CN114829183A - 具有结合的端部叉的复合车辆传动轴组件及其生产方法 - Google Patents

具有结合的端部叉的复合车辆传动轴组件及其生产方法 Download PDF

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Publication number
CN114829183A
CN114829183A CN202080086979.2A CN202080086979A CN114829183A CN 114829183 A CN114829183 A CN 114829183A CN 202080086979 A CN202080086979 A CN 202080086979A CN 114829183 A CN114829183 A CN 114829183A
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CN
China
Prior art keywords
peripheral surface
sleeve
fork
composite
tube
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Pending
Application number
CN202080086979.2A
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English (en)
Inventor
詹姆斯·李·多尔曼
丹尼尔·P·伦切
格雷格·皮珀
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Composite Transmission System Co ltd
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Composite Transmission System Co ltd
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Publication date
Application filed by Composite Transmission System Co ltd filed Critical Composite Transmission System Co ltd
Publication of CN114829183A publication Critical patent/CN114829183A/zh
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C3/00—Shafts; Axles; Cranks; Eccentrics
    • F16C3/02—Shafts; Axles
    • F16C3/026—Shafts made of fibre reinforced resin
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C3/00—Shafts; Axles; Cranks; Eccentrics
    • F16C3/02—Shafts; Axles
    • F16C3/023—Shafts; Axles made of several parts, e.g. by welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B29C65/4835—Heat curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B29C65/54—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive between pre-assembled parts
    • B29C65/542—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive between pre-assembled parts by injection
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/1222—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a lapped joint-segment
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/1224—Joint cross-sections combining only two joint-segments, i.e. one of the parts to be joined comprising only two joint-segments in the joint cross-section comprising at least a butt joint-segment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/342—Preventing air-inclusions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/52—Joining tubular articles, bars or profiled elements
