Patent Publication Number: US-2021190133-A1

Title: Tubular body used for power transmission shaft and power transmission shaft

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a PCT Bypass Continuation application of and claims the priority benefit under 35 U.S.C. § 120 to PCT application No. PCT/JP2019/010024, filed on Mar. 12, 2019 and therefore also claims the priority benefit under 35 U.S.C. § 119 of Japanese Patent Application No. 2019-033412, filed on Feb. 27, 2019, the entire contents of each of PCT application No. PCT/JP2019/010024 and Japanese Patent Application No. 2019-033412 is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates to a tubular body used in a power transmission shaft and to a power transmission shaft. 
     BACKGROUND ART 
     A power transmission shaft (propeller shaft) mounted in a vehicle extends in a front-rear direction of the vehicle and transmits power, generated in a motor and subjected to speed reduction in a transmission, to a final drive gear. As such a power transmission shaft, there is a shaft made of a fiber reinforced plastic. 
     As a tubular power transmission shaft made of a fiber reinforced plastic, there is a shaft which includes a main body portion, a connection portion having a larger diameter than the main body portion, and an inclined portion formed between the main body portion and the connection portion and in which a shaft portion of a universal joint is fitted into the connection portion (see, for example, Patent Literature 1). 
     In the aforementioned power transmission shaft, when a vehicle is hit from the front side and impact load exceeding a predetermined value is inputted into the power transmission shaft, the shaft portion slides relative to the connection portion and abuts on an inner surface of the inclined portion and the inclined portion thereby fails. This causes an engine and a transmission mounted in a front portion of a vehicle body to quickly retreat and the front portion of the vehicle body absorbs impact energy. 
     Moreover, as another configuration of the power transmission shaft, there is a configuration in which a peripheral wall portion of a connection portion is formed of multiple layers and, when impact load exceeding a predetermined value is inputted into the power transmission shaft, an inner layer portion of the connection portion peels off and moves together with a shaft portion (see, for example, Patent Literature 2). 
     CITATION LIST 
     Patent Literature 
     Patent Literature 1: Japanese Patent Application Publication No. H09-175202 
     Patent Literature 2: Japanese Patent Application Publication No. H07-208445 
     SUMMARY OF INVENTION 
     Technical Problem 
     In the configuration in which the shaft portion slides relative to the connection portion only when the impact load exceeding the predetermined value is inputted out of the aforementioned conventional power transmission shafts, joining force between the connection portion and the shaft portion needs to be accurately set. To this end, the dimensions of the connection portion and the shaft portion need to be accurately molded and this causes a problem of an increase in manufacturing cost. 
     Moreover, in the configuration in which the inner peripheral portion of the connection portion peels off together with the shaft portion in impact out of the aforementioned conventional power transmission shafts, the peripheral wall portion of the connection portion is formed of multiple layers and this causes a problem of an increase in manufacturing cost. 
     An object of the present invention is to solve the aforementioned problems and provide a tubular body used in a power transmission shaft and a power transmission shaft that can achieve low cost and that surely fail when predetermined load is inputted in a direction of an axis. 
     Solution to Problem 
     A first aspect of the present invention for solving the aforementioned problems is a tubular body used in a power transmission shaft that transmits power by rotating and that is made of a fiber reinforced plastic. The tubular body includes: a tubular main body portion that is centered at an axis; a connection portion which has a smaller diameter than the main body portion and to which a coupling member is joined; and an inclined portion that is formed between the main body portion and the connection portion and that decreases in outer diameter while extending from the main body portion toward the connection portion. A weak portion that fails when load inputted in an axial direction exceeds a predetermined value is formed in the inclined portion. 
     A second aspect of the present invention for solving the aforementioned problems is a tubular body used in a power transmission shaft that transmits power by rotating and that is made of a fiber reinforced plastic. The tubular body includes: a tubular main body portion that is centered at an axis; a connection portion which has a larger diameter than the main body portion and to which a coupling member is joined; and an inclined portion that is formed between the main body portion and the connection portion and that increases in outer diameter while extending from the main body portion toward the connection portion. A weak portion that fails when load inputted in an axial direction exceeds a predetermined value is formed in the inclined portion. 
