Abstract: Composite continuous filament wound flexible composite driveshafts with integral spacing tube and flexible diaphragms and methods of manufacture. Fully anisotropic material properties are mapped to the deeply sculpted diaphragm geometry of flexible composite coupling elements attached at outer diameters for high torque applications. Continuous filament wound spacing tubes of the shaft control natural frequencies and torsional stability in conjunction with multiple flexible composite diaphragms.

Abstract: An all-composite continuous filament wound flexible composite driveshaft with integral spacing tube and flexible diaphragms and methods of manufacture is disclosed. The flexible composite driveshaft obsoletes the split lines and associated fasteners required to attach metallic flex elements and either metallic or composite spacing tubes in current solutions. Sub-critical driveshaft weights half that of incumbent technology are projected for typical rotary wing shaft lengths. Fully anisotropic material properties are mapped to the deeply sculpted diaphragm geometry of flexible composite coupling elements, and a parametric numerical study of the complex shell disclosed. Continuous filament wound spacing tubes are described, which comprise an integral part of the initial tooling but which remain part of the finished shaft and control natural frequencies and torsional stability in conjunction with the flexible composite diaphragms.

Abstract: A torsion box, useful for skis, snowboards or the like, has a constant cross section and a hollow interior. The torsion box is made from a plurality of plies and a resin matrix, at least some of the plies consisting of fibers disposed at an angle with respect to a longitudinal axis of the torsion box. The plies include fibers preferably selected from the group consisting of glass, carbon and Kevlar.RTM.. Particularly, the fibers will be angled with respect to the longitudinal axis of the torsion box within a range of about 0.degree. to about 45.degree.. The torsion box may be made by a pultrusion process where the desired fibers are pulled through a resin bath, or injected with resin, and heated in a die, then cut to a desired length. The plies are arranged to impart a material imbalance to the torsion box so that, upon cooldown, the product exhibits a predetermined camber.

Abstract: A flexible composite coupling (20) wherein a wound filament or roving is wound between two attachment members (22) and (24) and is fully or partially impregnated with a resin matrix such as urethane to form a flexible element (32). The attachment members (22) and (24) include radially extending flanges (26) and (28) which have a radiused periphery (30) formed on them, over which the flexible element (32) is wound. The flexible element (32) diverges inwardly from the flanges' (26) and (28) radiused periphery (30) to form opposed diaphragm portions (34) and (35) of the flexible element (32) which smoothly meet at a minimum diameter (36). Hoop winds (38) of a material with high strain capacity wrapped about this minimum diameter (36) pretension the filaments or roving within the flexible element (32).