JPH0911763A - Drive shaft and its manufacture - Google Patents

Abstract

PURPOSE: To realize a light weight of a tube body by making one side sleeve in a large diameter sleeve, and the other side sleeve in a small diameter sleeve, in a drive shaft made by synchronous integrating formation of a metallic sleeve to both ends of a fiber reinforced plastic tube body. CONSTITUTION: In the manufacture of a drive shaft 1, a mandrel 5 is formed of a mandrel main body 5a with the outer diameter D, and a mandrel end body 5b with the outer diameter d extended from the main body 5a. A mold release agent is applied on the surface of the mandrel 5, and after a large diameter sleeve 3 is fitted to the mandrel main body 5a, and a small diameter sleeve 4 is fitted to the mandrel end body body 5b, respectively, a reinforcement fiber is wound by a filament winding method. As a result, a tube body 2 made of a fiber reinforced plastic is formed, and then, the hardening of the plastic, and the connection with the metallic sleeves 3 and 4 are carried out at a time by heating adequately, and after the resin is hardened, the mandrel 5 is released from the die, so as to obtain a final product.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a drive shaft made of fiber reinforced plastic.

[0002]

2. Description of the Related Art Recently, it has been required to reduce the weight of automobiles, and the weight of the drive shaft, which has been conventionally heavy, is also reduced by constructing the fiber reinforced plastic so-called FRP. The fiber reinforced plastic is obtained by orienting reinforcing fibers such as carbon fiber CF, glass fiber GF, Kevlar fiber (trade name of DuPont) and curing them with a thermosetting resin such as epoxy resin. When the shaft is configured, it is said that the weight can be reduced to less than half that of the conventional one, and further reduction of noise and vibration can be expected.

However, when such a fiber reinforced plastic is used for a drive shaft, it is necessary to attach yokes of metal joints or the like to both ends of the fiber reinforced plastic tube body, and therefore, metal sleeves are first attached to both ends of the tube body. In general, a method in which the yoke end is welded to the sleeve is fixed afterwards.

There is also a method of fixing the sleeve to the fiber-reinforced plastic pipe body by fixing the sleeve to the already completed pipe body with an adhesive, but there is a possibility that slip will occur when impact torque is applied, There are problems such as poor fatigue. Therefore, a method of embedding a sleeve at the same time when molding a fiber-reinforced plastic tube has already been adopted.

An example thereof (Japanese Patent Publication No. 1-60686)
Is illustrated in FIG. On the mandrel 01 coated with release agent,
The annular metal sleeve 02 is fitted at predetermined positions corresponding to both ends of the drive shaft, the reinforcing fiber 03 is wound thereon by the filament winding method, and the mandrel 01 is pulled out after curing. In the example shown in FIG. The drive shaft is manufactured by cutting at AA '. By simultaneously hardening the reinforcing fibers and integrally bonding the sleeve, the adhesive strength is increased and problems such as slippage are substantially eliminated as compared with the method of bonding after molding.

As another example (Japanese Patent Publication No. 59-8568), as shown in FIG. 8, yokes 06 are joined to both ends of a thin metal cylindrical tube 05, and the cylindrical tube 05 is used as a mandrel and a fiber is formed thereon. There is a method of manufacturing a drive shaft by winding and hardening the reinforced plastic 07 by a filament winding method. Since the yoke 06 of the joint is already joined to the cylindrical tube 05, the manufacturing process is simplified and there is no problem of slippage.

[0007]

[Problems to be Solved] However, in the case of the former example, the inner diameter of the sleeve is set so that the mandrel can be smoothly removed at the time of demolding.
At a minimum, it is larger than the outer diameter of the mandrel, and the diameters of both sleeves 02 at both ends are large in comparison with the diameter of the required pipe body, and the weight increases accordingly, and the joint welded to the sleeve also becomes large, small and lightweight. Is not fully achieved.

