at an angle between about either +80 or ~80 and 90 relative to a line parallel to the central longitudinal axis of the process mandrel.
For a truck drive shaft tube made using a process man-duel having a four inch diameter and proceeding at a rate dPscrib~d the hoop applicator spins around the process man-duel at between about 18 and 72 rum in depositing a 1 inch wide band of Glass filaments that contains of between ll3 and 1800 yards. per lb.
Station L deposits continuous graphite filaments about the fiber wound and resin impregnated process mandrel pro-ceding from stations J and K respectively. Station L depose its continuous filaments about the process mandrel at annoyingly of about 0 relative to a line parallel to the long-tudinal axis of the process mandrel. Station L preferably utilizes two or more longitudinally spaced distribution rings. Rovings pass through these rings and then lay upon the previously fiber covered and resin impregnated process mandrel as it travels through the rings. see Figure 4 for a view of the longitudinally spaced applicators of station L).
The rings each comprise an orifice which encircles the process mandrel; the rings each have holes spaced around their peripheries. The holes guide the rovings as they lay upon the fixer covered and resin impregnated process mandrel proceeding through the rings from station K or from an up-stream ring of station L. Holes of the adjacent distribution rinks are offset from each other so that the yarns or rovings are lazed all around the fiber covered and resin impregnated process mandrel.
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The yarns or rovings at station h have between about 1200U and 36000 filaments per roving in making the truck drive shaft composite tubes. The yarn or roving in making these drive shaft tubes comprise graphite filaments that are S Graphite Together these filaments weigh between about 0.l~7 and U.328 lobs per linear foot of the process mandrel after exit from station, L. The rovings issue from the disk tribution rings at up to about six feet per minute in making such tubes.
lo Station N (of the sequence of Figure l) wraps the long-tudinally disposed filaments carried on the process mandrel from station L with a hoop ply of dry filaments The hoop ply is deposited by rotating hoop wheel applicator such as discussed in reference to station J. Stations J and N each deposit the hoop ply of dry fiber at plus and minus angles of either between about ~80D and 90~ or between about -80 and 90 relative to a line parallel to the center longitudinal axis of the process mandrel in making the truck drive shaft composite tubes.
station o applies liquid thermosetting resin to the it-bier and resin covered process mandrel proceeding from station N, as described above.
The fiber and resin covered process mandrel, impregnated at station o then proceeds therefrom to station P which in-shuts cure of the thermosettable resin, station P being shown in the sequence of Figure l.
A plurality of induction coils initiate this cure at station P. (The device carrying these induction coils is de-plated schematically in Figure 7). The induction coils pro-vise a sufficient temperature increase in the resin to result ultimately in a cure thereof. Generally in making the truck drive shaft tubes, the temperature of a mandrel segment leaving station P desirably will be between about 250F and 325F, when using vinyl ester thermosettable resin such as Darken from Dow Chemical Corp.
station Q of the sequence depicted in FicJure l comprises infrared heaters. The heaters increase the outside skin temperature to 200F. bank of five infrared heaters are Jo I
monotype around a 6 foot long cylinder. Station Q eliminates surface tack which may exist when curing thermosettable rosin cor.tainin~ a styrenes monomer in air.
Some distance exists between station Q and station R.
S Station R of the sequence depicted in Figure 1 grips the hardened resin tub proceeding from station Q. Station P
grips the composite tube sufficiently to pull it through the proceedirlg stations. Station R has two land over hand grip-ping clamps. The hand over hand gripping mechanism may be lo purchased from Golds worthy Engr. of Torrance, Cal.
Station S of the process sequence depicted in Figure 1 severs the hardened tune proceeding from station R. Station S comprises a pair of rotating saw blades. The saw blades cut the curing or cured tube around either side of the junk-lure between two joined mandrel segments of the process man-duel. The blades rotate about the process mandrel to sever a composite tube completely from the upstream portion thereof.
(See Figure 8 for a view of the cutter. The short cylinder-eel section of composite tube formed between the blades by the cutting action thereof is removed at station U during the pulling of the mandrel segments from their respective compost tie tubes.) The blades translate along a line parallel to the central longitudinal axis of the process mandrel in so-vexing the cured tube as it proceeds through station S.
After the tube is severed, the blades together translate upstream to their starting position.
Station T of the process sequence identified in Figure 1 disconnects the mandrel segment carrying a severed tube from the rest of the process mandrel. A clamping jaw at station T
prevents rotation of the process mandrel by gripping an up-stream portion thereof around the cured composite tune that it carries. The downstream joined mandrel segment is then disconnected from the rest of the process mandrel by a rotate in hex wrench at station T. The rotating hex wrench engages the leading mandrel segment (carrying the composite tube so-vexed at station I) and spins it free of the moving upstream train of joined mandrel segments. (See Figure 9 for schema-tic Yo-yo of the mandrel segment disconnecting and tube extracting device combination.) 23~
The disconnected mandrel segment carrying the cured come posit tube proceeds to station of the process sequence de-plated in Figure 1. Station U is at the side of the main machine axis. The composite tube is extracted from the disk connect mandrel segment in an extraction die. The disco-netted mandrel segment is pulled through the extraction die stripping the cured composite tube. The disconnected mandrel sec3inent proceeding from the extraction die, now free of the cured composite tube, then proceeds to station V which con-lo twins a mold release bath. Thy freed mandrel segment instill at elevated temperature (e.g. 130F.) as it enters this mold release bath. The elevated temperature helps bake the mold release of the extracted mandrel segment.
The cured composite tubular member, when freed of the disconnected mandrel segment, can be rolled to a storage cart. The mandrel segment, when freed of the cured composite tubular member can be returned to station A for further use.
The composite tubular member when used in a truck drive shaft can incorporate a metal sleeve at each end The metal sleeve can be adhesively bonded within, or on the outside of, the tube. Alternately each mandrel segment can carry metal sleeves at its ends through the fabrication sequence of Fig-use 1. These sleeves act as parts of the mandrel segment in that the composite tube is formed about them. A riveting opt oration can rivet the sleeves in this latter case to the come posit tubular member after completion of tube manufacture (i.e. after station V).
The method of this invention has been described in a tube fabrication sequence suited for making truck drive shaft conlposit~ tubes. As, however, may be apparent, such sequence is but illustrative of the many sequences that can be used in making these or other composite tubular members using prince-pies of this invention. Another sequence is A, B, C, D, E, J, K, L, M, N, P, Q, R, S, T, U and V; different combinations of fiber yield and numbers of rovings can also be employed in any of these sequences.
Figures 2 through 9 illustrate equipment identified in prevails description of the process sequence of Figure 1.
Figure 2 is a cross-section of the joined ends of two cylindrical mandrel SegTnentS 10, 12 that are used in making composite drive shaft tubes for certain light trucks in con-section with the process sequence of Figure 1. Joined man-duel segments 10, 12 have cylindrical steel sleeves lo, wish slip over their respective ends. Plastic sleeve 18 fits cylindrically about and between adjoining en portions of steel sleeves 14, 16 and between segments 10, 12.