    • B29C66/524—Joining profiled elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/61—Joining from or joining on the inside
    • B29C66/612—Making circumferential joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • F16D1/06—Couplings for rigidly connecting two coaxial shafts or other movable machine elements for attachment of a member on a shaft or on a shaft-end
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    • F16D1/068—Couplings for rigidly connecting two coaxial shafts or other movable machine elements for attachment of a member on a shaft or on a shaft-end non-disconnectable involving gluing, welding or the like
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    • F16D3/38—Hooke's joints or other joints with an equivalent intermediate member to which each coupling part is pivotally or slidably connected with a single intermediate member with trunnions or bearings arranged on two axes perpendicular to one another
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    • F16C2226/40—Material joints with adhesive
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2326/00—Articles relating to transporting
    • F16C2326/01—Parts of vehicles in general
    • F16C2326/06—Drive shafts
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C2361/00—Apparatus or articles in engineering in general
    • F16C2361/41—Couplings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T403/00—Joints and connections
    • Y10T403/47—Molded joint
    • Y10T403/473—Socket or open cup for bonding material

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  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Ocean & Marine Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Shafts, Cranks, Connecting Bars, And Related Bearings (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)

Abstract

一种复合车辆传动轴组件(10)，其包括复合管(40)以及结合至管(40)的端部中的一个端部的叉(12、14)。叉具有被同轴地接纳在管(40)的端部中的内部套筒(56)。该套筒(56)具有面向管(40)的内周表面(58)的外周表面(60)，其中，在管的内周表面与套筒的外周表面之间形成有腔(70)。在所述叉中形成有粘合剂注射通道(74)，并且该粘合剂注射通道从形成在叉的轴向表面中的入口(76)以锐角延伸至形成在套筒的外周表面中并通向腔(70)的出口。还公开了一种将这种传动轴组件的叉结合至复合管的方法。

Description

具有结合的端部叉的复合车辆传动轴组件及其生产方法
