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Title:
A SHAFT AND PRODUCTION METHOD THEREOF
Document Type and Number:
WIPO Patent Application WO/2019/216848
Kind Code:
A2
Abstract:
The invention is related to a shaft (S) which enables to transmit power between the transmission and the differential gear and production method of said shaft (S), which comprises a composite torsion rod (10) which is made of carbon fibre reinforced polymer resin, a joint (20) having an joint connection part (21) which comprises a protrusion at the end thereof which is suitable to be adhered to said torsion rod (10) a connection flange (30) having a connection flange fixing part (31), and joint (20) and connection flange (30).

Inventors:
ÜNAL, Mehmet Akif (Küçükbakkalköy Mh. Kayışdağı Cad. Defne Sokak Büyükhanlı Plaza No:3 Kat:1, Ataşehir/İstanbul, TR)
KARAGÜL, Ferhunde Sedef (Küçükbakkalköy Mh. Kayışdağı Cad. Defne Sokak Büyükhanlı Plaza No:3 Kat:1, Ataşehir/İstanbul, TR)
ERSOY, Merve (Küçükbakkalköy Mh. Kayışdağı Cad. Defne Sokak Büyükhanlı Plaza No:3 Kat:1, Ataşehir/İstanbul, TR)
ERSOY, Nuri Bülent (Boğaziçi Üniversitesi Makinesi Mühendisliği Bölümü, Bebek, İstanbul, TR)
ÇAKIL, Semih (Aselsan Elektronik Sanayi Ve Ticaret Anonim Sirketi Mgeo Grup Başkanlığı Çankırı Yolu 7 Km, Akyurt/Ankara, TR)
KARTAL BERKER, Ayşe Meriç (Kozyatağı Mah Şakacı S Deval Apt 45/12, Kadıköy/İstanbul, 34742, TR)
ÖZÇELİK, Yunus Emre (Küçükbakkalköy Mh. Kayışdağı Cad. Defne Sokak Büyükhanlı Plaza No:3 Kat:1, Ataşehir/İstanbul, TR)
Application Number:
TR2018/050708
Publication Date:
November 14, 2019
Filing Date:
November 20, 2018
Export Citation:
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Assignee:
BORUSAN TEKNOLOJİ GELİŞTİRME VE ARGE A.Ş. (Pürtelaş Hasan Efendi Mahallesi Meclis-i Mebusan Cad. No.35/4, Beyoğlu/Istanbul, TR)
BOĞAZİÇİ ÜNİVERSİTESİ (Güney Kampüs Bebek, Beşiktaş/İstanbul, TR)
Attorney, Agent or Firm:
BİLEN SINAİ MÜLK. HİZ. DAN. MÜH. İTH. İHR. TİC. LTD. ŞTİ. (Hüdavendigarmah. Bent Cad. No:163/B, Osmangazi/Bursa, TR)
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Claims:
CLAIMS

1. The invention is a shaft (S) production method made of composite material, characterized in that it comprises the below process steps,

The fibre is wound around the mandrel (40) such that it provides an certain angle which is repetitive

Following the winding process the mandrel (40) is placed into a two-piece mould (50)

A suitable amount of resin is injected into the mould (50)

Curing stage is carried out

It is taken out of the mould (50) and the mandrel (40)

The burrs of the torsion rod (10) is removed and cleaned

The joint (20) and connection flange (30) which forms the parts of the shaft (S) is mounted to the torsion rod (10).

2. A production method of a shaft (S) made of composite material according to claim 1 , comprising the process step of winding the fibre around the mandrel (40) with an alignment of ([+45°, -45°]).

3. A shaft (S) production method according to claim 1 , which allows a composite torsion rod (10) to be produced in a mould (50) which is made of a top mould (51 ) and bottom mould (52) which allows a certain amount of resin to be injected therein and which comprises at least a mandrel (40) which allows fibre to be wound around it a certain alignment.

4. A shaft (S) production method made of composite material according to claim 1 , which comprises the process step of winding carbon fibre around a mandrel (40).

5. A shaft (S) production method made of composite material according to claim 1 , which comprises the process step of winding fibre glass around a mandrel (40).

6. A shaft (S) production method made of composite material according to claim 1 , which comprises the process step of winding aramid fibre around a mandrel (40).

7. A shaft (S) production method made of composite material according to claim 1 , which comprises the process step of winding Kevlar fibre around a mandrel (40).

8. A shaft (S) production method made of composite material according to claim 1 , which comprises the process step of injecting thermoplastic resin inside the mould (50).

9. A shaft (S) production method made of composite material according to claim 1 , which comprises the process step of injecting thermoset resin inside the mould (50).

10. A shaft (S) production method made of composite material according to claim 1 , which comprises the process step of injecting elastomeric resin inside the mould (50).