The opposite ends (not shown) of each mandrel segments 10, 12 are configured to permit their respective joining with other mandrel segments. -Mandrel segment male member 20 is bolted to mandrel sex-mint 12 and has integral male acme threads 22 for connecting mandrel segment 12 to mandrel segment lo Mandrel segment 10 lo has socket 24 with threads 26 for receipt of threads 22 in locking relation. mandrel segment it joins to mandrel sex-mint 12 with relative rotation between them of between about 1 and 2 revolutions. The unthreaded portion of male member 20 guides the approach and retreat of mandrel segment 12 to and from mandrel segment 12.
Mandrel segments lo 12 depicted in Figure 2 have pro-ceded through tube cutting station S in the sequence of Fig-use 1. Circumferential spaces 28, 30 depict where station S
has severed the composite tube carried by the mandrel sex-mints 10, 12. Mandrel seglilent lo leads mandrel segment 10 in this sequence in the direction shown in Figure 2. Accord-tingly, mandrel segments 10, 12 carry downstream cured compost tie tube 32, upstream composite tube 34 and intermediate come posit tube 36. Downstream composite tube 32 becomes, with sleeve 16 and a sleeve (not shown) at the other end of man-duel segment 12, a drive shaft member of this invention after it is separated from mandrel segment 12. Upstream composite tube 34 becomes another drive shaft member with sleeve 14 (and other sleeve) once tube 34 is severed and the severed tube separated from mandrel segment lo Intermediate compost tie tube 36 remains with mandrel segment 10 after disco-section of mandrel segment 12 therefrom until stripping of tube 34 from mandrel segnl~nt 10 at station U.
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_ 14 -Int~r~diate composite tube 36 has been cut out at tube cutting station S. Plastic sleeve 18 serves to provide tolerance in the depth of this cut.
Figure 3 depicts an apparatus which is depositing fiber about process mandrel portion 38 as it passes through wheels 40, 42 carried by respective fixed mounts 44 and 46. Each of wheels I 42 has a plurality of spools (a few pairs of which are depicted as respectively, 48, 50 and 52, 54) of continue out filament fixed around their respective faces 56, 58 and 60, 62. The wheels counter rotate, such as in the directions shown in figure 3, in depositing continuous filaments about process mandrel portion 38 as discussed above in connection with stations B and D and F and H of Figure 1. Resin impregnation chamber 64 is between wheels 40, 42.
Continuous filaments from spools 48, 50 and 52, 54 pass to respective annular deposition ring assemblies 66~ 68 which rotate with their respective wheels 40, 42. This fiber past sues through holes in the annular ring assemblies 66, 68 for orientation onto process mandrel portion 380 The speed at which wheels 40, 42 and consecluently rings assemblies 66, 68 rotate relative to the axial translation of process mandrel portion 3B through these ring assemblies determines the angle at which the fixers deposit on process mandrel portion 38.
Figure PA is a detail of ring assembly 66 of Figure 3 Continuous filament 70 feeds from plastic tubes such as 72 and through holes such as 74, 76 respectively in orienting plates 78, 80. Tubes 72 serve to protect filaments 70 and unable ready threading thereof from the spools (e 9. 48, 50) of filaments.
Figures 4 and PA schematically illustrate longitudinal fixer applicator 82 which is depositing continuous filaments longitudinally (relative the center longitudinal axis of pro-cuss mandrel portion 84) along the process mandrel. Spaced fiber disposition rings 86, 88, 90, 92 permit issuance of continuous fixer passing from remote spools or creels (not shown) through their respective offset holes 94, 96, 98 and 100. Holes 94, 96, 98 and 100 are respectively spaced about segmented mandrel portion 84 in these rings 86, 88, 90, 92.
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There are about 51 holes in each of the spaced disposition rings 86, 88, 90, 92. Each individual hole in holes 94, 96, I and loo receives up to about 36000 or more filaments.
Conduits 102, 104, 106, 108 lead from the creels to respect live holes I 96, 98 and 100 to maintain alignment of thriving or yarn passing to each of these holes. The roving or yarn issue from these holes to process mandrel portion 84 without any surrounding conduit.
In making the light truck composite tubes, there are lo four rings longitudinally spaced between about 12 and 18 in-ekes from each other. These rings deposit continuous fife-mints at a zero degree ankle relative to a line parallel to the central longitudinal axis of the process mandrel.
Figure 5 schematically illustrates device 110 that is depositing fiber circumferential about process mandrel port lion 112. Device 110 serves the function of providing hoop windings in the fabrication sequence of Figure 1 and rotatable mounts to fixed mount 128.
Device 110 has wheels 114, 116 which rotate in tandem.
20 wheels 114, 116 carry spools ll8, l20 about their respective outer face peripheries 122, 124. Continuous filament feeds from these spools to a rotating Eyelet (not shown) between wheels 114, ll6 for depositing the filaments onto mandrel portion 11~. i The eyelet rotates about process mandrel portion 112 with wheels ll4, 116 at a rate, relative axial translation of process mandrel portion 112, which permits a desired angle of fiber disposition.
Figure 6 is a diagrammatic cross-section of resin apt placatory device 130 which is serving to impregnate fiber as discussed in connection with the fabrication sequence of Fig-use 1. Applicator device 130 comprises resin chamber 132.
Fibrous tube 134 carried by process mandrel portion 136 past sues through resin chamber 132 which is circumfexentially sealed at its mandrel entry and Pit orifices by rubber ring seals l38t l40, respectively. Resin coroner 132 is filled continuously with resin ~42 at inlet l44 with liquid resin at a pressure of between about 4 ft. and 8 ft. resin head. Out-let 146 can be used as overflow, if desired. The resin can be any hard enable liquid resin and preferably is vinyl ester thermosettable resin (e.g. Derakane*,from Dow Chemical Co., Midland, Michigan formulated with suitable peroxide catalyst and maintainer at between about 60 and 90F. in chamber l32. The use of vinyl ester resin with peroxide catalyst gives thermosettable resins with appropriate pot lives (e.g.
between about 8 and 12 hours) for shift operations.
Figure 7 is a schetilatic illustration of induction heater device 148 which is serving the function of curing thermoses-table resin as described in reference the tube fabrication sequence in Figure 1. Curing device 148 is mounted on fixed mounts 154 arid has a plurality of induction coils 150 spaced about resin and fiber covered process mandrel portion 152 passing there through. The heating by induction coils 150 is calibrated at various mandrel speeds to permit automatic operation of the tube fabrication.
Figure 8 is a schematic illustration of tube cutting de-vice 156 which is serving to sever hardened tube 158 adjacent thy juncture between joined mandrel segments of the process mandrel as discussed in conjunction with the process steps in Figure 1.