相关申请的交叉引用
本申请要求于2019年10月15日提交的、题为“COMPOSITE VEHICLE DRIVESHAFTASSEMBLY WITH BONDED END YOKE(具有结合的端部叉的复合车辆传动轴组件)”、序列号为62/915,370的美国临时专利申请以及于2019年10月15日提交的、题为“COMPOSITE VEHICLEDRIVESHAFT ASSEMBLY(复合车辆传动轴组件)”、序列号为62/915,427的美国临时专利申请的优先权，上述两个美国临时专利申请中的每个美国临时专利申请的全部内容在此通过参引并入本文中。
技术领域
本发明总体上涉及车辆推进轴或传动轴，车辆推进轴或传动轴包括部分地由复合材料制成的一个或多个管状部段。本发明还涉及具有结合至复合管的端部的叉的复合车辆传动轴组件，并且本发明还涉及生产这种传动轴的过程以及生产这种传动轴组件的方法。
背景技术
可获得复合传动轴组件，这是使旋转组件减轻重量的努力的结果。这样的传动轴组件具有由树脂黏附螺旋缠绕丝形成的长管状部段以及呈金属传动系部件(比如叉、挠性接头等)形式的端部联接器或接头。然而，复合传动轴组件还没有广泛应用于车辆用途。设计具有连接至金属部件、比如常规车辆传动系部件的复合管的复合传动轴组件提出了许多挑战。
例如，复合管在与其他传动轴应用基本上不同的使用环境中操作。车辆传动轴在使车辆传动轴暴露于高的操作温度和大的温度变化的热包封件中操作，以高的旋转速度和大的旋转速度变化操作，并经历大量的扭转载荷条件、比如冲击载荷和/或其他极端扭矩峰值，并且受到更严格的直径限制及其他尺寸限制。
将复合管连接至其他传动系部件、比如叉提出尤其困难的挑战。难以设计并组装接头、配件或适配器以从复合管过渡至叉或其他端部联接器，所述叉或其他端部联接器能够在处理这些操作条件时保持与复合管的连接完整性并且还是足够可制造的和经济性的。由于复合管不能够进行焊接，所以必须将复合管结合至端部联接器。一种方法是将复合管的端部的内表面结合至端部联接器的外表面。必须在管和/或端部联接器中设置孔，以允许在管与端部联接器之间注射粘合剂。然而，在管中钻出径向孔会削弱管。这些孔也易于被松散的丝堵塞，从而阻碍或阻止粘合剂的注射。
因此，需要提供一种复合传动轴组件，该复合传动轴组件具有复合管，该复合管牢固且可靠地结合至端部叉而不会不可接受地削弱复合管或端部叉。
此外，还需要提供一种将复合管结合至端部以形成复合传动轴组件的方法。
发明内容
根据本发明的第一方面，一种复合车辆传动轴组件包括复合管，该复合管具有在该管的输入端部与输出端部之间纵向延伸的管侧壁。叉被结合至管的端部中的一个端部。叉具有同轴地被接纳在管的相关端部中的内部套筒。该套筒具有面向该管的内周表面的外周表面，其中，在套筒的外周表面与管的内周表面之间形成有腔。在叉中形成有粘合剂注射通道，并且该粘合剂注射通道从形成在叉的轴向表面中的入口以锐角延伸至形成在套筒的外周表面中的出口。注射通道的角度被选择成在不会移除大量材料且不会在不可接受地削弱叉的位置处的情况下连接至腔。因为出口与套筒的表面以锐角相交而不是垂直地相交，所以出口的形状是椭圆形的，从而提供了相对大的开口，粘合剂可以穿过该开口流动到腔中。
根据本发明的另一方面，一种将传动轴组件的叉结合至传动轴组件的复合管的方法包括：将粘合剂从叉的轴向表面以锐角注射通过叉的套筒的外周表面中的开口，并且注射到形成在叉的套筒的外周表面与复合管的内周表面之间的腔中。然后使粘合剂固化。
根据本发明的另一方面，提供了一种制造复合车辆传动轴组件的方法。该方法可以包括在将套筒插入到复合管中并将套筒结合至复合管之前执行各个预备步骤。预备步骤可以包括准备复合管和准备套筒。管准备可以包括对复合管的端部的内周表面进行清洁，并且对复合管的端部进行切割以提供所期望的长度。可以对复合管的端部的内周表面进行火焰处理，以便于结合。套筒准备可以包括对套筒的外周表面进行清洁。
在结合以下描述和附图考虑时，将更好地领会并理解本发明的这些及其他特征和方面。然而，应当理解的是，尽管以下描述指示了本发明的优选实施方式，但是这些描述是通过说明性而非限制性的方式给出的。在不脱离本发明的范围的情况下，可以在本发明的范围内进行许多改变和修改。
附图说明
附图中图示了本文中所公开的主题的各个示例性实施方式，在附图中，相同的附图标记始终表示相同的部分，并且在附图中：
图1示意性地图示了具有根据本发明构造的复合车辆传动轴组件的车辆；
图2为图1的传动轴组件的截面正视图；
图3为图1的传动轴组件的一部分的局部截面图，其示出了传动轴组件的端部叉与复合管的连接；
图4为图1至图3的复合传动轴组件的端部叉的立体图；
图5为图4的端部叉的正视图；
图6为图4和图5的端部叉的截面正视图；
图7为图4至图6的叉的外部端视图；
图8为图4至图7的叉的内部端视图；
图9为表示用于生产复合车辆传动轴的表面准备阶段的流程图；
图10为表示用于生产复合车辆传动轴的组装阶段的流程图；以及
图11为表示用于生产复合车辆传动轴的结合阶段的流程图。
在详细地说明本发明的实施方式之前，应理解的是，本发明在其应用方面不限于在以下描述中阐述或在以下附图中图示的部件的结构和布置的细节。本发明能够具有其他实施方式，并且能够以各种方式实践或实施。此外，应理解的是，本文中所使用的措辞和术语是出于描述的目的，并且不应当被认为是限制性的。“包括”和“包含”及其变型的使用意在涵盖其后列出的项目及其等同方案以及附加项目及其等同方案。
