KR20060000716A - Hybrid propeller shaft which is composed of metal and composite material and fabrication method thereof - Google Patents

Abstract

The present invention discloses a hybrid power transmission shaft made of a metal and a composite material having excellent non-rigidity and which can be produced relatively simply, and a method of manufacturing the same. Hybrid power transmission shaft according to the invention is composed of a hollow shaft, a composite layer cured and bonded to the inner surface of the hollow shaft, and a protective layer coated on the inner surface of the composite material layer, the method of manufacturing a hybrid power transmission shaft according to the present invention Stacking the silver composite material, bonding the composite material layer to the hollow shaft by means of the composite material contacting means, consolidating the composite material layer to the hollow shaft by the consolidation means, and curing the composite material layer on the hollow shaft. It consists of steps. Accordingly, the present invention provides a hybrid power transmission shaft made of a metal and a composite material, which is manufactured through a lamination and a curing process of a composite material without undergoing a separate vacuum bag forming process or an autoclave process, and has an improved straightness.

Specific Rigidity, Specific Strength, Hybrid, Power Transmission Shaft, Composite, Consolidation, Hardening

Description

HYBRID PROPELLER SHAFT WHICH IS COMPOSED OF METAL AND COMPOSITE MATERIAL AND FABRICATION METHOD THEREOF}

1 is a perspective view of a hybrid power transmission shaft made of a metal and a composite material according to the present invention.

2 is a cross-sectional view of a hybrid power transmission shaft made of a metal and a composite material according to the present invention.

3 is a perspective view showing a plurality of laminated composite layers according to the present invention.

4 is a perspective view showing the composite material layer contact means according to the first embodiment of the present invention.

5 is an enlarged view of a portion 'A' of FIG. 4.

6 is a perspective view showing the composite material layer contact means according to a second embodiment of the present invention.

7A, 7B, and 7C are process drawings for closely contacting a composite material layer to a hollow shaft according to a second embodiment of the present invention.

8 is a perspective view of a tube used in accordance with the present invention.

9A, 9B, and 9C are process flow diagrams in which a composite layer is consolidated on a hollow shaft by a tube used in accordance with the present invention.

10 is a perspective view showing a state in which the consolidated hollow shaft is fixed according to the present invention.

11 is a flow chart of a hybrid power transmission shaft manufacturing method consisting of a metal and a composite material according to the present invention.

♣ Explanation of symbols for main parts of drawing ♣

1: Hollow shaft 3: Composite material layer

4: backup film 5: protective layer

11: composite material adhesion means 13: metal thin plate

15: rubber plate 17: safety clamp

21: composite layer contact means 23: hollow rubber sheet

25: mandrel

31 consolidation means 33 polymer tube

35: reinforcing fiber material 41: V block

43: clamp 44: clamp screw

The present invention relates to a hybrid power transmission shaft made of a metal and a composite material having excellent non-rigidity and relatively simple, and a method of manufacturing the same. In particular, the straightness is improved and relatively simple for power transmission of a vehicle. The present invention relates to a hybrid power transmission shaft composed of a metal and a composite material, and a method of manufacturing the same.

Because fiber reinforced composites have superior specific stiffness and specific strength compared to steel or aluminum materials, the power transmission shaft of rear-wheel drive vehicles currently has specific stiffness and specific strength compared to conventional steel or aluminum materials. Research into replacing excellent composite materials is actively underway. When the composite material is applied to the driving shaft of the vehicle, the axial rigidity increases, so that the natural frequency in the bending direction increases. Accordingly, the structure of the conventional metal drive shaft consisting of two shafts of about 1.5 m in length can be manufactured integrally, thus eliminating the need for the members used to connect the two conventional shafts.

On the other hand, a drive shaft made of only a composite material has a disadvantage that the price is more expensive than the conventional metal drive shaft. Therefore, in consideration of the production cost, it is preferable to use a composite material having a superior rigidity such as a carbon fiber composite material and a metal such as aluminum alloy, which is light and has excellent torque transfer capability, rather than using only the composite material. Here, the metal material plays a role of supporting the torque and the composite material increases the axial rigidity, thereby increasing the natural frequency of the drive shaft.