Cutting device 156 has rotating saw blades 164, 166 mounted to rotating disc l68. Rotating disc 168 rotates no-toting saw blades 164, 166 about axis 170 while at the same I time translating longitudinally along this axis 170 (in the direction shown) at the same rate as the joined mandrel sex-mints. Saw blades 164, 166 rotate around their own axes and this axis 170 in severing a cylindrical section (e.g. tube 36, Figure 2) from composite tube 158 on either side of the juncture between the adjacently joined mandrel segments. The plastic sleeve (see Figure 2) underneath the composite tube 158 provides tolerance for the cutting of blades 164, 166.
hydraulically activated clamp 160 grips composite tube 158 and prevents rotation thereof while translating with the moving process mandrel. Clamp 160 moves in tandem with blades 164, 166 along axis 170 while they cut tube 158 and then indexes with them back to the starting yositionO
* denotes trade mark Figure 9 illustrates mandrel release and extraction de-vice 172 which has functions as discussed in connection with the fabrication sequence in Figure 1.
In disconnecting mandrel segments, threaded, hex wrench l74 receives a flex heat portion of a forward mandrel segment, such as Shari my socket end 25 of mandrel segment 10 in Fig-use 2. Wr~llch 174 rotates while clamps in housing 176 pro-vent rotation of the adjacent upstream mandrel segment of process mandrel portion 178 my gripping an intermediate tube lo section such as section 36 in Figure 2. Pistons carrying the hex wrench 174 within housing 180 translate axially in the direction process mandrel travel during engagement of hex wrench 174 with the end of the mandrel segment being disco-noted Also, the clamps are piston loaded in housing 176 so as to allow axial translation with the process mandrel port lion 178 during this disconnecting. Hex wrench 174 and the clamps in housing 176 index after each disconnection operation to their starting positions.
once rotating hex wrench 174 disconnects the terminal segment of the process mandrel, the disconnected segment is moved off line (mechanically, by pistons) to tune extraction vie 182 having extractor 184. Extractor 184 pulls mandrel segment 186 out of tube 188. disconnected mandrel segments, when being drawn from composite tubes, are simultaneously 25 drawn through mold release bath 190. The composite tube 188 once freed can then be sent to storage, or alternatively, sent to a riveting operation which rivets the metal sleeves to the composite tubular members thereby completing manufacture of the drive shaft member.
Figure lo depicts composite tube drive shaft member 200 which is for use in the drive train of a vehicle classified as a light truck. The drive shaft tube member 200 has been made using the techniques discussed in connection with the fabrication sequence of Figure 1. Composite tube 202 carries 35 hollow metal sleeves 204, 206 inside its flared ends 208, 210. Hollow ~iletal sleeves 204, 206 are generally cylindrical in configuration; each of sleeves 204, 206, however, has a wall that thins toward the center of composite tube 202 with an inner diameter that is constant. Because of this thinning I
of the wall of the sleeves 204, 206, there is about a 1 tax per- to each sleeve. Rivets 212, 214 respectively pass through and around flared ends 208, 210 of composite tube 202 and through sleeves 204, 206 in fixing these sleeves 204, 206 in composite tube 202, Rivets 212, 2l4 are added after the tube fabrication sequence of Figure 1 as a separate opera-lion. Alternatively, sleeves such as sleeves 208, 210 can be adhesively bonded to a composite tube such as tube 202 after fabrication thereof.
Rivets 212, 214 each are disposed circumferential about composite tube 202 in a pair of circles. Each circle of rivets has seven rivets making 28 rivets per drive shaft.
Figure lo diagrammatically depicts a wall portion of tube member 200 of Figure 10 that includes a portion of sleeve 206. The wall depicted in Figure lo typifies a wall of a composite tube that can be made in accordance with this invention; the filament in this wall is positioned for trays-milting torque in the drive train of a motor vehicle that would be classified as a light truck.
The wall depicted in Figure lo has distinct, but inked grated zonks of continuous filament and resin. Zone A is composed of four sub zones Al, A, A and A. Each of sub-zones Al, I A and A is a ply of E glass filament in then-most resin matrix. The angle at which the continuous glass filaments art disposed in these sub zones is +45 or ~45 (~30) relative to a line parallel to central longitudinal axis 216 of the composite tube 202 of figure 10. The fife-mints in zone A were deposited at stations B, D, F Andy in the sequence of Figure 1.
zone B comprises sub zones By and By spaced on either side of zone C in Figure loan Each of sub zones By and By has a ply of substantially circumferential disposed contain-use glass filaments. These filaments in zone B are E-glass and disposed desirably at an angle with an absolute value of 35 between about 82 and 88, normally between about 84 and 86, relative to a little parallel to central longitudinal axis 216 of Taipei 202. Tll4 filaments in zone B were deposited at stations J and N in the sequence of Figure 1.
I
zone C of Figure lo comprises carbon or graphite fiber at an angle of zero degrees (+3) relative to a line parallel to central longitudinal axis 216 of tube 202. These carbon or graphite fibers are 36,000 filament. The filaments in zone C were deposited at station L in the sequence of Figure l.
The filaments in composite tube 202 comprise between about 50% and 60% by volume of tube 202, the remainder being a cross linked vinyl ester resin.
In an alternative embodiment, zone B has but a single sly of filament and this single ply is around the outside of zone C. In a variation of this embodiment, zone A has but a single layer of filament, i.e. zones Al and A. In still other applications of this invention, the filaments can ye positioned during manufacture to suit requirements of such other applications.
This application is a division of Canadian Patent Application No. ~30,871, filed June 21, 1983.
Lucy invention relates to manufacture of hollow, file-Monterey composite tubes that can be used, for example, to transmit torque in the drive train of motor vehicles. Fife-Monterey composite tubes have been proposed for reduced weight S shafts in the drive train of motor vehicles. See, for exam-pie, US. Patents 4,17l,626; 4,236,3~6; 4,238,539; 4,238,540 and 4,289,557. See, also, "Development of an Advanced Come posit Tail Rotor Drive shaft" by Zinberg et Al presented at the Thea annual National Forum of the American Helicopter lo Society, Washington, DO June l970.
Fabrication of composite tubes by applying fiber to a cylindrical mandrel is known. See, for example, US. Patents 4,248,062; 4,532,579 and 3,407,101. This invention differs from these prior art techniques in that it provides for suck cessive production of suitably reinforced composite tubes using a continuous tubular mandrel of joined mandrel segments.
US. Patents: 2,714,414 (Gunwale et at.); 3,723,705 Collins); 4,125,423 (Golds worthy); 4,309,865 (Brunch et at.) disclose tube making yrocPsses in which a segmented man-duel body is in relative motion with respect to composite tube forming devices operatively engaging such segmented man-duel body. The present invention is characterized by in pro-cuss aspect as passing a tube-shaped, segmented mandrel come prosing endues joined segments lengthwise through a series of tube fabricating devices for (it forming a resin and fiber tube comprising continuous filamentary reinforcements about said segmented mandrel passing there through (ii) hardening said rosin and fiber tube around said segmented mandrel after said forming; and (iii) s~vertng adjacent the juncture be-tweet adj~c4ntly joined segments of said segmented mandrel the tubular product of said resin and fiber tube that has hardened sufficiently for said severing; as this passage . . . . _ . .
~32~
through said series continues, disconnecting from segmented mandrel the leading segment thereof that carries a composite tube that has been severed from said tubular product in conjunction with connecting a fresh mandrel segment -to the other end of said segmented mandrel as a replacement for such disconnected leading segment; separating the composite -tubes from said mandrel segments that are disconnected from said segmented mandrel to provide said hollow composite tube members.