具体实施方式
现在参照附图并且首先参照图1，复合车辆传动轴组件10被图示为安装在车辆中，该车辆在此被表示为汽车16。汽车16具有前端部18和后端部20以及包括诸如发动机22之类的原动机的动力系。变速器24接纳来自发动机22的动力，并将该动力通过复合车辆传动轴10向下游传递至差速器26，该差速器26将动力通过驱动车轴28传递至一对驱动轮30。所图示的传动轴组件10具有复合管40以及端部部件或联接器12和14，所述端部部件或联接器12和14分别将传动轴前端部34连接至变速器24并且将传动轴后端部36连接至差速器26。应当理解的是，代替变速器24和差速器26，复合车辆传动轴组件10可以替代地将来自发动机22的动力传输至将变速器和传动车轴组合的驱动桥。
现在参照图2和图3，复合式车辆传动轴组件10包括复合管40，该复合管40限定了复合式车辆传动轴组件10的中间部分，并且该复合管40分别在其前端部处结合至联接器12并且在其后端部处结合至联接器14。复合管40可以是由包括纤维和树脂材料成分在内的复合材料制成的筒形中空管。复合管40具有本体46，本体46具有内周表面58和外周表面48以及被示出为前管端部50和后管端部52的一对端部。复合管40可以是缠绕工艺的产品。丝缠绕工艺可以包括将浸泡在树脂中的一根或多根丝或绳、例如单纤维绳围绕钢或其他足够刚性的芯或心轴卷绕或缠绕。纤维可以包括例如碳纤维和/或玻璃纤维。纤维浸泡能够提供湿层压材料，或者纤维可以被预浸泡在树脂中以提供工业中有时称为“预浸材料”的材料。不管具体的纤维浸泡过程如何，在丝缠绕工艺之后，缠绕的丝或者缠绕的管状产品然后被烘箱加热固化。
管长度、直径和厚度可以根据应用和设计者偏好而变化，较薄的管通常用于较短的传动轴，并且较厚的管用于较长的传动轴。10英寸至70英寸(254mm至1780mm)的管长度针对汽车传动轴应用是典型的。管内径可以从约2.5英寸至5英寸(65mm至125mm)变化。管厚度可以从约0.125英寸至0.155英寸(31.75mm至39.37mm)变化，其中，针对较长的传动轴，较厚的管是更典型的。针对汽车应用的管直径通常将为2.5英寸(63.5mm)、3英寸(76.2mm)或3.5英寸(88.9mm)，这取决于具体应用。
不管复合管40的特定构型如何，复合管40均具有输入端部和输出端部，输入端部和输出端部在此表示为结合至端部联接器12、14的前管端部50和后管端部52。所述结合可以将由不同材料制成的部件连接至彼此。这允许诸如复合管40之类的非金属部件提供复合车辆传动轴组件10的长度的主要部分或大部分，同时还通过传动轴组件前端部34与变速器24之间和传动轴组件后端部36与差速器28之间的接合部处的接头提供金属部件连接。
仍参照图2，在所图示的示例中，端部部件或联接器12和14中的至少一个端部部件或联接器和在图示示例中的两个端部部件或联接器采用结合至复合管40的端部的叉的形式。尽管图示了两个相同的叉，但是应当理解的是，叉中的一个叉可以由不同的叉或者不同的端部部件/联接器或端部接头代替，比如由挠性联接器、CV(恒速)联接器、滑动叉或其他花键联接器代替。因此，对叉12的以下描述同样适用于叉14。
参照图2至图8，叉12连接至万向接头110(并在技术上形成万向接头110的一部分)。叉12具有由单一金属铸件、通常为铝或钢形成的外部联接器54和内部管状套筒56。外部联接器54具有冠部100以及从冠部100轴向向外延伸的第一和第二相对的臂102和104。如所示出的，臂102和104具有用于连接至万向接头110的耳轴112的贯通孔106和108。耳轴112和相应的轴承(未示出)将叉12的臂102和104连接至外部叉114，外部叉114又联接至另一传动系部件。替代性地，臂102、104可以通过用于附接至其他传动系接头、比如挠性接头或恒速(CV)接头的连接器来代替或者使用所述连接器来补充。
参照图3至图6，套筒56具有内周表面59和外周表面60。套筒56同心地配装在管40的前管端部50中，使得复合管40的内周表面58面向套筒56的外周表面60，其中，套筒56的被插入到管40中并同心地被保持在管40中的部分限定了插入部段。套筒56可以是铝或者由含铁金属、比如钢制成。如图3中可以看出，在复合管40的内表面58与套筒56的外表面60之间形成有腔70，以用于接纳粘合剂。腔70在其轴向端部处通过在套筒56与复合管40之间径向延伸的结构进行密封。在所图示的实施方式中，这些结构采用从套筒56的外周表面60径向向外延伸至复合管40的内周表面的内凸台和外凸台68和69的形式，其中，凸台68和69沿着套筒56彼此纵向间隔开。叉12和管40在腔70处(例如，在凸台68、69之间)的各自的外周表面和内周表面中的每一者均限定了相应的结合区域。凸台68和69通过紧贴配合而接合复合管40的内周表面58，该紧贴配合可以是需要压力组装的干涉配合。对于具有3.5英寸(90mm)的标称复合管内径和约4.8英寸(122mm)的套筒长度的3.5英寸(90mm)的结合叉，套筒56在凸台68和60处的外径为3.505英寸(89.7mm)并且在凸台之间的外径为3.46英寸(87.9mm)。腔70的厚度可以为0.045英寸(1.14mm)并且腔70的长度可以为约4.4英寸(112mm)。这种配合通过以防止套筒56相对于管40的纵向轴线径向偏移或角度倾斜的方式将套筒56同轴地定位在复合管40内来确保套筒56在复合管40内的同心度。
