Abstract: A shaft may include a first coupling member, a second coupling member, a filament wound shaft member, and a pilot shaft. The first coupling member may couple the shaft to one of a rotationally driving and a rotationally driven component. The second coupling member may be axially spaced from the first coupling member and may couple the shaft to the other of the rotationally driving and the rotationally driven component. The filament wound shaft member may have a first end fixed to the first coupling member, a second end fixed to the second coupling member, and a body portion extending therebetween. The pilot shaft may be disposed radially within the filament wound shaft member and may extend from the first coupling member to the second coupling member.

Abstract: A shaft may include a first coupling member, a second coupling member, a filament wound shaft member, and a pilot shaft. The first coupling member may couple the shaft to one of a rotationally driving and a rotationally driven component. The second coupling member may be axially spaced from the first coupling member and may couple the shaft to the other of the rotationally driving and the rotationally driven component. The filament wound shaft member may have a first end fixed to the first coupling member, a second end fixed to the second coupling member, and a body portion extending therebetween. The pilot shaft may be disposed radially within the filament wound shaft member and may extend from the first coupling member to the second coupling member.

Abstract: A composite shaft assembly may include a shaft body and a flange. The shaft body may include a filament and the flange may include an external surface having a plurality of lugs extending therefrom. A first and second of the plurality of lugs may have an axial spacing therebetween. The filament may be wound between the first and second lugs.

Abstract: A method for forming stabilized preforms for complex composite articles is disclosed using a solid meltable uncatalyzed thermosetting resin as the stabilizing agent. The resin is applied to each layer of the preform and heated to melt the resin and bond the layers together. After cooling, the resin resolidifies but does not set and thereby holds the layers in the desired preform shape. The layers can be first formed into a flat sheet as a raw material from which shaped preforms can be made by cutting the sheet into sections which are placed over a mandrel and reheating to thereby remelt the solid resin to allow the preform to conform to the shape of the mandrel. Utilizing this process allows complex composite parts to be easily preformed and assembled prior to placement in a mold for resin injection molding, without inhibiting part strength as the resin is compatible with the injection resin and is cocatalyzed by the catalyst contained in the injection resin.

Abstract: A method for forming stabilized preforms for complex composite articles is disclosed using a solid meltable uncatalyzed thermosetting resin as the stabilizing agent. The resin is applied to each layer of the preform and heated to melt the resin and bond the layers together. After cooling, the resin resolidifies but does not set and thereby holds the layers in the desired preform shape. The layers can be first formed into a flat sheet as a raw material from which shaped preforms can be made by cutting the sheet into sections which are placed over a mandrel and reheating to thereby remelt the solid resin to allow the preform to conform to the shape of the mandrel. Utilizing this process allows complex composite parts to be easily preformed and assembled prior to placement in a mold for resin injection molding, without inhibiting part strength as the resin is compatible with the injection resin and is cocatalyzed by the catalyst contained in the injection resin.

Abstract: A preform assembly for use with a resin transfer molding apparatus. The preform assembly includes a dry fabric preform and a thin high density foam insert, the preform being folded about and firmly fastened to said insert to form a preform assembly having a stiffened and stabilized preform edge, wherein the edge aids in the insertion of the preform assembly into a mold cavity or channel of the resin transfer mold apparatus. Methods for making such preform assembly and composite article are also disclosed.

Abstract: A method for fabricating and stabilizing three dimensional composite fabric preforms. The method comprises disposing a plurality of fabric plies between upper and lower templates that have substantially the desired preform shape and openings in at least two planes. The fabric plies are joined through the template openings and the templates are removed from the preform. These stabilized preforms maintain tighter tolerances.