1 1 . The invention is a shaft (S) of the automotive sector which enables to transmit power between the transmission and the differential gear, characterized in that it comprises a composite torsion rod (10) which is made of carbon fibre reinforced polymer resin, a joint (20) having an joint connection part (21 ) which comprises a protrusion at the end thereof which is suitable to be adhered to said torsion rod (10) a connection flange (30) having a connection flange fixing part (31 ) , and joint (20) and connection flange (30).

12. A shaft (S) according to claim 1 1 which comprises a joint connection part (21 ) that is suitable to the inner diameter of the torsion rod (10).

13. A shaft (S) according to claim 1 1 which comprises connection flange fixing part (31 ) that is suitable to the inner diameter of the torsion rod (10).

14. A shaft (S) according to claim 1 1 which comprises a torsion rod (10) that is produced from carbon fibre composite material.

15. A shaft (S) according to claim 1 1 which comprises a torsion rod (10) that is produced from glass fibre composite material.

16. A shaft (S) according to claim 11 which comprises a torsion rod (10) that is produced from aramid fibre composite material.

17. A shaft (S) according to claim 11 which comprises a torsion rod (10) that is

produced from Kevlar fibre composite material.

Description:
A SHAFT AND PRODUCTION METHOD THEREOF

TECHNICAL FIELD

The invention is related to a novelty carried out on a shaft which is a part that enables the power received from the transmission to be transmitted to the rear axles.

The invention is particularly related to a shaft and a production method thereof whose weight has been reduced and whose torsional resistance has been increased.

PRIOR ART

The shaft is a part that has been positioned between the transmission and the differential gear. The power received by the transmission is transmitted to the differential gear by means of the shaft particularly in rear wheel drive or four wheel drive vehicles. In the known state of the art a coupling part is mounted to one of the shaft and a slider or universal joint is mounted to the other end. Power transmission at different angles can be carried out between the transmission and the differential gear by means of the universal joints. By this means the difference of height between the axle and the transmission does not constitute a problem. By virtue of the universal joints, the damage that may be incurred on the shaft or the elements it is connected to is prevented as the shaft lengthens and shortens upon receiving negative forces arising from road conditions.

As a result of the developed technology in the automotive sector it is crucial for the weights to be reduced and durability to be increased. In the known state of the art composite or composite metal hybrid shaft configurations that are an alternative to shafts that are produced from metal or preferably steel materials are available.

In the European Patent Office document EP0537035 a type of composite shaft is described. The invention is particularly formed of a fibre reinforced tube that has been further reinforced with synthetic material. In said document a protruding type of a tube l configuration is mentioned. The production method of said shaft has not been described and the end resulting product is completely different.

In the SIPO patent document numbered CN10539833 a type of hybrid shaft is described. In said configuration the shaft body is made of aluminium alloy rod and composite material is coated around the external part of the aluminium pipe. By means of this configuration the weight of the metal shaft is reduced up to 63%. The torsional resistance has been increased more than 50% compared to metal material.

In the SIPO patent document numbered CN205371275 a shaft production method which is produced by means of a three dimensional braiding method is described. Due to the production method subject to the invention, this invention is completely different from the one described below.

In the WIPO patent document numbered WO2016KR04355 the increasing of the natural frequency of the shaft in order to solve the resonance problem by producing the rod in a hybrid way, using composite material has been described. Obtaining a cylindrical rod which is hollow, by winding several plates and placing a pipe made of composite material inside said rod by applying a number of thermal processes is described.

In the KIPRIS Patent Office document numbered KR20120047713 a shaft made of carbon and fibre glass reinforced material whose weight has been reduced in order to reduce overall weight has been described. It is also aimed to prevent potential corrosion by means of said invention.

As a result all of the problems mentioned above, have made it necessary to provide a novelty in the related field.

OBJECTS OF THE INVENTION

The present invention makes it a necessity to eliminate the problems mentioned above and to provide novelty in the related technical field.

The main object of the invention is to provide a shaft structure which enables to reduce the weight of the shaft which transmits power in vehicles, to increase efficiency and resistance and to provide energy saving and economical saving during the production of the shaft by means of the developed method.

Another aim of the invention is to increase efficiency during torque transition phases at the time of power transmission between the transmission and the differential gear.

Another aim of the invention is to eliminate the production challenges in cylindrical geometry during composite shaft production.

Another aim of the invention is to increase the composite shaft production capacity.

BRIEF DESCRIPTION OF THE INVENTION

The invention is related to a shaft and production method thereof in order to carry out all of the aims that shall be construed from the information mentioned above and the detailed description below.