仍参照图3，腔70填充有粘合剂71，以将套筒56结合至复合管40。粘合剂可以是各种工业、航空或其他合适的粘合剂、环氧树脂或其他结合剂，比如合适的甲基丙烯酸酯粘合剂或者可从
Figure BDA0003696001340000061
公司以Scotch-WeldTM和各种其他商品名获得的各种粘合剂中的任一者。下面结合图9至图11对粘合剂注射以及可能的结合过程及其相关过程的其他方面进行更详细地讨论。
套筒56与复合管40之间的结合可以允许合适的汽车应用和其他高扭矩应用，包括需要具有高扭矩能力的传动轴的高性能车辆应用。套筒56与复合管40之间的结合强度可以在套筒56与复合管40之间不发生结合失效的情况下提供在复合车辆传动轴组件10的至少约300磅/英尺的扭矩能力到高达约80000磅/英尺至100000磅/英尺的扭矩能力的范围内的扭矩能力。
参照图2、图4、图6和图7，叉12中设置有至少一个端口、孔或粘合剂注射通道74，以用于在粘合剂注射过程期间将粘合剂注射到腔70中。粘合剂注射通道74在此示出为具有粘合剂入口76(图7)和粘合剂出口78，粘合剂入口76轴向定位得超过复合管40的端部，粘合剂出口78通向腔70。对于外径为3.54英寸(90mm)的套筒，通道的直径可以在0.078英寸(2mm)与0.276英寸(7mm)之间，并且更通常地直径为0.157英寸(4mm)。通道74从形成在叉12的轴向端面中的入口76相对于复合传动轴组件10的轴向中心线以锐角线性地延伸至形成在腔70内的套筒56的外周表面中的出口78。该角度的斜率可以根据不同的应用而变化。理想地，通道应该尽可能平缓，以便使椭圆形出口78的面积最大化，而不会由于集中或在给定表面附近去除太多的材料而不可接受地削弱叉，或者在替代方案中不得不向叉增加额外的质量以适应平缓的通道。5度至20度的角度是典型的，约10度至15度的角度是最典型的。图示的通道74以10度的角度延伸，并且长1.18英寸(30毫米)。
入口76在叉12的冠部100上的定位消除了在复合管40上钻孔的需要。入口76在臂102与臂104之间的大约中间定位在冠部100上。入口76可以是阶梯状的或以其它方式定形状成与给定尺寸和形状的注射喷嘴配合，以抑制或防止粘合剂通过填充喷嘴的周缘泄漏。在所示的实施方式中，入口76包括外筒形沉孔80和将沉孔80连接至通道74的内部的内截头圆锥形埋头孔82。
如上所述，尽管事实上通道74为圆形，但是由于通道74与套筒56的外周表面60以锐角相交而非垂直相交的事实，通道74的出口78为椭圆形或卵形而非圆形。因此，出口78在与圆形出口的那些出口相比时具有相对较大的表面积和轴向范围，从而在粘合剂从入口76通过通道74注射时有利于腔70的溢流。在其中通道具有4mm的直径并且以10度的角度延伸的本示例中，出口78具有约为3.25英寸2(80mm2)的面积、显著地大于将由圆形出口形成的0.50英寸2(12.5mm2)的开口。
仍然参照图2、图6和图7，在叉12中在与注射通道74周向地间隔开的位置处形成第二排放通道84。排放通道84构造成在粘合剂注射过程期间将空气从腔70排出或释放。排放通道84在与注射通道74间隔180度时是最有效的，但是明显更少的和/或附加的排放通道84的间隔当然是可能的。排放通道84从形成在腔70内的套筒56的外周表面60中的入口86相对于复合轴组件10的轴向中心线以锐角线性地延伸至可以采取形成在叉12的冠部100的轴向端面中的出口88的形式的端口或通道。该角度可以与注射通道74的角度相对于轴向在相同的范围内，并且最典型地，该角度将与注射通道74的角度相同、即在5度与20度之间，并且最典型地约为10度至15度。出口88在叉12的冠部100上的定位消除了在复合管40上钻孔的需要。出口88示出为沉孔和埋头孔，使得如果需要，通道84可以用作注射通道，在这种情况下，通道74可以用作排放通道。换句话说，端口或通道74和端口或通道84的功能是可互换的。
替代性地或者代替该布置结构，两个或更多个相对的排放通道可以设置成各自在相反方向上与粘合剂注射通道74间隔约150°至175°。
现在参照图9至图11，无论复合传动轴组件10上实施的特定粘合剂注射孔构型或特定类型的传动系接头如何，传动轴组件10通常通过具有多个阶段的构建程序进行组装，所述多个阶段表示为图9中的表面准备阶段200、图10中的组装阶段300、以及图11中的结合阶段400。在开始多阶段构建程序之前，进行一般的工作站准备。这包括例如通过彻底清洁构建区域以确保将要使用的任何工作表面完全没有油和碎屑、由此看不到或感觉不到碎屑和油来为多阶段构建程序准备工作站的构建区域。如果在多阶段构建程序的任何阶段中使用压缩空气，则用户应当确保对工作站进行供给的压缩空气系统具有空气干燥器和过滤系统，并且该系统操作成确保压缩空气不含油和水。