As such, there is a co-curing method for producing a power transmission shaft using a metal material and a composite material together. According to the co-curing method, when the composite material is wound around the hollow metal shaft and cured, the composite material is cured and the bonding is performed between the two materials, thereby simplifying the production process and lowering the manufacturing cost.

In a conventional hybrid power transmission shaft composed of a metal material and a composite material, a vacuum bag molding process or an autoclave process is applied to fabricate a power transmission shaft coated with a composite material on the inner surface of the metal material. Vacuum bag forming process is a method of inserting the composite material on the inner surface of the metal shaft and processing the vacuum bag surrounding the inner surface of the composite material. In this case, the entire inner surface of the composite material must be vacuumed so that the composite material is consolidated on the metal shaft. The autoclave process is a process of inserting a composite material into the metal shaft to heat and pressurize the inside of the composite material to bring the composite material into close contact with the inside of the metal shaft.

The conventional power transmission shaft as described above has a problem that is produced through a separate vacuum bag molding process or an autoclave process, which is expensive and complicated in the process. In addition, the conventional power transmission shaft has a disadvantage in that moisture is absorbed into the material formed inside the shaft when the device is driven, thereby deteriorating the physical properties of the power transmission shaft.

The present invention has been made to solve the above problems, the object of the present invention is a metal and composite material that can be produced through the stacking and curing process of the composite material without a separate vacuum bag molding process or autoclave process It is to provide a hybrid power transmission shaft and a method of manufacturing the same.

Another object of the present invention is to provide a hybrid power transmission shaft made of a metal and a composite material that can be used for a long time by blocking moisture and a method of manufacturing the same.

Still another object of the present invention is to provide a hybrid power transmission shaft made of a metal and a composite material having improved straightness so that sag does not occur at a relatively low cost, and a method of manufacturing the same.

Other objects, specific advantages and novel features of the present invention will become more apparent from the following detailed description and the preferred embodiments associated with the accompanying drawings.

As a feature of the present invention for achieving the above object, a hybrid power transmission shaft made of a metal and a composite material according to the present invention is a hollow shaft, a composite layer cured and bonded to the inner surface of the hollow shaft, the inner surface of the composite material layer It consists of a protective layer coated on.

As another feature of the present invention, the hybrid power transmission shaft manufacturing method consisting of a metal and a composite material according to the present invention comprises the steps of laminating the composite material, the step of contacting the composite material layer to the hollow shaft by the composite material contact means, and consolidation Consolidating the composite material layer on the hollow shaft by means, and curing the composite material layer on the hollow shaft.

Hereinafter, a hybrid power transmission shaft made of a metal and a composite material and a method of manufacturing the same according to the present invention will be described in detail with reference to the accompanying drawings.

1 is a perspective view of a hybrid power transmission shaft made of a metal and a composite material according to the present invention, Figure 2 is a cross-sectional view of the hybrid power transmission shaft made of a metal and a composite material according to the present invention. 1 and 2 together, the hybrid power transmission shaft according to the present invention is manufactured in a hollow cylinder type inside.

A plurality of composite material layers 3 are laminated on the inner surface of the hollow shaft 1 manufactured in a cylindrical shape. A protective layer 5 for protecting the composite material layer 3 is coated on the composite material layer 3 laminated on the innermost surface of the plurality of laminated composite material layers.

The hollow shaft 1 is made of a material having good non-rigidity such as aluminum alloy material. In addition, the hollow shaft 1 may be manufactured by mixing a carbon fiber-reinforced composite material having a relatively higher specific rigidity with an aluminum alloy material.

The composite material layer 3 is made of prepreg having adhesiveness at room temperature. Since the prepreg is in a semi-cured state at room temperature, the prepreg is easily laminated with self adhesiveness. In general, the backing film 4 (see FIG. 3) is coated on both sides of the prepreg in order to prevent the adhesive prepreg from adhering to an unwanted portion. The backing film 4 is made of polyethylene or Teflon so as to protect the side of the sticky prepreg and to be easily separated during lamination.

The protective layer 5 is coated on the innermost surface of the composite material layer 3. The protective layer 5 is made of a polymer film or paper. The protective layer 5 is coated by pressing on the composite material layer 3 by a heating roller so that the adhesive force is maintained for a long time. The protective layer 5 may be replaced with the remaining backing film as it does not peel off the backing film 4 attached to the innermost surface of the composite material layer 3 which is stacked in plural.