The invention is a shaft which enables to transmit power between the transmission and the differential gear and production method of said shaft, characterized in that it comprises a composite torsion rod which is made of carbon fibre reinforced polymer resin, a joint having an joint connection part which comprises a protrusion at the end thereof which is suitable to be adhered to said torsion rod, a connection flange having a connection flange fixing part, and joint and connection flange.

The shaft production method subject to the invention is a shaft production method made of composite material which is characterized in that it comprises the process steps of,

The fibre is wound around the mandrel such that it provides an certain angle which is repetitive

Following the winding process the mandrel is placed into a two-piece mould

A suitable amount of resin is injected into the mould

Curing stage is carried out

It is taken out of the mould and the mandrel

The burrs of the torsion rod is removed and cleaned The joint and connection flange which forms the parts of the shaft is mounted to the torsion rod

In a preferred embodiment the invention comprises the process step of winding fibre around the mandrel at an alignment of ([+45°, -45°]).

In another preferred embodiment a composite torsion rod is produced in a mould by means of a top mould and bottom mould which allows a certain amount of resin to be injected therein and which comprises at least a mandrel which allows fibre to be wound around it in a certain alignment.

According to another preferred embodiment of the invention the method comprises the process step of winding carbon fibre around the mandrel.

According to another preferred embodiment of the invention thermoplastic resin is injected into the mould.

According to another preferred embodiment of the invention thermoset resin is injected into the mould.

According to another preferred embodiment of the invention elastomeric resin is injected into the mould.

In another preferred embodiment of the invention the end of the joint connection part comprises a protrusion which surrounds said joint connection part.

In another preferred embodiment the invention comprises a joint connection part which is suitable to the inner diameter of the torsion rod.

In another preferred embodiment the invention comprises a connection flange which is suitable to the inner diameter of the torsion rod.

According to another preferred embodiment the invention comprises a torsion rod which is made of carbon fibre composite material.

According to another preferred embodiment the invention comprises a torsion rod which is made of fibre glass composite material. According to another preferred embodiment the invention comprises a torsion rod which is made of aramid fibre composite material.

According to another preferred embodiment the invention comprises a torsion rod which is made of Kevlar ® fibre composite material.

In another preferred embodiment of the invention the torsion rod which is made of composite material (10) comprises glass fibre or carbon fibre or aramid fibre or Kevlar ® fibre or a combination thereof. The resin used in order to obtain composite material can be selected from thermoset or thermoplastic or elastomeric resin according to other preferred embodiments of the invention.

In a preferred embodiment of the invention the mandrel has been produced from any type of cylindrical solid profile. In another embodiment of the invention, a torsion rod is produced by using an inflatable bladder or case instead of the mandrel.

The protection scope of the invention has been defined in the claims and it should not be deemed to be limited with these illustrative descriptions and brief description. It is obvious that a person skilled in the art can provide similar embodiments in view of the information described above without deviating from the main scope of the invention.

BRIEF DESCRIPTION OF THE FIGURES

Figure 1A is the perspective view of the invention.

Figure 1 B is the exploded perspective view of the invention.

Figure 2A is the front view of the invention.

Figure 2B is the exploded front view of the invention.

Figure 3B is the section view of the mandrel which represents the fibre that is wound around the mandrel during the production of the shaft subject to the invention.

Figure 4A is the perspective view of the mould used during the production of the invention.

Figure 4B is the section view of the mould used during the production of the invention. DESCRIPTION OF THE REFERENCE NUMBERS GIVEN IN THE DRAWINGS

10. Torsion rod 20. Joint

21 . Joint connection part 30. Connection flange

31. Connection flange fixing part 40. Mandrel 50. Mould

51. Top mould

52. Bottom mould S. Shaft

DETAILED DESCRIPTION OF THE INVENTION

In this detailed description a shaft and production method thereof subject to the invention is described by means of examples that do not limit the invention but are intended to further describe the invention.

The invention is related to a method which enables to increase torsion and the weight of said shaft and a shaft which is a part that enables the power received from the transmission to be transmitted to the rear axles.

The invention is a shaft (S) which enables to transmit power between the transmission and the differential gear and production method of said shaft (S), characterized in that it comprises a composite torsion rod (10) which is made of carbon fibre reinforced polymer resin, a joint (20) having an joint connection part (21 ) which comprises a protrusion at the end thereof which is suitable to be adhered to said torsion rod (10) a connection flange (30) having a connection flange fixing part (31 ) , and joint (20) and connection flange (30). In Figure 1A the perspective view of the invention, in Figure 1 B the exploded perspective view of the invention, in Figure 2A the front view of the invention and in figure 2B the exploded front view of the invention has been provided.