现在参照图9，表面准备阶段200包括且表示为至少两个阶段，所述至少两个阶段示出为管表面准备202和端部部件表面准备204。在管表面准备202期间，复合管40基于正在构建的特定传动轴组件10的要求而利用适当的刀片被切割至一长度，如在过程框206处所表示的。通常，在切割复合管40时使用旋转式锯或其他湿锯来减少灰尘。在判定框208处，对复合管40的切割端部的切割清洁度进行检查，其应当没有可见的毛刺或突出的纤维。如在过程框210处所表示的，如果在切割后存在毛刺或突出的纤维，则使用适当的工具将毛刺或突出的纤维从端部去除，适当的工具为比如锉刀、研磨布比如砂布、或研磨垫比如能够从
Figure BDA0003696001340000081
以Scotch-WeldTM和各种其他商品名获得的各种研磨垫。在复合管40的切割端没有毛刺或突出的纤维的情况下，对复合管40的内周表面或ID(内径)进行漂洗，如由过程框212所表示的。在漂洗期间通常使用水来去除切割操作中的任何残留碳尘。清洁的车间毛巾(shoptowels)等通常经过复合管40，以干燥和擦拭复合管40内部的碎屑。清洁的车间毛巾经过复合管40的孔，直到在车间毛巾上发现来自复合管40的碎屑最小为止。如在过程框214处所表示的，使用脱脂剂或溶剂、通常为丙酮来清洁复合管40的ID，例如采用被来自活塞罐的丙酮浸湿的清洁的布比如新的、清洁的、不起毛的车间毛巾来清洁复合管40的ID。通过经丙酮浸湿的毛巾对复合管40的端部的ID进行擦拭，以彻底清洁端部部件12、14插入其中的复合管40的ID的整个结合区域或长度。在每次擦拭清洁的情况下通常使用新的或没用过的、清洁的、不起毛的车间毛巾或其他合适的布来重复这种方式的擦拭。在重复擦拭过程期间将布进行重新放置或更换，直到布在擦拭后保持清洁为止。通常，需要若干次(比如三次或更多次)擦拭循环来将液体或固体颗粒污染物从储存、运输以及切割灰尘和碎屑中去除。在通过擦拭循环充分清洁后，布应该完全没有任何可见的碳尘，并且在复合管40内应该没有可见的毛巾屑或其它布屑。如在判定框216处所表示的，如果复合管40的另一端部还没有被清洁，则在过程框212、214处对该复合管40的另一端部重复进行漂洗、干燥和清洁的过程。
如在过程框218处所表示的，在将复合管40的两个端部50、52中的结合区域清洁之后，复合管40在端部部件表面准备204期间被搁置。在不触及复合管的端部50、52的内侧或者不对经清洁的表面以其他方式造成污染风险的情况下，将复合管40搁置。通常，这是借助于仅处理复合管42的外周表面并且使用不起毛的布比如不起毛的车间毛巾覆盖复合管42的开口端部，通过将复合管42移动到其搁置位置来完成的。仍然参照图9，如由过程框220所表示的，端部部件端口在可结合端部部件12、14的表面准备期间被气动清理。这通常是通过气溶胶型罐装空气产品、比如那些用于将灰尘从电子部件清除的产品来完成的。也可以使用其他干燥和清洁的压缩空气，比如经过滤的、干燥的、无油的、车间空气等。对端口的气动清理去除了例如在制造过程或运输/储存期间可能已经积聚在注射孔或端口中的加工碎屑、切削流体或其他污染物。如在过程框222处所表示的，对端口进行机械地清洁，例如通过擦洗对端口进行机械地清洁。这通常是通过管道清洁器来完成的，该管道清洁器定尺寸成在机械地移除固体碎屑的同时施加足够的擦拭接合和阻力来推动通过端口。如在过程框224处所表示的，端部部件的外周表面或OD(外径)被磨损或机械地清洁。这通常通过使用Scotch-BriteTM垫或其他合适的研磨垫对端部部件12、14的插入部段(包括结合区域和凸台68、69)的OD进行研磨来完成。在过程框226和过程框228处，端口被冲洗，并且端部部件12、14的插入部段被彻底漂洗。端口冲洗和插入部段漂洗两者通常通过脱脂剂或溶剂来完成，并且更通常地通过从例如丙酮输送瓶输送的丙酮来完成，丙酮输送瓶通常是压挤型瓶。
如在过程框230处所表示的，在端部部件的插入部段已经被清洁之后，端部部件12、14被搁置以用于进一步处理、比如组装。将端部部件12、14搁置通常包括在不触及插入部段或使端部部件暴露于与任何外来物质的潜在接触的情况下将端部部件放置在工作站中的清洁位置处。在搁置端部部件12、14期间，如果插入部段触及或接触任何外来物质，则重复过程框220、222、224、226、228处的清理、擦洗、研磨、冲洗以及漂洗过程。在判定框323处，如果另一端部部件12、14还没有被清洁，则对该另一端部部件12、14重复过程框220、222、224、226、228处的清理、擦洗、研磨、冲洗和漂洗过程。如在过程框234处所表示的，当两个端部部件都被清洁和搁置时，表面准备阶段200完成。
现在参照图10，组装阶段300通常在表面准备阶段200(图9)的30分钟内进行、并且更通常地在15分钟内进行。组装阶段300被表示为至少三个阶段，所述至少三个阶段示出为组装准备302、初步润滑304和按压306。组装准备302包括分别在过程框308、310、312、314处表示的工作站准备、工具准备、检查和火焰处理。在框308处的工作站准备期间，丙酮、车间毛巾和/或其他可燃材料被移动远离工作表面和周围区域例如至少10英尺。在框310处的工具准备期间，准备用于粘合剂注射的粘合剂输送枪，比如气动式、电动式或手动手持式粘合剂枪或其他粘合剂枪。这通常包括将粘合剂筒装入粘合剂枪中，并且将盖从筒移除。如上所述，一种合适的粘合剂可以从3M公司以商标名DP460下获得。混合喷嘴附接至筒的喷嘴。执行枪的初步启动，以清除混合喷嘴中的空气和未混合的粘合剂。这通常通过从混合管中分配足够量的材料直到产生均匀的颜色和粘度为止来完成。同样，在过程框310处的工具准备期间，准备火焰处理炬。通常，炬是MAPP气体炬，并且所述准备包括将一瓶MAPP气体旋拧到适当的炬头上。在过程框312处的检查期间，复合管40的ID和可结合端部部件的OD两者被检查，以确保在任一部件中或任一部件上不存在灰尘或其它碎屑或污染物。如过程框314处所表示的，如果复合管40和可结合端部部件12、14没有灰尘、碎屑和污染物，则对复合管40和可结合端部部件12、14中的每一者进行火焰处理。