3 is a perspective view showing a plurality of laminated composite layers according to the present invention. As shown in FIG. 3, the composite material layer 3 is coated with a backup film 4 which protects the composite material layer 3 so as not to adhere to other materials before lamination. Since the backup film 4 is easily peeled off when the composite material layer 3 is laminated, the plurality of composite material layers 3 are easily laminated with each other. The innermost surface of the plurality of composite material layers 3 is coated with a protective layer 5 which protects the composite material layer 3 so as not to penetrate the composite material layer 3 with chemical components or moisture.

4 is a perspective view showing the composite material layer contact means according to the first embodiment of the present invention, Figure 5 is an enlarged view of portion 'A' of FIG. 4 and 5 together, the composite material layer contact means 11 is surrounded by a plurality of laminated composite material layer 3 and the protective layer 5 coated on the inner surface of the composite material layer (3). The composite material contacting means 11 is made of a hollow cylindrical shape and is made of a material in which a radial radial outward force is embedded. In the first embodiment of the present invention, the composite material layer contact means 11 is composed of a metal sheet 13 bent in a cylindrical shape and a rubber plate 15 attached to an outer surface thereof.

The metal thin plate 13 is bent from a thin plate shape to a cylindrical shape, and is unfolded radially outward unless the metal thin plate 13 is restrained by a force to be restored to its original state. The rubber plate 15 is attached to the outer surface of the metal thin plate 13. The rubber plate 15 is made of a material such as silicon. The rubber material is in close contact with the protective layer 5 fixed in the interior of the composite material layer 3 to distribute the force evenly radially outward.

As shown in Figure 4, the composite material layer contact means 11 is equipped with safety clamps 17 on both sides to restrain the means. The safety clamp 17 restrains the composite layer contact means 11 to such an extent that the safety clamp 17 can be fitted to the hollow shaft 1 before being fitted to the hollow shaft 1.

In the above, only the case where the composite material contacting means 11 is in close contact with the protective layer 5 having no adhesive force to separate from the hollow shaft 1 after the hybrid power transmission shaft is manufactured, but the composite material contacting in accordance with the present invention In order to permanently use the means 11, the protective layer 5 may be peeled off so that the composite layer adhesion means 11 may be attached to the composite layer 3. In this case, the composite layer contact means 11 functions as a permanent constrained damping layer.

The composite material contacting means 11 constrained by the safety clamp 17 is fitted into the hollow shaft 1 together with the composite material layer 3 surrounded by its outer surface. After that, when the safety clamp 17 is removed and the composite layer adhesion means 11 exerts a force on the composite layer 3 toward the outside in the radial direction, the composite layer 3 is applied to the hollow shaft 1. Close contact.

6 is a perspective view showing the composite material layer contact means according to the second embodiment of the present invention, Figures 7a, 7b, and 7c is a contact of the composite material layer to the hollow shaft in accordance with the second embodiment of the present invention It is a process chart. As shown in Figure 6, the composite material layer contact means 21 according to the second embodiment of the present invention a plurality of laminated composite material layer 3 and a protective layer coated on the inner surface of the composite material layer (3) (5) is surrounded.

Composite layer contact means 21 is composed of a hollow rubber plate 23 and the mandrel 25 interposed in the hollow rubber plate (23). The hollow rubber plate 23 is made relatively thick compared to the general plate shape to maintain the cylinder shape during the close contact process. The hollow rubber plate 23 and the mandrel 25 interposed inside the hollow rubber plate 23 are inserted into the hollow shaft 1 together with the composite material layer 3 surrounded by the outside thereof.

7A to 7C, the mandrel 25 rotates in the circumferential direction while being inserted into the hollow shaft 1. The composite material layer 3 made of a prepreg having an adhesive force at room temperature is in close contact with the hollow shaft 1 by the rotation of the mandrel 25. In this case, the hollow rubber plate 23 evenly distributes the force due to the rotation of the mandrel 25 to the composite material layer 3. In addition, since the hollow rubber plate 23 is thicker than the general plate, the force is dispersed and transmitted to the composite material layer 3 while maintaining the hollow cylinder shape.