The shaft (S) subject to the invention is made of three basic parts as can be seen from the figures. The shaft comprises a torsion rod (10) which is the power transmitting part at the mid section, and a connection flange (30) at one end of said torsion rod (10), which enables the torsion rod (10) to be connected to the differential gear. A joint (20) has been placed at the other end of the torsion rod (10) which enables the connection of the torsion rod (10) to the transmission. The joint (20) can be a sliding joint or universal joint according to the vehicle type in which the shaft (S) will be used.

The joint (20) of the invention comprises a joint connection part (21 ) that has been produced from metal at the end thereof and the connection flange (30) similarly comprises a connection flange fixing part (31 ) at the end thereof. The joint (20) and the connection flange (30) can be fixed onto the torsion rod (10) by means of said joint connection part (21 ) and connection flange fixing part (31 ). The end of the joint connection part (21 ) comprises a protrusion which surrounds said joint connection part (21 ).

The torsion rod (10) of the invention is made of composite material and is in a hollow cylindrical form. The torsion rod (10) made of composite material has been aligned such that it creates a +45° and -45° angle with the horizontal axis of fibre threads that the carbon fibre comprises. By this means when the shaft (S) is operating on the vehicle it provides high resistance against the torque received at both directions.

The joint (20) of the invention comprises a joint connection part (21 ) that has been produced from metal at the end thereof and the connection flange (30) similarly comprises a connection flange fixing part (31 ) at the end thereof. The joint (20) and the connection flange (30) can be fixed onto the torsion rod (10) by means of said joint connection part (21 ) and connection flange fixing part (31 ). The end of the joint connection part (21 ) comprises a protrusion which surrounds said joint connection part (21 ).

The mould (50) of the invention is formed of two pieces, namely the top mould (51 ) and the bottom mould (52). The resin injection to the mould (50) is preferably carried out via nozzles inside the top mould (51 ) and the bottom mould (52). The shaft (S) production method made of composite material subject to the invention comprises the below mentioned process steps,

The fibre is wound around the mandrel (40) such that it provides an certain angle which is repetitive

Following the winding process the mandrel (40) is placed into a two-piece mould (50)

A suitable amount of resin is injected into the mould (50)

Curing stage is carried out

It is taken out of the mould (50) and the mandrel (40)

The burrs of the torsion rod (10) is removed and cleaned

The joint (20) and connection flange (30) which forms the parts of the shaft (S) is mounted to the torsion rod (10).

A mandrel (40) which has the same outer diameter with the inner hollow diameter of the torsion rod (10) that is targeted to be obtained is used in the method subject to the invention. The fibre to be used is wound around preferably the carbon fibre mandrel (40) such that it shall have an angle of -45° and +45° between the mandrel (40) axes.

The winding process can be carried out manually, and in the preferred embodiment it can also be carried out using winding equipment. In Figure 3, the section view of the fibre that has been wound around the mandrel (40) n times is shown.

The mandrel (40) having fibre wound around in a suitable configuration is placed inside the mould (50) that is formed of two pieces, namely the top mould (51 ) and the bottom mould (52). Polymer resin injection is injected into the mould (50) and the resin is enabled to be completely absorbed by the fibre around the mandrel (40). In the next stage the processes of curing and extracting out of the mould are performed. The burrs of the torsion rod (10) that is obtained is cleaned and the rod is transferred to the mounting process.

In another preferred embodiment of the invention the fibre with absorbed resin is wound around the mandrel (40) at a pre determined number of winding processes and the rod is cured inside the mould (50). The torsion rod (10) that is prepared at the next stage is taken out of the mould (50) and the mandrel (40) and is made ready to be mounted. The winding of the fibre that has absorbed the resin, around the mandrel (40) and placing it inside the mould (50) takes longer than injecting resin into the mould. In a preferred embodiment of the invention the amount of the fibre wound around the mandrel (40) and the preferred thickness of the fibre can be changed in accordance with the resistance that is required.

The joint (20) and the connection flange (30) of the invention is fixed by placing the joint connection part (21 ) of the joint (20) at the end of the torsion rod (10) and similarly the connection flange fixing part (31 ) at the ends of the connection flange (30) inside the hollow section of the torsion rod (10). The fixing process can be carried out by means of an adhesive according to another embodiment of the invention. The adhesive that is used is preferably a metal plastic adhesive and in another referred embodiment a different type of adhesive can be used. In another preferred embodiment of the invention the joint (20) and the connection flange (30) are fixed to the torsion rod (10) by form fitting.

In another preferred embodiment of the invention the joint (20) and the connection flange (30) are fixed to the torsion rod (10) by close fitting.

In a preferred embodiment of the invention the mandrel (40) has been produced from any type of cylindrical solid profile. In another embodiment of the invention, a torsion rod (10) is produced by using an inflatable bladder or case instead of the mandrel (40).




 
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