The above cited patents also disclose machines for implementing each of -the disclosed methods. The machine of the present invention is characterized by; support for passing a segmented mandrel lengthwise through a plurality of longitudinally spaced tube fabricating devices; longitudinally spaced filament applicators -for applying diversely angled continuous filamentary plies to said segmented mandrel atop each other; a reciprocating wrench for periodically joining segments to an end of said segmented mandrel that is upstream Eros said tube fabricating devices; a reciprocating wrench for periodically disconnecting joined segments from an end of said segmented mandrel that is downstream from said tube fabricating stations; a saw for severing a composite tube circumferential, said saw located between the other tube fabricating devices and said downstream wrench.
In one broad aspect, the present invention relates to a hollow, mass produced, filament wound composite tube suited for transmitting -torque in a motor vehicle as par-t of the drive train thereof, said tube in absence of end fittings joining I
said tube to said drive train consisting essentially of continuous filaments in a thermoses resin matrix said continuous filaments disposed in resin and fiber zones integrated together in the wall of said tube by said thermoses resin matrix substantially along lines parallel to -the central longitudinal axis of said tube wherein said resin and fiber zones, proceeding radially from closest to farthest from said center longitudinal axis consist essentially of said thermoses resin matrix and: (a) inner glass filaments disposed (i) in one or more inner glass layers and (ii) at angles, with respect to a line drawn parallel to said longitudinal axis, between about ~30 and +55 and -30 and -55 in respective plies of said one or more inner glass layers; (b) intermediate glass filaments disposed (i) in a single intermediate glass ply, (ii) radially between, and adjacent to, said inner glass layers and a single graphite or carbon ply and (iii) substantially circumferential in the wall around said tube; (c) graphite or carbon filaments disposed (i) in said single graphite or carbon ply, (ii) radially between, and adjacent to, said single intermediate glass ply and a single outer glass ply and (iii) at an angle, with respect to a line parallel to said longitudinal axis, of zero degrees; (d) outer glass filaments disposed (i) in said single outer glass ply and (ii) substantially circumferential in the wall around said tube.
Also disclosed are: a method of manufacturing a hollow composite tube, the subject matter or parent Canadian Patent application No. 430,871, which matured to patent on October 14, 1986 as Canadian Patent Jo. 1,212,529; a machine that manufactures composite tubes, the subject matter of Canadian ~32~
Patent application Jo. 514,909, a division of Canadian patent application Jo. 430,871 filed contemporaneously with the present application; and a segmented mandrel, -the subject matter of Canadian Patent No. 51~,911, a division of Canadian patent application No. 430,871, filed contemporaneously with -the present application.
In the following description of -this invention:
"Process mandrel" means a continuous tubular mandrel formed of discrete mandrel segments joined to each other along their central longitudinal axes and around which a tubular composite can be formed. "Mandrel segment" means a tubular segment that can be connected to and disconnected from the process mandrel.
"Composite tubular member for a light truck" means a fiber and resin tubular body having continuous filaments in thermoses resin, the structural properties of which tubular body are exemplified by critical frequency not to exceed 9~.23Hz, shear torque 56,000 in-lb, buckling torque 56,000 in-lb. "Process mandrel portion" means a longitudinal portion of the process mandrel which includes any number or portion of its joined segments. "Layer" means a pair of filamentary plies, a first of which it disposed a-t a plus or minus first angle relative to a line parallel to an axis and the second of which is disposed a-t a second ankle of about the same magnitude as the first angle but the negative /
~=~
~23~
thereof relative to such line. ply" means a group of fife-mints disposed at the substantially same angle in a geometric plane concentric with a mandrel portion which plural is nor-molly cylindrical or substantially cylindrical in this invention.
Figure 1 outlines diagrammatically a process sequence that utilizes this invention in producing composite tubes thereof, Figure 2 schematically depicts a cross section of end portions of two joined mandrel segments used in practicing this invention. The end portions are depicted with the come posit tubes they carry after the cutting operation in the sequence of Figure 1.
Figure 3 schematically depicts in perspective an apply-actor for applying helically disposed fibers to a process mandrel portion passing through the applicator.
Figure PA is a detail of the annular deposition ring as-symbol of a wheel depicted in Figure 3.
Figure 4 schematically depicts in perspective an apply-actor for applying longitudinally disposed fibers to a pro-cuss mandrel portion passing through the applicator down stream from the portion of Figure 3.
Figure assay a detail of fiber application ring of an applicator in Figure 4.
Figure 5 schematically depicts in perspective an apply-actor for applying circumferential disposed fibers to a process mandrel portion passing through the applicator down-stream from the portion of Figure 4 or Figure 3.
Figure 6 schematically depicts a cross section of a resin applicator chamber for impregnating fiber carried by a process mandrel portion passing through the chamber down-stream from the portion of Figure 5.
Figure 7 schematically depicts in perspective a bank of induction coils used to cure a resin and fiber tube carried by a process mandrel portion passing through the coils down-sternly from the portion of Figure 6.
Figure 8 schematically depicts in perspective a two blade rotating cutting wheel for cutting a moving tube of I
hardened resin and fiber produced in accordance with this in-mention arid carried by a process mandrel portion downstream from the portion of Figure 7.
Figure g schematically depicts in perspective an into-grated device that disconnects mandrel segments and subset quaintly draws a composite tube from each of the disconnected mandrel segments. The mandrel segment being disconnected is downstrearll of the process mandrel portion of Figure 8.
Figure 10 is a view of a drive shaft member of this in-mention in elevation, including end fittings.
Figure lo is a diagrammatic depiction of a wall portion of the coïnposite of Figure 10.
Figure 1 shows the fabrication steps which result in composite drive shaft tubes for light trucks in accordance with this invention. The fabrication sequence is illustrated in Figure l as a series of steps set forth in the order in which the tubes asp made.
In general, endues joined segments of a process mandrel sequentially proceed lengthwise through the tube fabricating stations identified in the fabrication sequence of Figure 1.
In the final tube forming;operatiorl, however, individual man duel segment ox the process mandrel are disconnected and a completed composite tube is extracted from each disconnected segment, the latter occurring off line from steps that pro-cede it. Also, in the beginning of this process sequence afresh mandrel segment is periodically joined to the rear man-duel segment of the process mandrel. The fresh mandrel sex-merit being joined to the process mandrel may have a cylinder-eel metal sleeve around either or both of its ends whereby the metal sleeve becomes integrated into the composite tube produced by the sequence of Figure 1.
t the beginning of the tube fabricating process so-quince depicted in Figure 1, a mandrel segment, as mentioned, is joined to the rear of a previously assembled process man duel at joining station A. The process mandrel comprises number of connected segments which together have a common central longitudir,~l axis. (See Figure 2 for a cross-section of two joined mandrel segments). Hand over hand clamps at I
station R continually pull the process mandrel away from joining station A and through the other tube fabricating stations that art downstream thereof.