     A third aspect of the present invention for solving the aforementioned problems is a power transmission shaft and includes: the aforementioned tubular body used in the power transmission shaft; and the coupling member joined to the connection portion. 
     Advantageous Effects of Invention 
     In the power transmission shaft including the tubular body used in the power transmission shaft of the present invention, when load is inputted in the axial direction, shear force acts on the inclined portion. Then, when the shear force acting on the inclined portion exceeds a predetermined value, the weak portion of the inclined portion fails. In this configuration, there is no need to accurately set joining force between the connection portion and the coupling member and molding of the connection portion is facilitated. 
     Accordingly, in the tubular body used in the power transmission shaft and the power transmission shaft of the present invention, facilitation of molding of the connection portion can achieve cost reduction. Moreover, forming the weak portion in the inclined portion causes the weak portion to surely fail by input of predetermined load in the axial direction. 
     Furthermore, in the tubular body used in the power transmission shaft and the power transmission shaft in the first aspect of the present invention, the outer diameter of the connection portion is small and the weight and cost can be thus reduced. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a side view illustrating a power transmission shaft of a first embodiment. 
         FIG. 2  is a side cross-sectional view illustrating an inclined portion of the power transmission shaft in the first embodiment. 
         FIG. 3  is a side cross-sectional view illustrating a state where a weak portion is failed in the power transmission shaft of the first embodiment. 
         FIG. 4  is a side view illustrating a power transmission shaft of a second embodiment. 
         FIG. 5  is a side cross-sectional view illustrating an inclined portion of the power transmission shaft in the second embodiment. 
         FIG. 6  is a side cross-sectional view illustrating a state where a weak portion is failed in the power transmission shaft of the second embodiment. 
         FIG. 7  is a side view illustrating a power transmission shaft of a third embodiment. 
         FIG. 8  is a side cross-sectional view illustrating an inclined portion of the power transmission shaft in the third embodiment. 
         FIG. 9  is a side view illustrating a power transmission shaft of a fourth embodiment. 
         FIG. 10  is a side cross-sectional view illustrating an inclined portion of the power transmission shaft in the fourth embodiment. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     Next, a tubular body and a power transmission shaft in each of embodiments are described with reference to the drawings. Note that, in each embodiment, description is given of an example in which the power transmission shaft of the present invention is applied to a propeller shaft mounted in a FF (front-engine, front-drive)-based four-wheel drive vehicle. Moreover, technical elements common among the embodiments are denoted by the same reference numerals and description thereof is omitted. 
     First Embodiment 
     As illustrated in  FIG. 1 , a power transmission shaft  1  of a first embodiment includes a substantially-cylindrical tubular body  2  (pipe) that extends in a front-rear direction of the vehicle. Moreover, the power transmission shaft  1  includes a stub yoke  3  of a Cardan joint joined to a front end of the tubular body  2  and a stub shaft  4  (“coupling member” in the scope of claims) of a constant-velocity joint joined to a rear end of the tubular body  2 . 
     The power transmission shaft  1  is coupled to a transmission, mounted in a front portion of a vehicle body, via the stub yoke  3  and is also coupled to a final drive gear, mounted in a rear portion of a vehicle body, via the stub shaft  4 . 
     When power (torque) is transmitted from the transmission to the power transmission shaft  1 , the power transmission shaft  1  rotates about an axis O 1  and the power is transmitted to the final drive gear. 
     The tubular body  2  is made of a carbon fiber reinforced plastic (CFRP). Note that reinforcement fibers used in the fiber reinforced plastic of the present invention are not limited to carbon fibers and may be glass fibers or aramid fibers. 
     A method of manufacturing the tubular body  2  is such that a continuous carbon fiber is wound around a not-illustrated mandrel to form a molded body and then a pre-preg (sheet obtained by impregnating carbon fibers with a resin) is wound around an outer periphery of the molded body. Accordingly, the power transmission shaft  1  is manufactured by incorporating two crafting methods of the filament winding method and the sheet winding method. 
     In this case, the molded body manufactured by the filament winding method has high mechanical strength (particularly, torsional strength) because the continuity of the fiber (carbon fiber) is maintained. 