仍然参照图10，在可结合端部部件12、14的火焰处理314期间，MAPP气体炬被点燃，并且其火焰在可结合端部件的整个结合区域的OD上均匀地移动，以活化结合区域的表面，从而优化结合。火焰的蓝色部分应该接触结合区域的表面，并且可结合端部元件12、14在与火焰接触的同时旋转以确保完全覆盖。火焰处理在不将可结合端部部件的结合区域加热超过160°F的情况下进行。对第二可结合端部部件12、14重复火焰处理阶段、关闭MAPP气体炬、并将可结合端部部件搁置在清洁的区域中。表1示出了根据可结合端部部件12、14的尺寸用于可结合端部部件12、14的合适的火焰处理时间的各种示例，可结合端部部件的尺寸在其以英寸为单位的OD方面表示。
表1
Figure BDA0003696001340000111
在复合管40的端部的火焰处理314期间，MAPP气体炬被再次点燃，并且其火焰围绕复合管的结合区域的ID均匀地移动，以活化结合区域的表面，从而优化结合。火焰的运动是连续进行的，并且通常在旋转的同时连续进行，使得火焰不会接触复合管的任何单一区域超过一秒，以降低损坏复合管的可能性。火焰处理在不将复合管的结合区域加热到超过140°F的情况下进行，但是要加热到触摸起来足够热，通常加热在110°F至140°F之间，这可以通过精密温度计/热电偶进行测量。对复合管40的第二端部重复火焰处理阶段314。表2示出了根据复合管40的尺寸用于复合管40的端部的合适的火焰处理时间的各种示例，复合管40的尺寸在其以英寸为单位的ID方面表示。
表2
Figure BDA0003696001340000112
对复合管的第二端部重复火焰处理阶段314。关闭MAPP气体炬，并且过程前进至初步润滑阶段304。
仍然参照图10，如在过程框316处所表示的，在初步润滑阶段304期间，围绕复合管40的端部的内边缘注射粘合剂的薄珠，其中，粘合剂用作润滑剂。用戴手套的手将粘合剂围绕复合管的ID涂在其结合区域中。粘合剂以这种方式涂抹在周围，直到结合区域被完全涂覆为止，从而为结合区域提供充分的润滑并防止划伤和产生灰尘。如在过程步骤318处所表示，可结合端部部件12、14和复合管40被转移到工作站处的上压工具。这是在不触及复合管40的ID或可结合端部部件12、14的经火焰处理的结合区域的OD的情况下完成的。该上压工具是工业标准的上压工具，例如传动轴压力机、立式压力机或车床。在按压阶段306期间，执行如在过程框320处所表示的初始部分按压。这通常包括将可结合端部部件12、14按压进入复合管40的端部的路径的一小部分，比如小于进入管中的路径的约1/8，或者足够远以使可结合端部部件12、14自支承在复合管40的端部中。对可结合端部部件12、14相对于复合管40的对准进行检查，以确保可结合端部部件相对于复合管40笔直插入且不偏离中心。如在过程框322处所表示的，可结合端部部件12、14按压进入复合管40的端部的路径的其余部分。这通常包括按压端部部件12、14，直到端部部件的肩部止挡件或其他止挡型结构完全抵靠复合管40的端部坐置为止。
现在参照图11，结合阶段400包括注射阶段402和固化阶段404。在注射阶段402期间，如在过程框406处所表示的，确认可结合端部部件12、14在复合管40内的对准。对可结合端部部件12、14和复合管40进行检查以确保管定位成使得位于端部部件12、14的端部或端面处的端口的孔彼此竖向对准。如在过程框408处所表示的，执行粘合剂的主动注射。粘合剂枪的混合喷嘴的梢部被紧紧地压入竖向对准的端口的下端口中，并且粘合剂被注射到该下端口中。粘合剂被注射到下端口中，直到粘合剂开始从上端口冒泡为止。在这一点上，混合喷嘴的梢部在没有额外粘合剂注射的情况下保持就位约10秒至30秒、通常暂停15秒，以允许任何截留的空气逸出。通过下端口继续注射粘合剂，直到所有空气被完全排出为止。完全排出的状态通常与没有任何气泡通过上端口相对应。如在过程框410处所表示的，使用清洁剂或溶剂、比如经丙酮润湿的车间毛巾将任何多余的粘合剂去除。两个端口的开口上方放置有丝胶带的条状件，以防止粘合剂在固化过程或固化阶段404期间从端口泄漏。
接下来，如在图11的过程框412处所表示的，使粘合剂固化。如在过程框414处所示出的，可以在室温或环境温度下以相对较慢的方式进行固化。在将复合传动轴组件10安装到车辆中之前，完成至少48小时的环境温度或室温固化，以确保粘合剂的完全固化状态。如在过程框414处所表示的，固化可以在升高温度下以相对较快的方式完成，如在过程框416处示出的。升高温度固化或加热固化通常在较大的烘箱中或使用另一热源完成。如在过程框418和过程框420处所表示的，热源被启用以开始预热，并且传动轴组件10或者端部部件和复合轴40的组件被放置在烘箱中或以其他方式暴露于来自热源的热。这通常是通过将烘箱或其他热源预热到150°F，并且然后将组件10放置到烘箱中或者相对于要被其加热的热源布置来完成。如在过程框422处所表示的，组件10被留在烘箱中或接收来自热源的热并持续20分钟至45分钟、通常为在150°F下持续30分钟，以将组件10的温度升高至固化温度。在过程框424处，组件10在固化温度下加热并持续适当的时间量，通常为在150°F的固化温度下持续1小时。如在过程框426、428处所表示的，将烘箱或其他热源关闭，或者将组件从烘箱或热源暴露中移除，并且然后允许组件10冷却。冷却在室温或环境温度下通常需要至少30分钟。