A moving grip jaw at station prevents rotation of the moving process mandrel. The grip jaw holds the process man-duel while thy unconnected, fresh mandrel segment is spun into locking engagement with, and becomes the rear segment of, the process mandrel proceedinc3 as a train of seglnents through downstream tube fabricating operations. An upstream ball rail mounted wrench rotates in spinning this unconnected mandrel segment into the locking relation at station A. The rotating wrench translates in a downstream direction long-tudinally along the upstream extension of the process mandrel central longitudinal axis in joining the new mandrel segment to the process mandrel. A bed of rollers carry the end of the process mandrel and the mandrel segment being joined thereto during the joining operation. The rollers are rota able in the directiorl that the process mandrel proceeds.
At station B dry fiber is deposited around the portion of the process mandrel that proceeds there through. Station B
comprises a helical applicator. The helical applicator de-posits a ply or plies of continuous filaments either at an angle between about +35 and +55 or between about -35 and -55 relative to a line parallel to the central longitudinal axis of thy process mandrel. There are four helical applique-ions in the fabrication sequence of Figure 1, labeled B, D, F
and Al, each of which applicators deposits a ply or pair of plies at an angle within the above ranges.
Helical applicators of station B, D, F and H each come prose a wheel having a plurality of fiber carrying spools spaced about its periphery. The wheels of adjacent stations rotate at similar rates (but opposite each other in spinning the continuous filaments about the process mandrel from these spools see Figure 3 for a view of the two counter rotating wheels). AS a result of passage of the process mandrel through fiber deposition at these wheels, segments of the process mandrel are covered with a layer or layers of con-tenuous foments, as desired. For example, two layers of continuous filamerlt can be deposited by stations B, Do F and H. Unmaking light truck drive shaft tubes, each pair of the stations deposits a layer of filament. The layer has a +45 ply and a -~5 ply where these ankles are each relative to a line parallel to the central longitudinal of the process mandrel.
In making these truck drive shaft tubes, each of stay lions B, D, F and H deposits between about .02~ and .334 lobs of fiber per linear foot of the process mandrel. Each of these station B, DO and H can utilize up to 80 rovings with yields of 113 and 1~00 yards. per lb. where the rovings each comprise E-glass filaments.
Stations C, E, G, I, K, M and o in the sequence of Fig-use l provide for impregnation of the fiber deposited on the process mandrel. Station C like the other of these stations (except station o) includes a resin impregnation coralberry. (A
cross-section of a typical resin impregnation chamber appears in Figure 6.) Station o utilizes a tubular conduit communicating with, and suspended from, a resin supply tank for direct applique-lion of resin. The resin passes through the conduit and onto the passing fiber and resin tube proceeding from station N.
The resin is worked into the passing fiber at station O by a downstream roller such as a paint roller that continuously circles the segmented mandrel. A rotating elastomers wiper blaze downstream of this roller wipes resin from the fiber.
Impregnation alternatively, however, can occur by means of impregnation chamber or such direct application at any or all of stations C, E, G, I, K, M and O. For example, station M could be omitted.
The process mandrel proceeds through the impregnation chamber of stations C, E, G, I, K, I and o (and the other stations) at any desired rate preferably between 1.5 and 6 feet per minute in the sequence being described. it these rates, the fiber absorbs about an equal volume of thermoses-table resin. Fiber wetting reaches an equilibrium at about 50 percent of the total composite volume. Additional impreg-nation stations do not significantly affect the fiber to resin ratio.
Station J in the sequence of Figure 1 deposits dry fiber around the process mandrel over the impregnated fixers there-of as it proceeds from the impregnation at station I. Stay lion J comprises a rotating hoop applicator wheel that no-tats to wind a band of continuous fiber as it spins around the moving process mandrel. (See Figure 5 for a view of this wheel). The hoop applicator applies a ply of continuous lit-amens to the moving process mandrel at an angle between about either +80 or ~80 and 90 relative to a line parallel to the central longitudinal axis of the process mandrel.
For a truck drive shaft tube made using a process man-duel having a four inch diameter and proceeding at a rate dPscrib~d the hoop applicator spins around the process man-duel at between about 18 and 72 rum in depositing a 1 inch wide band of Glass filaments that contains of between ll3 and 1800 yards. per lb.
Station L deposits continuous graphite filaments about the fiber wound and resin impregnated process mandrel pro-ceding from stations J and K respectively. Station L depose its continuous filaments about the process mandrel at annoyingly of about 0 relative to a line parallel to the long-tudinal axis of the process mandrel. Station L preferably utilizes two or more longitudinally spaced distribution rings. Rovings pass through these rings and then lay upon the previously fiber covered and resin impregnated process mandrel as it travels through the rings. see Figure 4 for a view of the longitudinally spaced applicators of station L).
The rings each comprise an orifice which encircles the process mandrel; the rings each have holes spaced around their peripheries. The holes guide the rovings as they lay upon the fixer covered and resin impregnated process mandrel proceeding through the rings from station K or from an up-stream ring of station L. Holes of the adjacent distribution rinks are offset from each other so that the yarns or rovings are lazed all around the fiber covered and resin impregnated process mandrel.
I
The yarns or rovings at station h have between about 1200U and 36000 filaments per roving in making the truck drive shaft composite tubes. The yarn or roving in making these drive shaft tubes comprise graphite filaments that are S Graphite Together these filaments weigh between about 0.l~7 and U.328 lobs per linear foot of the process mandrel after exit from station, L. The rovings issue from the disk tribution rings at up to about six feet per minute in making such tubes.
lo Station N (of the sequence of Figure l) wraps the long-tudinally disposed filaments carried on the process mandrel from station L with a hoop ply of dry filaments The hoop ply is deposited by rotating hoop wheel applicator such as discussed in reference to station J. Stations J and N each deposit the hoop ply of dry fiber at plus and minus angles of either between about ~80D and 90~ or between about -80 and 90 relative to a line parallel to the center longitudinal axis of the process mandrel in making the truck drive shaft composite tubes.
station o applies liquid thermosetting resin to the it-bier and resin covered process mandrel proceeding from station N, as described above.
The fiber and resin covered process mandrel, impregnated at station o then proceeds therefrom to station P which in-shuts cure of the thermosettable resin, station P being shown in the sequence of Figure l.
A plurality of induction coils initiate this cure at station P. (The device carrying these induction coils is de-plated schematically in Figure 7). The induction coils pro-vise a sufficient temperature increase in the resin to result ultimately in a cure thereof. Generally in making the truck drive shaft tubes, the temperature of a mandrel segment leaving station P desirably will be between about 250F and 325F, when using vinyl ester thermosettable resin such as Darken from Dow Chemical Corp.
station Q of the sequence depicted in FicJure l comprises infrared heaters. The heaters increase the outside skin temperature to 200F. bank of five infrared heaters are Jo I
monotype around a 6 foot long cylinder. Station Q eliminates surface tack which may exist when curing thermosettable rosin cor.tainin~ a styrenes monomer in air.
Some distance exists between station Q and station R.
S Station R of the sequence depicted in Figure 1 grips the hardened resin tub proceeding from station Q. Station P
grips the composite tube sufficiently to pull it through the proceedirlg stations. Station R has two land over hand grip-ping clamps. The hand over hand gripping mechanism may be lo purchased from Golds worthy Engr. of Torrance, Cal.