     Meanwhile, in the sheet winding method, the carbon fibers can be arranged to extend in an axial direction of the mandrel. Thus, the molded body with high elasticity in the axis O 1  direction can be manufactured. 
     Specifically, in the aforementioned manufacturing method, a fiber layer made of a fiber wound about the axis O 1  and a fiber layer made of fibers extending in the axis O 1  direction are stacked one on top of the other in the tubular body  102  and the tubular body  2  with high mechanical strength and high elasticity in the axis O 1  direction can be manufactured. 
     Note that a PAN (polyacrylonitrile) based fiber is preferable as the fiber aligned in a circumferential direction and pitch fibers are preferable as the fibers aligned in the axis O 1  direction. 
     The method of manufacturing the tubular body  2  of the present invention is not limited to the manufacturing method described above. As a method of manufacturing the tubular body  2 , it is possible to employ a method in which a pre-preg is wound around a mandrel to form a molded body and a continuous carbon fiber is wound around an outer periphery of the molded body. Alternatively, one type of manufacturing method (filament winding method or sheet winding method) may be used as the manufacturing method of the tubular body  2 . 
     The tubular body  2  includes a tubular main body portion  10  having the axis O 1  as a center axis, a first connection portion  20  arranged in front of the main body portion  10 , a second connection portion  30  arranged behind the main body portion  10 , and an inclined portion  40  formed between the main body portion  10  and the second connection portion  30 . Moreover, in the tubular body  2 , as illustrated in  FIG. 2 , a weak portion  50  is formed in the inclined portion  40 . 
     When the main body portion  10  illustrated in  FIG. 1  is cut along a plane whose normal is the axis O 1 , a cross-sectional shape of an outer peripheral surface of the main body portion  10  is a circular shape. 
     Moreover, the main body portion  10  decreases in outer diameter while extending from a center portion toward both end portions and the outer diameter in the center portion is larger than the outer diameters in both end portions. 
     Specifically, when the main body portion  10  is cut along the axis O 1 , the cross-sectional shape of the outer peripheral surface of the main body portion  10  is an arc shape that forms gentle curves and protrudes outward. Thus, the outer shape of the main body portion  10  is a barrel shape having a center portion bulging outward in a radial direction. 
     Although the cross-sectional shape of the outer peripheral surface of the main body portion  10  in the case where the main body portion  10  is cut along the axis O 1  is the arc shape in the tubular body  2  of the first embodiment, the cross-sectional shape of the outer peripheral surface of the main body portion  10  may be formed to be a step shape in the present invention. 
     Alternatively, the cross-sectional shape of the outer peripheral surface of the main body portion  10  in the case where the main body portion  10  is cut along the axis O 1  may be linearly inclined to come closer toward the center while extending from the center portion toward both end portions. In other words, the main body portion  10  may be formed to have a rhombus shape in a side view. 
     A shaft portion (not illustrated) of the stub yoke  3  is fitted into the first connection portion  20 . An inner peripheral surface of the first connection portion  20  has a polygonal shape following a polygonal outer peripheral surface of the shaft portion of the stub yoke  3 . The tubular body  2  and the stub yoke  3  are thus configured not to rotate relative to each other. 
     As illustrated in  FIG. 2 , a shaft portion  5  of the stub shaft  4  is fitted into the second connection portion  30 . 
     An inner peripheral surface  31  of the second connection portion  30  has a polygonal shape following a polygonal outer peripheral surface  6  of the shaft portion  5  of the stub shaft  4 . The tubular body  2  and the stub shaft  4  are thus configured not to rotate relative to each other. 
     Although the inner peripheral shape of the second connection portion  30  is formed to be the polygonal shape in the first embodiment, the inner peripheral shape is not limited to this shape and is formed to match the shape of the outer peripheral surface  6  of the shaft portion  5  in the present invention. 
     The outer diameter of the second connection portion  30  is formed to correspond to the outer diameter of the shaft portion  5  of the stub shaft  4  and is smaller than the diameter of a rear end portion of the main body portion  10 . 