From now on, the apparatus for consolidating the composite material layer 3 in close contact with the hollow shaft 1 and the process thereof will be described.

Figure 8 is a perspective view of a tube used in accordance with the present invention, Figures 9a, 9b, and 9c is a process flow diagram of the composite material layer is consolidated to the hollow shaft by the tube used in accordance with the present invention. As shown in FIG. 8, the consolidation means 31 according to the present invention is composed of a polymer tube 33 into which air is inserted and a reinforcing fiber material 35 attached to an outer surface of the polymer tube 33.

The consolidation means 31 is inserted into the inner surface of the metal thin plate 13 or the hollow rubber plate 23. The polymer tube 33 has a space in which air can be injected. Accordingly, the polymer tube 33 will expand when air is injected. The reinforcing fiber material 35 is attached to the outer surface of the polymer tube 33. The reinforcing fiber material 35 is attached to the outer surface of the polymer tube 33 in order to disperse excessive pressure acting in the tube when the polymer tube 33 is excessively expanded.

9A to 9C, the consolidation means 31 inserted into the metal thin plate 13 or the hollow rubber plate 23 is formed of the metal thin plate 13 or the hollow rubber plate 23 by the expansion force 26 during air injection. ) Slide radially outward. Thus, the composite material layer 3 is consolidated on the hollow shaft 1. The consolidation means 31 in the expanded state is expanded so as to have a diameter equal to or slightly larger than the inner diameter of the hollow shaft 1 so that a relatively large and uniform consolidation force can be transmitted to the composite material layer 3.

10 is a perspective view showing a state in which the consolidated hollow shaft is fixed according to the present invention. As shown in FIG. 10, the hollow shaft 1 is supported by the V block 41 on the inner surface thereof with the composite material layer 3 consolidated by the air pressure of the consolidation means 31. The V block 41 supports the hollow shaft 1 in a plurality of three or more so that sagging of the shaft does not occur in the machining process of the hybrid power transmission shaft according to the present invention.

The clamp 43 fixes the hollow shaft 1 supported by the V block 41 so as not to shake. The clamp screw 44 formed in the clamp 43 is symmetrically disposed up and down of the hollow shaft 1. Accordingly, the hollow shaft 1 tightened by the clamp screw 44 does not deform asymmetrically. According to the invention, the clamp 43 is preferably arranged between the plurality of V blocks 41 to prevent the flow of the hollow shaft 1.

The hollow shaft 1 fixed by the V block 41 and the clamp 43 is heated from an external heat source. Hardening of the composite material layer 3 advances by heating. In this state, since the consolidation means 31 is maintained in an expanded state, the composite material layer 3 is strongly adhered to the hollow shaft 1. Thereafter, when the heated hollow shaft 1 is cooled, the composite material layer 3 is hardened and attached to the hollow shaft 1 with high adhesive force.

11 is a flow chart of a hybrid power transmission shaft manufacturing method consisting of a metal and a composite material according to the present invention. According to the hybrid power transmission shaft manufacturing method of the present invention, first, the composite material is laminated (S10). Since the composite material has adhesive strength at room temperature before lamination, both sides are protected by the backup film 4. In this state, the backing film 4 is peeled off in order to laminate the composite material, and in turn, the composite material is laminated to produce the composite material layer 3.

Next, the composite material is in close contact with the hollow shaft by the composite material contact means (11; 21) (S20). To this end, the metal thin plate 13 is bent in a cylindrical shape and tightened with a safety clamp 17. Thereafter, the metal thin plate 13 and the rubber plate 15 attached to the outer surface thereof are inserted into the inner surface of the composite material layer 3, and the metal thin plate 13 fastened by the safety clamp 17 is unfolded. The composite material layer 3 is in close contact with the hollow shaft 1 by the unfolded metal thin plate 13. In addition, by inserting the hollow rubber plate 23 and the mandrel 25 interposed therein into the composite material layer 3 and rotating the mandrel 25, the composite material layer 3 to the hollow shaft (1) It can be in close contact.