在不背离本发明的精神的情况下，可以对本发明做出许多改型和变型。这些变化的范围将在所附权利要求中变得明显。

Claims (20)

1.一种复合车辆传动轴组件，包括：
复合管，所述复合管由缠绕的丝和树脂材料形成，并且所述复合管具有内周表面和外周表面以及内部轴向端部和外部轴向端部；以及
叉，所述叉包括外部联接器和内部套筒，所述内部套筒被同轴地接纳在所述管的输入端部和输出端部中的一者中，所述套筒具有面向所述管的所述内周表面的外周表面，其中，在所述管的所述内周表面与所述套筒的所述外周表面之间形成有腔，在所述叉中形成有粘合剂注射通道，并且其中，所述粘合剂注射通道从形成在所述叉的轴向表面中的入口以锐角延伸至形成在所述套筒的所述外周表面中并通向所述腔的出口。
2.根据权利要求1所述的复合传动轴组件，其中，所述腔在其内部轴向端部和外部轴向端部处通过在所述套筒的所述外周表面与所述管的所述内周表面之间延伸的结构进行密封。
3.根据权利要求2所述的复合传动轴组件，其中，所述结构包括形成在所述套筒的所述外周表面上的凸台。
4.根据权利要求1所述的复合传动轴组件，其中，所述锐角介于5度与20度之间。
5.根据权利要求1所述的复合传动轴组件，其中，所述注射通道的横截面为圆形，并且所述出口的开口的形状为椭圆形。
6.根据权利要求1所述的复合传动轴组件，其中，所述叉具有第一臂和第二臂，所述第一臂和所述第二臂从所述叉的所述轴向表面轴向向外延伸并构造成用于连接至传动系接头。
7.根据权利要求1所述的复合传动轴组件，其中，所述复合管的所述丝由玻璃纤维和碳纤维中的至少一者形成。
8.根据权利要求1所述的复合传动轴组件，其中，所述复合管的内径为65mm至125mm，所述复合管的厚度为31.75mm至39.37mm，并且所述复合管的长度为254mm至1780mm。
9.一种构造成用于与复合传动轴组件一起使用的叉，所述复合传动轴组件包括所述叉和复合管，所述复合管由缠绕的丝和树脂材料形成，并且所述复合管具有内周表面和外周表面以及内部轴向端部和外部轴向端部，所述叉包括：
外部联接器和内部套筒，所述内部套筒构造成被同轴地接纳在所述管的输入端部和输出端部中的一者中，其中，
所述套筒具有构造成面向所述管的所述内周表面的外周表面，其中，在所述管的所述内周表面与所述套筒的所述外周表面之间形成有腔，其中，
在所述叉中形成有粘合剂注射通道，并且其中，
所述粘合剂注射通道从形成在所述叉的轴向表面中的入口以锐角延伸至形成在所述套筒的所述外周表面中并通向所述腔的出口。
10.根据权利要求9所述的叉，其中，所述腔在其内部轴向端部和外部轴向端部处通过所述叉上的构造成在所述套筒的所述外周表面与所述管的所述内周表面之间延伸的结构进行密封。
11.根据权利要求10所述的叉，其中，所述结构包括形成在所述套筒的所述外周表面上的凸台。
12.根据权利要求9所述的叉，其中，所述锐角介于5度与20度之间。
13.根据权利要求9所述的叉，其中，所述注射通道的横截面为圆形，并且所述出口的开口的形状为椭圆形。
14.根据权利要求9所述的叉，其中，所述叉具有第一臂和第二臂，所述第一臂和所述第二臂从所述叉的所述轴向表面轴向向外延伸并构造成用于连接至传动系接头。
15.一种将复合传动轴组件的叉结合至所述复合传动轴组件的复合管的方法，所述方法包括：
将粘合剂从所述叉的轴向表面以锐角注射通过所述叉的套筒的外周表面中的开口，并且注射到形成在所述叉的所述套筒的所述外周表面与所述复合管的内周表面之间的腔中；以及
允许所述粘合剂固化。
16.根据权利要求15所述的方法，所述方法在注射之前还包括：
对所述复合管的端部的内周表面进行清洁；
对所述复合管的所述端部进行切割以提供期望长度的所述复合管；
对所述套筒的外周表面进行清洁；
对所述复合管的所述端部的所述内周表面进行润滑；
将所述套筒与所述复合管的所述端部同轴地对准；以及
将所述套筒朝向所述复合管的所述端部按压到所述端部处的开口中。
17.根据权利要求16所述的方法，其中，准备所述复合管包括对所述复合管的所述端部的所述内周表面进行火焰处理。
18.根据权利要求15所述的方法，其中，所述套筒包括外周表面以及一对凸台，所述一对凸台彼此间隔开并且从所述套筒的所述外周表面径向地延伸，其中，在所述复合管的所述内周表面、所述套筒的所述外周表面与所述一对凸台之间限定有腔。
19.根据权利要求15所述的方法，还包括在将所述粘合剂注射通过从所述腔延伸至所述套筒的轴向表面的排放通道时，将空气从所述腔排出。
20.根据权利要求19所述的方法，其中，所述排放通道是所述注射通道关于纵向轴线反射的镜像，以将空气沿与所述粘合剂流动到所述腔中的流动方向基本上相反的方向从所述腔引导出。
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