Station S of the process sequence depicted in Figure 1 severs the hardened tune proceeding from station R. Station S comprises a pair of rotating saw blades. The saw blades cut the curing or cured tube around either side of the junk-lure between two joined mandrel segments of the process man-duel. The blades rotate about the process mandrel to sever a composite tube completely from the upstream portion thereof.
(See Figure 8 for a view of the cutter. The short cylinder-eel section of composite tube formed between the blades by the cutting action thereof is removed at station U during the pulling of the mandrel segments from their respective compost tie tubes.) The blades translate along a line parallel to the central longitudinal axis of the process mandrel in so-vexing the cured tube as it proceeds through station S.
After the tube is severed, the blades together translate upstream to their starting position.
Station T of the process sequence identified in Figure 1 disconnects the mandrel segment carrying a severed tube from the rest of the process mandrel. A clamping jaw at station T
prevents rotation of the process mandrel by gripping an up-stream portion thereof around the cured composite tune that it carries. The downstream joined mandrel segment is then disconnected from the rest of the process mandrel by a rotate in hex wrench at station T. The rotating hex wrench engages the leading mandrel segment (carrying the composite tube so-vexed at station I) and spins it free of the moving upstream train of joined mandrel segments. (See Figure 9 for schema-tic Yo-yo of the mandrel segment disconnecting and tube extracting device combination.) 23~
The disconnected mandrel segment carrying the cured come posit tube proceeds to station of the process sequence de-plated in Figure 1. Station U is at the side of the main machine axis. The composite tube is extracted from the disk connect mandrel segment in an extraction die. The disco-netted mandrel segment is pulled through the extraction die stripping the cured composite tube. The disconnected mandrel sec3inent proceeding from the extraction die, now free of the cured composite tube, then proceeds to station V which con-lo twins a mold release bath. Thy freed mandrel segment instill at elevated temperature (e.g. 130F.) as it enters this mold release bath. The elevated temperature helps bake the mold release of the extracted mandrel segment.
The cured composite tubular member, when freed of the disconnected mandrel segment, can be rolled to a storage cart. The mandrel segment, when freed of the cured composite tubular member can be returned to station A for further use.
The composite tubular member when used in a truck drive shaft can incorporate a metal sleeve at each end The metal sleeve can be adhesively bonded within, or on the outside of, the tube. Alternately each mandrel segment can carry metal sleeves at its ends through the fabrication sequence of Fig-use 1. These sleeves act as parts of the mandrel segment in that the composite tube is formed about them. A riveting opt oration can rivet the sleeves in this latter case to the come posit tubular member after completion of tube manufacture (i.e. after station V).
The method of this invention has been described in a tube fabrication sequence suited for making truck drive shaft conlposit~ tubes. As, however, may be apparent, such sequence is but illustrative of the many sequences that can be used in making these or other composite tubular members using prince-pies of this invention. Another sequence is A, B, C, D, E, J, K, L, M, N, P, Q, R, S, T, U and V; different combinations of fiber yield and numbers of rovings can also be employed in any of these sequences.
Figures 2 through 9 illustrate equipment identified in prevails description of the process sequence of Figure 1.
Figure 2 is a cross-section of the joined ends of two cylindrical mandrel SegTnentS 10, 12 that are used in making composite drive shaft tubes for certain light trucks in con-section with the process sequence of Figure 1. Joined man-duel segments 10, 12 have cylindrical steel sleeves lo, wish slip over their respective ends. Plastic sleeve 18 fits cylindrically about and between adjoining en portions of steel sleeves 14, 16 and between segments 10, 12.
The opposite ends (not shown) of each mandrel segments 10, 12 are configured to permit their respective joining with other mandrel segments. -Mandrel segment male member 20 is bolted to mandrel sex-mint 12 and has integral male acme threads 22 for connecting mandrel segment 12 to mandrel segment lo Mandrel segment 10 lo has socket 24 with threads 26 for receipt of threads 22 in locking relation. mandrel segment it joins to mandrel sex-mint 12 with relative rotation between them of between about 1 and 2 revolutions. The unthreaded portion of male member 20 guides the approach and retreat of mandrel segment 12 to and from mandrel segment 12.
Mandrel segments lo 12 depicted in Figure 2 have pro-ceded through tube cutting station S in the sequence of Fig-use 1. Circumferential spaces 28, 30 depict where station S
has severed the composite tube carried by the mandrel sex-mints 10, 12. Mandrel seglilent lo leads mandrel segment 10 in this sequence in the direction shown in Figure 2. Accord-tingly, mandrel segments 10, 12 carry downstream cured compost tie tube 32, upstream composite tube 34 and intermediate come posit tube 36. Downstream composite tube 32 becomes, with sleeve 16 and a sleeve (not shown) at the other end of man-duel segment 12, a drive shaft member of this invention after it is separated from mandrel segment 12. Upstream composite tube 34 becomes another drive shaft member with sleeve 14 (and other sleeve) once tube 34 is severed and the severed tube separated from mandrel segment lo Intermediate compost tie tube 36 remains with mandrel segment 10 after disco-section of mandrel segment 12 therefrom until stripping of tube 34 from mandrel segnl~nt 10 at station U.
. . . .
Jo $
_ 14 -Int~r~diate composite tube 36 has been cut out at tube cutting station S. Plastic sleeve 18 serves to provide tolerance in the depth of this cut.
Figure 3 depicts an apparatus which is depositing fiber about process mandrel portion 38 as it passes through wheels 40, 42 carried by respective fixed mounts 44 and 46. Each of wheels I 42 has a plurality of spools (a few pairs of which are depicted as respectively, 48, 50 and 52, 54) of continue out filament fixed around their respective faces 56, 58 and 60, 62. The wheels counter rotate, such as in the directions shown in figure 3, in depositing continuous filaments about process mandrel portion 38 as discussed above in connection with stations B and D and F and H of Figure 1. Resin impregnation chamber 64 is between wheels 40, 42.
Continuous filaments from spools 48, 50 and 52, 54 pass to respective annular deposition ring assemblies 66~ 68 which rotate with their respective wheels 40, 42. This fiber past sues through holes in the annular ring assemblies 66, 68 for orientation onto process mandrel portion 380 The speed at which wheels 40, 42 and consecluently rings assemblies 66, 68 rotate relative to the axial translation of process mandrel portion 3B through these ring assemblies determines the angle at which the fixers deposit on process mandrel portion 38.
Figure PA is a detail of ring assembly 66 of Figure 3 Continuous filament 70 feeds from plastic tubes such as 72 and through holes such as 74, 76 respectively in orienting plates 78, 80. Tubes 72 serve to protect filaments 70 and unable ready threading thereof from the spools (e 9. 48, 50) of filaments.
Figures 4 and PA schematically illustrate longitudinal fixer applicator 82 which is depositing continuous filaments longitudinally (relative the center longitudinal axis of pro-cuss mandrel portion 84) along the process mandrel. Spaced fiber disposition rings 86, 88, 90, 92 permit issuance of continuous fixer passing from remote spools or creels (not shown) through their respective offset holes 94, 96, 98 and 100. Holes 94, 96, 98 and 100 are respectively spaced about segmented mandrel portion 84 in these rings 86, 88, 90, 92.