Also, in the latter example, the yokes 06 at both ends of the cylindrical pipe 05 can be downsized in comparison with the required diameter of the drive shaft, but since the thin metal cylindrical pipe 05 remains in the drive shaft, Since the weight is increased and the cylindrical tube 05 as the mandrel cannot be reused, the cost is increased.

The present invention has been made in view of the above points, and an object of the present invention is to reduce the weight of the tubular body itself and the weight of the sleeve and the joint by reducing the size of the drive shaft. And a method for manufacturing the same.

[0010]

In order to achieve the above object, the present invention provides a drive shaft in which metal sleeves are integrally formed on both ends of a fiber reinforced plastic pipe body, and one sleeve is formed on both sides of the drive shaft. A drive shaft is a large-diameter sleeve having an inner diameter substantially equal to the inner diameter of a tubular body between the sleeves, and the other sleeve is a small-diameter sleeve having a smaller diameter than the large-diameter sleeve.

One large-diameter sleeve has the same inner diameter as the inner diameter of the tubular body and is the same as the conventional one, but the other small-diameter sleeve has a smaller diameter than the large-diameter sleeve and is smaller and lighter than the conventional one. A small joint can also be used for coupling to, and since the tube body is originally made only of fiber reinforced plastic and is lightweight, the weight of the drive shaft can be further reduced. Note that the mandrel and the like can be removed from the large-diameter sleeve side during the molding process, and there is no hindrance to demolding.

By using the drive shaft in which the small-diameter sleeve and the yoke are integrally formed, the yoke is integrally formed in the small-diameter sleeve in advance, so that the number of parts can be reduced and the working process can be shortened.

A large-diameter sleeve having an inner diameter substantially equal to the outer diameter of the mandrel body is formed on the mandrel body of the mandrel, which comprises the mandrel body having a predetermined outer diameter and the mandrel end body extending coaxially with a reduced diameter. Fit in place,
A small diameter sleeve having an inner diameter substantially equal to the outer diameter of the mandrel end body is fitted to the mandrel end body, and a fiber reinforced layer is integrally formed on part of both sleeves and the mandrel body by a winding method such as a filament winding method. A drive shaft was manufactured by molding, curing, and then removing the mandrel to remove the mold.

The working process is substantially the same as the conventional one (the example described in Japanese Patent Publication No. 1-60686), but the small diameter sleeve can be integrally molded with the fiber reinforced layer, and the size and weight can be reduced. Further, since the mandrel is removed by demolding and does not remain inside the fiber reinforced layer, the weight of the drive shaft can be reduced and the mandrel can be reused, which is advantageous in terms of cost.

The method of manufacturing the drive shaft in which the yoke is integrally formed in advance with the small-diameter sleeve fitted to the mandrel eliminates the work of joining the yoke to the sleeve and simplifies the work.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention shown in FIGS. 1 to 5 will be described below. 1 to 4 sequentially show the manufacturing process of the drive shaft 1 of the present embodiment, in which FIG. 1 is a perspective view of the mandrel 5, the large-diameter sleeve 3, and the small-diameter sleeve 4 which are coaxial with each other. .

The mandrel 5 has a cylindrical mandrel body 5a having an outer diameter D, and a mandrel end body portion 5b coaxially reduced in diameter from the mandrel body 5a and extended with an outer diameter d (<D). Consists of.

Both sleeves 3 and 4 are metal pipes,
The inner diameter of the large-diameter sleeve 3 is slightly larger than the outer diameter D of the mandrel body 5a, and one opening edge 3a of the cylinder is tapered. On the other hand, small-diameter sleeve 4
Has an inner diameter slightly larger than the outer diameter d of the mandrel end body portion 5b, and its outer diameter is substantially equal to the outer diameter D of the mandrel body portion 5a.

A mold release agent is applied to the surface of the mandrel 5, the large-diameter sleeve 3 is fitted in a predetermined position of the mandrel body 5a, and the small-diameter sleeve 4 is fitted in the mandrel end body 5b. As shown, the end surface of the small diameter sleeve 4 is brought into contact with the end surface of the mandrel body 5a.