     Note that reducing the diameter of the second connection portion  30  reduces the torsional strength thereof. Accordingly, the wall thickness of the second connection portion  30  is made larger than the wall thickness of the rear end portion of the main body portion  10  and the second connection portion  30  thus made to have predetermined torsional strength. 
     The inclined portion  40  is a cylindrical section formed between the main body portion  10  and the second connection portion  30 . The inclined portion  40  gradually decreases in outer diameter while extending from the main body portion  10  toward the second connection portion  30  and has a truncated cone shape. 
     The inclined portion  40  gradually decreases in wall thickness while extending from an end portion (rear end portion, one end portion) on the second connection portion  30  side (rear side) toward an end portion (front end portion, other end portion) on the main body portion  10  side (front side). Accordingly, the wall thickness is smallest in the front end portion of the inclined portion  40  and the front end portion of the inclined portion  40  forms the weak portion  50 . The weak portion  50  is a portion in which the shear strength of the inclined portion  40  is lowest. 
     Although the wall thickness varies over the entire inclined portion  40  in the power transmission shaft  1 , the wall thickness may vary in a partial section of the inclined portion  40  in the present invention. 
     In the power transmission shaft  1  including the tubular body  2  of the first embodiment as described above, when the vehicle is hit from the front side and impact load is inputted into the power transmission shaft  1  in the axis O 1  direction, shear force in the axis O 1  direction acts on the inclined portion  40 . Then, when the shear force acting on the inclined portion  40  exceeds a predetermined value, the weak portion  50  of the inclined portion  40  fails as illustrated in  FIG. 3 . The failing of the power transmission shaft  1  in vehicle impact thus allows the engine and the transmission mounted in the front portion of the vehicle body to quickly retreat and the front portion of the vehicle body absorbs impact energy. 
     Although the weak portion  50  is failed in  FIG. 3 , in the present invention, the weak portion  50  only needs to be configured such that, when the load inputted into the power transmission shaft  1  in the axis O 1  direction exceeds the predetermined value, the length of the power transmission shaft  1  in the axial direction is reduced by the deformation of the weak portion  50 . 
     As described above, in the tubular body  2  and the power transmission shaft  1  of the first embodiment, joining force between the second connection portion  30  and the stub shaft  4  does not have to be accurately set and the molding of the second connection portion  30  is thus facilitated. Moreover, in the tubular body  2  and the power transmission shaft  1 , since the portion in which the wall thickness of the inclined portion  40  is smallest is the weak portion  50  as illustrated in  FIG. 2 , the weak portion  50  is easily formed in the molding of the inclined portion  40 . 
     Thus, in the tubular body  2  and the power transmission shaft  1 , the facilitation of the molding of the second connection portion  30  can reduce cost. Moreover, the weak portion  50  is formed in the inclined portion  40  and this can cause the weak portion  50  to surely fail by predetermined load inputted in the axis O 1  direction. 
     Furthermore, in the tubular body  2  and the power transmission shaft  1 , since the outer diameter of the second connection portion  30  is small as illustrated in  FIG. 2 , the weight and cost can be reduced. 
     Moreover, in the tubular body  2  and the power transmission shaft  1 , since the center portion of the main body portion  10  where the bending stress tends to concentrate is formed to have a large outer diameter as illustrated in  FIG. 1 , the center portion has predetermined bending strength. 
     Furthermore, in the tubular body  2  and the power transmission shaft  1 , since the tubular body  2  is made of the fiber reinforced plastic, a degree of freedom in design is high and the cost can be further reduced. 
     Second Embodiment 
     Next, a power transmission shaft  101  including a tubular body  102  according to a second embodiment of the present invention is described. 
     As illustrated in  FIG. 4 , the power transmission shaft  101  of the second embodiment includes the tubular body  102 , the stub yoke  3  joined to a front end of the tubular body  102 , and the stub shaft  4  joined to a rear end of the tubular body  102 . 
     The tubular body  102  of the second embodiment includes a main body portion  110 , the first connection portion  20  arranged in front of the main body portion  110 , the second connection portion  30  arranged behind the main body portion  110 , and an inclined portion  140  located between the main body portion  110  and the second connection portion  30 . Moreover, as illustrated in  FIG. 5 , a weak portion  150  is formed in the inclined portion  140 . 