, . . , _ .. _ , .. . . ...
I
There are about 51 holes in each of the spaced disposition rings 86, 88, 90, 92. Each individual hole in holes 94, 96, I and loo receives up to about 36000 or more filaments.
Conduits 102, 104, 106, 108 lead from the creels to respect live holes I 96, 98 and 100 to maintain alignment of thriving or yarn passing to each of these holes. The roving or yarn issue from these holes to process mandrel portion 84 without any surrounding conduit.
In making the light truck composite tubes, there are lo four rings longitudinally spaced between about 12 and 18 in-ekes from each other. These rings deposit continuous fife-mints at a zero degree ankle relative to a line parallel to the central longitudinal axis of the process mandrel.
Figure 5 schematically illustrates device 110 that is depositing fiber circumferential about process mandrel port lion 112. Device 110 serves the function of providing hoop windings in the fabrication sequence of Figure 1 and rotatable mounts to fixed mount 128.
Device 110 has wheels 114, 116 which rotate in tandem.
20 wheels 114, 116 carry spools ll8, l20 about their respective outer face peripheries 122, 124. Continuous filament feeds from these spools to a rotating Eyelet (not shown) between wheels 114, ll6 for depositing the filaments onto mandrel portion 11~. i The eyelet rotates about process mandrel portion 112 with wheels ll4, 116 at a rate, relative axial translation of process mandrel portion 112, which permits a desired angle of fiber disposition.
Figure 6 is a diagrammatic cross-section of resin apt placatory device 130 which is serving to impregnate fiber as discussed in connection with the fabrication sequence of Fig-use 1. Applicator device 130 comprises resin chamber 132.
Fibrous tube 134 carried by process mandrel portion 136 past sues through resin chamber 132 which is circumfexentially sealed at its mandrel entry and Pit orifices by rubber ring seals l38t l40, respectively. Resin coroner 132 is filled continuously with resin ~42 at inlet l44 with liquid resin at a pressure of between about 4 ft. and 8 ft. resin head. Out-let 146 can be used as overflow, if desired. The resin can be any hard enable liquid resin and preferably is vinyl ester thermosettable resin (e.g. Derakane*,from Dow Chemical Co., Midland, Michigan formulated with suitable peroxide catalyst and maintainer at between about 60 and 90F. in chamber l32. The use of vinyl ester resin with peroxide catalyst gives thermosettable resins with appropriate pot lives (e.g.
between about 8 and 12 hours) for shift operations.
Figure 7 is a schetilatic illustration of induction heater device 148 which is serving the function of curing thermoses-table resin as described in reference the tube fabrication sequence in Figure 1. Curing device 148 is mounted on fixed mounts 154 arid has a plurality of induction coils 150 spaced about resin and fiber covered process mandrel portion 152 passing there through. The heating by induction coils 150 is calibrated at various mandrel speeds to permit automatic operation of the tube fabrication.
Figure 8 is a schematic illustration of tube cutting de-vice 156 which is serving to sever hardened tube 158 adjacent thy juncture between joined mandrel segments of the process mandrel as discussed in conjunction with the process steps in Figure 1.
Cutting device 156 has rotating saw blades 164, 166 mounted to rotating disc l68. Rotating disc 168 rotates no-toting saw blades 164, 166 about axis 170 while at the same I time translating longitudinally along this axis 170 (in the direction shown) at the same rate as the joined mandrel sex-mints. Saw blades 164, 166 rotate around their own axes and this axis 170 in severing a cylindrical section (e.g. tube 36, Figure 2) from composite tube 158 on either side of the juncture between the adjacently joined mandrel segments. The plastic sleeve (see Figure 2) underneath the composite tube 158 provides tolerance for the cutting of blades 164, 166.
hydraulically activated clamp 160 grips composite tube 158 and prevents rotation thereof while translating with the moving process mandrel. Clamp 160 moves in tandem with blades 164, 166 along axis 170 while they cut tube 158 and then indexes with them back to the starting yositionO
* denotes trade mark Figure 9 illustrates mandrel release and extraction de-vice 172 which has functions as discussed in connection with the fabrication sequence in Figure 1.
In disconnecting mandrel segments, threaded, hex wrench l74 receives a flex heat portion of a forward mandrel segment, such as Shari my socket end 25 of mandrel segment 10 in Fig-use 2. Wr~llch 174 rotates while clamps in housing 176 pro-vent rotation of the adjacent upstream mandrel segment of process mandrel portion 178 my gripping an intermediate tube lo section such as section 36 in Figure 2. Pistons carrying the hex wrench 174 within housing 180 translate axially in the direction process mandrel travel during engagement of hex wrench 174 with the end of the mandrel segment being disco-noted Also, the clamps are piston loaded in housing 176 so as to allow axial translation with the process mandrel port lion 178 during this disconnecting. Hex wrench 174 and the clamps in housing 176 index after each disconnection operation to their starting positions.
once rotating hex wrench 174 disconnects the terminal segment of the process mandrel, the disconnected segment is moved off line (mechanically, by pistons) to tune extraction vie 182 having extractor 184. Extractor 184 pulls mandrel segment 186 out of tube 188. disconnected mandrel segments, when being drawn from composite tubes, are simultaneously 25 drawn through mold release bath 190. The composite tube 188 once freed can then be sent to storage, or alternatively, sent to a riveting operation which rivets the metal sleeves to the composite tubular members thereby completing manufacture of the drive shaft member.
Figure lo depicts composite tube drive shaft member 200 which is for use in the drive train of a vehicle classified as a light truck. The drive shaft tube member 200 has been made using the techniques discussed in connection with the fabrication sequence of Figure 1. Composite tube 202 carries 35 hollow metal sleeves 204, 206 inside its flared ends 208, 210. Hollow ~iletal sleeves 204, 206 are generally cylindrical in configuration; each of sleeves 204, 206, however, has a wall that thins toward the center of composite tube 202 with an inner diameter that is constant. Because of this thinning I
of the wall of the sleeves 204, 206, there is about a 1 tax per- to each sleeve. Rivets 212, 214 respectively pass through and around flared ends 208, 210 of composite tube 202 and through sleeves 204, 206 in fixing these sleeves 204, 206 in composite tube 202, Rivets 212, 2l4 are added after the tube fabrication sequence of Figure 1 as a separate opera-lion. Alternatively, sleeves such as sleeves 208, 210 can be adhesively bonded to a composite tube such as tube 202 after fabrication thereof.
Rivets 212, 214 each are disposed circumferential about composite tube 202 in a pair of circles. Each circle of rivets has seven rivets making 28 rivets per drive shaft.
Figure lo diagrammatically depicts a wall portion of tube member 200 of Figure 10 that includes a portion of sleeve 206. The wall depicted in Figure lo typifies a wall of a composite tube that can be made in accordance with this invention; the filament in this wall is positioned for trays-milting torque in the drive train of a motor vehicle that would be classified as a light truck.