Since the outer diameter of the small-diameter sleeve 4 is substantially equal to the outer diameter D of the mandrel body 5a, it forms the same outer peripheral surface as the mandrel body 5a. The large-diameter sleeve 3 is separated from the small-diameter sleeve 4 by a predetermined distance, and its tapered opening edge 3a is located on the small-diameter sleeve 4 side.

After the large-diameter sleeve 3 and the small-diameter sleeve 4 are fitted to the mandrel 5 at predetermined positions in this manner, the reinforcing fibers are wound thereon by the filament winding method. Strands made of resin-impregnated carbon fiber filaments are wound at a certain winding angle (angle between the fiber and the mandrel center axis) to form a tubular body, and the ends have a large diameter. At least half of each of the sleeve 3 and the small-diameter sleeve 4 is covered.

Therefore, referring to FIG. 5, the large-diameter sleeve 3
The diameter of the portion wound around the mandrel body 5a is larger than that of the portion wound around the mandrel body 5a, and the boundary forms a step portion along the taper of the opening edge 3a of the large-diameter sleeve 3. The boundary between the mandrel main body 5a and the small-diameter sleeve 4 has the same outer diameter and forms the same outer peripheral surface, and thus has a tubular shape with a constant diameter without forming a step.

When the reinforcing fibers are wound by the filament winding method in this manner, a tube body 2 made of fiber reinforced plastic as shown in FIG. 3 is formed, and thereafter, if necessary, heating is performed to harden the resin and simultaneously to make the metal. The large diameter sleeve 3 and the small diameter sleeve 4 are bonded. FIG. 5 is a sectional view in this state.

After the resin has hardened, the mandrel 5 is pulled out to the left in FIG. 5 and is removed from the mold. As shown in FIG. 4, the large-diameter sleeve 3 and the small-diameter sleeve 4 are provided on both ends of the fiber-reinforced plastic tube body 2. The drive shaft 1 in which and are integrally fixed is obtained. In the drive shaft 1 manufactured in this manner, the inner diameter of the large-diameter sleeve 3 is equal to the inner diameter of the tubular body 2 between the sleeves 3 and 4, but the outer diameter of the small-diameter sleeve 4 is equal.

As described above, the working process is substantially the same as that of the conventional one, but the small diameter sleeve 4 having a smaller diameter than the conventional one can be integrally fixed to the tube body 2, and the small diameter sleeve 4 itself is lightweight and coupled to this. Also, a small joint can be used, and the tubular body 2 is made only of fiber reinforced plastic, so that the weight of the drive shaft 1 as a whole can be reduced. Further, the mandrel 5 can be reused, which is advantageous in terms of cost.

Next, another embodiment will be described with reference to FIG. Mandrel body 10 that forms the column of the mandrel 10
Mandrel end body that is coaxially reduced in diameter and protrudes at the end of a
10b is formed. The protrusion length of the mandrel end body portion 10b is small, and the yoke 11 of the joint is fitted to the mandrel end body portion 10b at the fitting portion 11b.

The yoke 11 is formed with a bifurcated connecting portion 11a which is connected to the mating yoke and a cylindrical fitting portion 11b which is formed on the base portion of the yoke 11 and protrudes on the side opposite to the connecting portion 11a. The joint portion 11b corresponds to the small diameter sleeve 4. That is, the fitting portion 11b has a cylinder whose outer diameter is the mandrel body portion.
10a has an outer diameter substantially equal to that of the mandrel end body portion 11b and has an inner diameter substantially equal to that of the mandrel end body portion 11b.
It is almost equal to the protruding length of 11b.