     When the main body portion  110  in the second embodiment illustrated in  FIG. 4  is cut along a plane whose normal is the axis O 1 , a cross-sectional shape of an outer peripheral surface of the main body portion  110  is a circular shape. The main body portion  110  has a uniform outer diameter from a front end portion to a rear end portion. Specifically, the outer shape of the main body portion  110  in the second embodiment is a straight cylindrical body. 
     As illustrated in  FIG. 5 , the inclined portion  40  in the second embodiment gradually decreases in wall thickness while extending from an end portion (front end portion, other end portion) on the main body portion  10  side (front side) toward an end portion (rear end portion, one end portion) on the second connection portion  30  side (rear side). Accordingly, the wall thickness is smallest in the rear end portion of the inclined portion  40  and the rear end portion of the inclined portion  140  forms the weak portion  150 . 
     In the power transmission shaft  101  including the tubular body  102  of the second embodiment as described above, when the vehicle is hit from the front side and shear force acting on the inclined portion  140  exceeds a predetermined value, the weak portion  150  of the inclined portion  140  fails as illustrated in  FIG. 6 . Then, the engine and the transmission mounted in the front portion of the vehicle body quickly retreat and the front portion of the vehicle body absorbs impact energy. 
     As described above, in the tubular body  102  and the power transmission shaft  101  of the second embodiment illustrated in  FIG. 5 , it is possible to facilitate molding of the second connection portion  30  as in the power transmission shaft  1  (see  FIG. 2 ) of the first embodiment and, in addition, to facilitate the molding of the main body portion  110 . Accordingly, the cost can be reduced. 
     Moreover, in the tubular body  102  and the power transmission shaft  101  of the second embodiment, the weak portion  150  is formed in the inclined portion  140  and this can cause the weak portion  150  to surely fail by predetermined load inputted in the axis O 1  direction. 
     Third Embodiment 
     Next, a power transmission shaft  201  including a tubular body  202  according to a third embodiment of the present invention is described. 
     As illustrated in  FIG. 7 , the power transmission shaft  201  of the third embodiment includes the tubular body  202 , the stub yoke  3  joined to a front end of the tubular body  202 , and the stub shaft  4  joined to a rear end of the tubular body  202 . 
     The tubular body  202  of the third embodiment includes a main body portion  210 , the first connection portion  20  arranged in front of the main body portion  210 , the second connection portion  30  arranged behind the main body portion  210 , and an inclined portion  240  located between the main body portion  210  and the second connection portion  30 . Moreover, as illustrated in  FIG. 8 , a weak portion  250  is formed in the inclined portion  240 . 
     When the main body portion  210  of the third embodiment illustrated in  FIG. 7  is cut along a plane whose normal is the axis O 1 , a shape of an outer peripheral surface of the main body portion  210  is a circular shape. 
     The main body portion  210  is formed to have a uniform outer diameter from a front end portion to a center portion and decrease in outer diameter while extending from the center portion toward a rear end portion. Accordingly, the outer diameters in the front end portion and the center portion of the main body portion  210  are larger than the outer diameter in the rear end portion. 
     When the main body portion  210  is cut along the axis O 1 , a cross-sectional shape of an outer peripheral surface of the main body portion  210  is a linear shape from the front end portion to the center portion and is an arc shape that forms a gentle curve from the center portion to the rear end portion. 
     As illustrated in  FIG. 8 , the inclined portion  240  in the third embodiment has a uniform wall thickness from an end portion on the main body portion  210  side (front side) to an end portion on the second connection portion  30  side (rear side) except for a portion in which the weak portion  250  is formed. 
     The weak portion  250  is formed in an outer peripheral surface  241  of the inclined portion  240 . The weak portion  250  of the third embodiment is an annular groove formed over the entire circumference of the outer peripheral surface  241  of the inclined portion  240 . Forming the weak portion  250  in the outer peripheral surface  241  of the inclined portion  240  as described above partially reduces the wall thickness of the inclined portion  240 . 