The wall depicted in Figure lo has distinct, but inked grated zonks of continuous filament and resin. Zone A is composed of four sub zones Al, A, A and A. Each of sub-zones Al, I A and A is a ply of E glass filament in then-most resin matrix. The angle at which the continuous glass filaments art disposed in these sub zones is +45 or ~45 (~30) relative to a line parallel to central longitudinal axis 216 of the composite tube 202 of figure 10. The fife-mints in zone A were deposited at stations B, D, F Andy in the sequence of Figure 1.
zone B comprises sub zones By and By spaced on either side of zone C in Figure loan Each of sub zones By and By has a ply of substantially circumferential disposed contain-use glass filaments. These filaments in zone B are E-glass and disposed desirably at an angle with an absolute value of 35 between about 82 and 88, normally between about 84 and 86, relative to a little parallel to central longitudinal axis 216 of Taipei 202. Tll4 filaments in zone B were deposited at stations J and N in the sequence of Figure 1.
I
zone C of Figure lo comprises carbon or graphite fiber at an angle of zero degrees (+3) relative to a line parallel to central longitudinal axis 216 of tube 202. These carbon or graphite fibers are 36,000 filament. The filaments in zone C were deposited at station L in the sequence of Figure l.
The filaments in composite tube 202 comprise between about 50% and 60% by volume of tube 202, the remainder being a cross linked vinyl ester resin.
In an alternative embodiment, zone B has but a single sly of filament and this single ply is around the outside of zone C. In a variation of this embodiment, zone A has but a single layer of filament, i.e. zones Al and A. In still other applications of this invention, the filaments can ye positioned during manufacture to suit requirements of such other applications.
Claims (10)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:-
1. A hollow, mass produced, filament wound composite tube suited for transmitting torque in a motor vehicle as part of the drive train thereof, said tube in absence of end fittings joining said tube to said drive train consisting essentially of continuous filaments in a thermoset resin matrix, said continuous filaments disposed in resin and fiber zones integrated together in the wall of said tube by said thermoset resin matrix substantially along lines parallel to the central longitudinal axis of said tube wherein said resin and fiber zones, proceeding radially from closest to farthest from said center longitudinal axis consist essentially of said thermoset resin matrix and:
(a) inner glass filaments disposed (i) in one or more inner glass layers and (ii) at angles, with respect to a line drawn parallel to said longitudinal axis, between about +30°
and +55° and -30° and -55° in respective plies of said one or more inner glass layers;
(b) intermediate glass filaments disposed (i) in a single intermediate glass ply, (ii) radially between, and adjacent to, said inner glass layers and a single graphite or carbon ply and (iii) substantially circumferentially in the wall around said tube;
(c) graphite or carbon filaments disposed (i) in said single graphite or carbon ply, (ii) radially between, and adjacent to, said single intermediate glass ply and a single outer glass ply and (iii) at an angle, with respect to a line parallel to said longitudinal axis, of zero degrees;
(d) outer glass filaments disposed (i) in said single outer glass ply and (ii) substantially circumferentially in the wall around said tube.
(a) inner glass filaments disposed (i) in one or more inner glass layers and (ii) at angles, with respect to a line drawn parallel to said longitudinal axis, between about +30°
and +55° and -30° and -55° in respective plies of said one or more inner glass layers;
(b) intermediate glass filaments disposed (i) in a single intermediate glass ply, (ii) radially between, and adjacent to, said inner glass layers and a single graphite or carbon ply and (iii) substantially circumferentially in the wall around said tube;
(c) graphite or carbon filaments disposed (i) in said single graphite or carbon ply, (ii) radially between, and adjacent to, said single intermediate glass ply and a single outer glass ply and (iii) at an angle, with respect to a line parallel to said longitudinal axis, of zero degrees;
(d) outer glass filaments disposed (i) in said single outer glass ply and (ii) substantially circumferentially in the wall around said tube.
2. A mass produced, filament wound composite tube in accordance with claim 1, wherein said glass filaments comprise E-glass.
3. A mass produced, filament wound composite tube in accordance with claim 1, wherein said angle between 35° and 55° is45°.
4. A mass produced, filament wound composite tube in accordance with claim 3, wherein said angle between 35° and -55°
is -45°.
is -45°.
5. A mass produced, filament wound composite tube in accordance with claim 4, wherein said resin is polyvinyl resin, crosslinkable with peroxide.
6. A mass produced, filament wound composite tube in accordance with claim 5, wherein there are 36,000 filaments of graphite or carbon in tows making up said (c).
7. A drive shaft member comprising a mass produced, filament wound composite tube in accordance with claim 3, having a pair of open ended, hollow sleeves respectively riveted to each of its ends within said filament wound composite tube.
8. A drive shaft member in accordance with claim 7, wherein each of said sleeves is riveted to said filament wound composite tube through said sleeve and the wall of said filament wound composite tube by a plurality of independent rivets connected together solely through connection to either of said sleeves alone and said composite tube.
9. A drive shaft member in accordance with claim 7, wherein the rivets circumferentially extend around said sleeve and tube.
10. A drive shaft member in accordance with claim 3, wherein filament wound composite tube has flared ends into which metal sleeves respectively fit.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000514910A CA1232146A (en) | 1982-07-08 | 1986-07-29 | Manufacture of filamentary composites |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US39653682A | 1982-07-08 | 1982-07-08 | |
| US396,536 | 1982-07-08 | ||
| CA000430871A CA1212529A (en) | 1982-07-08 | 1983-06-21 | Manufacture of filamentary composites |
| CA000514910A CA1232146A (en) | 1982-07-08 | 1986-07-29 | Manufacture of filamentary composites |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000430871A Division CA1212529A (en) | 1982-07-08 | 1983-06-21 | Manufacture of filamentary composites |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1232146A true CA1232146A (en) | 1988-02-02 |
Family
ID=25670070
Family Applications (3)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000514909A Expired CA1232434A (en) | 1982-07-08 | 1986-07-29 | Apparatus for manufacture of filament-wound composite tubes |
| CA000514910A Expired CA1232146A (en) | 1982-07-08 | 1986-07-29 | Manufacture of filamentary composites |
| CA000514911A Expired CA1232435A (en) | 1982-07-08 | 1986-07-29 | Mandrel for manufacture of filament-wound composite tubes |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000514909A Expired CA1232434A (en) | 1982-07-08 | 1986-07-29 | Apparatus for manufacture of filament-wound composite tubes |
Family Applications After (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000514911A Expired CA1232435A (en) | 1982-07-08 | 1986-07-29 | Mandrel for manufacture of filament-wound composite tubes |
Country Status (1)
| Country | Link |
|---|---|
| CA (3) | CA1232434A (en) |
-
1986
- 1986-07-29 CA CA000514909A patent/CA1232434A/en not_active Expired
- 1986-07-29 CA CA000514910A patent/CA1232146A/en not_active Expired
- 1986-07-29 CA CA000514911A patent/CA1232435A/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| CA1232434A (en) | 1988-02-09 |
| CA1232435A (en) | 1988-02-09 |
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