After the composite material is in close contact with the hollow shaft, the composite material layer 3 is consolidated on the hollow shaft 1 by the consolidation means (S30). As the consolidation means according to the present invention, a polymer tube 33 into which air can be injected is applied. The polymer tube 33 is inserted into the metal thin plate 13 or the hollow rubber plate 23, and then air is injected. Thus, the composite material layer 3 is consolidated to the hollow shaft 1 by the air pressure injected into the polymer tube 33. In addition, according to the present invention, various consolidation means capable of consolidating the hollow shaft 1 by applying pressure to the composite material layer 3 may be applied.

Finally, the composite material layer 3 is cured in the hollow shaft 1 (S40). At this time, the hollow shaft 1 is supported by the V block 41 and fixed by the clamp 43. Thereafter, the composite material layer 3 is heated while being consolidated to the hollow shaft 1, and then the composite material layer 3 and the hollow shaft 1 are cooled. The composite material layer 3 is cured in a state of being attached to the hollow shaft 1 through heating and cooling.

The embodiments described above are merely illustrative of the preferred embodiments of the present invention, the scope of the present invention is not limited to the described embodiments, those skilled in the art within the spirit and claims of the present invention It will be understood that various changes, modifications, or substitutions may be made thereto, and such embodiments are to be understood as being within the scope of the present invention.

The present invention has the effect of producing a hybrid power transmission shaft made of a metal and a composite material that can be produced through the stacking and curing process of the composite material without a separate vacuum bag molding process or autoclave process. In addition, there is an effect that can produce a hybrid power transmission shaft made of a metal and a composite material that can be used for a long time by preventing the absorption of moisture. In addition, the straightness is improved so that the deflection does not occur, there is an effect that can produce a hybrid power transmission shaft made of a metal and a composite material that does not oscillate at the same time.

Claims (11)

Hollow shaft; A composite material layer formed on an inner surface of the hollow shaft; Hybrid power transmission shaft consisting of a metal and a composite material consisting of a protective layer coated on the inner surface of the composite material layer. The hybrid power transmission shaft of claim 1, wherein the composite material layer is formed of a metal and a composite material in which a plurality of prepregs having adhesive strength are stacked. The hybrid power transmission shaft of claim 2, wherein the protective layer is formed of a metal and a composite material made of a metal thin plate. The hybrid power transmission shaft of claim 2, wherein the protective layer is formed of a metal and a composite material made of a polymer film. The hybrid power transmission shaft of claim 2, wherein the protective layer is made of a metal and a composite material made of paper. Laminating the composite material; Bringing the composite material layer into close contact with the hollow shaft by the composite material contact means; Consolidating the composite material layer on the hollow shaft by consolidation means; Hybrid power transmission shaft manufacturing method consisting of a metal and a composite material consisting of curing the composite material layer on the hollow shaft. The method of claim 6, wherein the step of bringing the composite material layer into close contact with the hollow shaft Bending and bending the metal sheet into a cylindrical shape; Inserting the metal sheet and a rubber plate attached to an outer surface of the metal sheet into an inner surface of the composite material layer; Hybrid power transmission shaft manufacturing method consisting of a metal and a composite material consisting of the step of unfolding the tightened metal thin plate. The method of claim 6 or 7, wherein the step of consolidating the composite material layer on the hollow shaft Inserting a polymer tube into which the air can be injected into the metal sheet; Hybrid power transmission shaft manufacturing method consisting of a metal and a composite material consisting of injecting air into the polymer tube. The method of claim 6, wherein the step of bringing the composite material layer into close contact with the hollow shaft Inserting a hollow rubber plate and a mandrel interposed between the hollow rubber plate into the composite material layer; Hybrid power transmission shaft manufacturing method consisting of a metal and a composite material consisting of rotating the mandrel. 10. The method of claim 6 or 9, wherein the step of consolidating the composite material layer on the hollow shaft  Inserting a polymer tube into which the air can be injected into the metal sheet; Hybrid power transmission shaft manufacturing method consisting of a metal and a composite material consisting of injecting air into the polymer tube. The method of claim 6, wherein the curing of the composite material layer on the hollow shaft Supporting the hollow shaft with a V block and fixing the clamp with a clamp; Hybrid power transmission shaft manufacturing method consisting of a metal and a composite material consisting of heating the hollow shaft.

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