Therefore, when the fitting portion 11b of the yoke 11 is fitted into the mandrel end body portion 10b, the mandrel body portion 10a is
And the yoke fitting portion 11b are continuous so that their outer peripheral surfaces are the same. The mandrel body 10a and the yoke fitting portion 11
Reinforcing fibers are wound around b by the filament winding method to form the tubular body 12. After the reinforcing fibers are hardened, pull out the mandrel 10 to the left in FIG.
Demold.

Since the yoke 11 is directly and integrally fixed to the tubular body 12, the conventional sleeve is unnecessary, the number of parts is small, the work of connecting the sleeve and the yoke can be omitted, and the working process is shortened.

[0030]

According to the present invention, the small-diameter sleeve simultaneously formed integrally with the end portion of the fiber-reinforced plastic tube is smaller than the large-diameter sleeve in size and lighter in weight than before, and the joint to be joined thereto is also small in size. Anything can be used, and since the tube body is originally made only of fiber reinforced plastic and is lightweight, the weight of the drive shaft can be further reduced. In addition, small-sized sleeves and joint members can be made small, and the cost can be reduced.

By forming the yoke integrally with the small-diameter sleeve by forming the yoke with the small-diameter sleeve and the yoke integrally, it is possible to reduce the number of parts and work steps.

The work process is substantially the same as the conventional one, but the small diameter sleeve can be integrally formed with the fiber reinforced layer, and the drive shaft can be made smaller and lighter. Also, since the mandrel is removed by demolding and does not remain inside the fiber reinforced layer, the weight of the drive shaft can be reduced in that respect as well.
The mandrel is reused, which is advantageous in terms of cost.

By adopting the drive shaft manufacturing method in which the yoke is integrally formed in advance with the small diameter sleeve fitted to the mandrel, the work of joining the yoke to the sleeve is unnecessary and the work is simplified.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a state in which a large-diameter sleeve, a small-diameter sleeve, and a mandrel according to an embodiment of the present invention are coaxially arranged.

FIG. 2 is a perspective view showing a state in which a large-diameter sleeve and a small-diameter sleeve are fitted to predetermined positions on a mandrel.

FIG. 3 is a perspective view showing a state in which reinforcing fibers are wound by a filament winding method.

FIG. 4 is a perspective view of the drive shaft after demolding.

FIG. 5 is a cross-sectional view in the state shown in FIG.

FIG. 6 is a cross-sectional view in a process before demolding of another example.

FIG. 7 is a schematic view showing a conventional drive shaft molding method.

FIG. 8 is a sectional view of another conventional drive shaft.

[Explanation of symbols]

1 ... Drive shaft, 2 ... Tube, 3 ... Large diameter sleeve,
4 ... small sleeve, 5 ... mandrel, 10 ... mandrel,
11 ... Yoke, 12 ... Tube.

Claims (4)

[Claims] 1. A drive shaft in which metal sleeves are integrally formed on both ends of a fiber reinforced plastic pipe body, and one sleeve is a large diameter sleeve having an inner diameter substantially equal to the inner diameter of the pipe body between the sleeves. The drive shaft, wherein the other sleeve is a small-diameter sleeve having a smaller diameter than the large-diameter sleeve. 2. The drive shaft according to claim 1, wherein a yoke is integrally formed with the small diameter sleeve. 3. A mandrel body comprising a mandrel body having a predetermined outer diameter and a mandrel end body extending coaxially with the mandrel body having a large diameter sleeve having an inner diameter substantially equal to the outer diameter of the mandrel body. Is fitted in a predetermined position, a small-diameter sleeve having an inner diameter substantially equal to the outer diameter of the mandrel end body is fitted to the mandrel end body, and a filament winding method or the like is applied to a part of the sleeve and the mandrel body. A drive shaft manufacturing method characterized in that a fiber reinforced layer is integrally molded by a winding method, and after curing, the mandrel is pulled out and demolded. 4. The method of manufacturing a drive shaft according to claim 3, wherein a yoke is integrally formed in advance with a small diameter sleeve fitted to the mandrel.