     Although the annular weak portion  250  is formed in the outer peripheral surface  241  of the inclined portion  240  in the tubular body  202  in the tubular body  202  and the power transmission shaft  201  of the third embodiment, recess-shaped weak portions may be formed in the outer peripheral surface  241  of the inclined portion  240 . In this case, multiple weak portions are preferably arranged in a circumferential direction of the outer peripheral surface  241  of the inclined portion  240 . 
     In the power transmission shaft  201  including the tubular body  202  of the third embodiment as described above, when the vehicle is hit from the front side and shear force acting on the inclined portion  240  exceeds a predetermined value, the weak portion  250  of the inclined portion  240  fails. Then, the engine and the transmission mounted in the front portion of the vehicle body quickly retreat and the front portion of the vehicle body absorbs impact energy. 
     As described above, in the tubular body  202  and the power transmission shaft  201  of the third embodiment illustrated in  FIG. 7 , the molding of the second connection portion  30  is facilitated as in the power transmission shaft  1  (see  FIG. 2 ) of the first embodiment and the cost can be thus reduced. 
     Moreover, in the tubular body  202  and the power transmission shaft  201  of the third embodiment, the weak portion  250  is formed in the inclined portion  240  and this can cause the weak portion  250  to surely fail by predetermined load inputted in the axis O 1  direction. 
     Fourth Embodiment 
     Next, a power transmission shaft  301  including a tubular body  302  according to a fourth embodiment of the present invention is described. 
     The power transmission shaft  301  of the fourth embodiment includes the tubular body  302 , the stub yoke  3  joined to a front end of the tubular body  302 , and the stub shaft  4  joined to a rear end of the tubular body  302 . 
     As illustrated in  FIG. 9 , the tubular body  302  of the fourth embodiment includes the main body portion  10 , the first connection portion  20  arranged in front of the main body portion  10 , a second connection portion  330  arranged behind the main body portion  10 , and an inclined portion  340  located between the main body portion  10  and the second connection portion  330 . Moreover, as illustrated in  FIG. 10 , a weak portion  350  is formed in the inclined portion  340 . 
     The outer shape of the main body portion  10  in the fourth embodiment is a barrel shape having a center portion bulging outward in a radial direction as illustrated in  FIG. 9 . 
     As illustrated in  FIG. 10 , the outer diameter of the second connection portion  330  in the fourth embodiment is larger than the outer diameter of the rear end portion of the main body portion  10 . 
     The inclined portion  340  in the fourth embodiment has a truncated cone shape in which the inclined portion  340  gradually increases in outer diameter while extending from the main body portion  10  toward the second connection portion  330 . 
     The inclined portion  340  gradually decreases in wall thickness while extending from an end portion (front end portion, other end portion) on the main body portion  10  side (front side) toward an end portion (rear end portion, one end portion) on the second connection portion  330  side (rear side). Accordingly, the wall thickness is smallest in the front end portion of the inclined portion  340  and the front end portion of the inclined portion  340  forms the weak portion  350 . 
     Note that the inclined portion  340  may decrease in wall thickness while extending from the main body portion  10  side toward the second connection portion  330 . 
     In the power transmission shaft  301  including the tubular body  302  of the fourth embodiment as described above, when the vehicle is hit from the front side and shear force acting on the inclined portion  340  exceeds a predetermined value, the weak portion  350  of the inclined portion  340  fails. Then, the engine and the transmission mounted in the front portion of the vehicle body quickly retreat and the front portion of the vehicle body absorbs impact energy. 
     As described above, in the tubular body  302  and the power transmission shaft  301  of the fourth embodiment, the molding of the second connection portion  30  is facilitated as in the power transmission shaft  1  (see  FIG. 2 ) of the first embodiment and the cost can be thus reduced. 
     Moreover, in the tubular body  302  and the power transmission shaft  301  of the fourth embodiment, the weak portion  350  is formed in the inclined portion  340  and this can cause the weak portion  350  to surely fail by predetermined load inputted in the axis O 1  direction. 
     Although the embodiments are described above, the present invention is not limited to the examples described in the embodiments. 
     For example, in the power transmission shafts of the embodiments, the inclined portion is provided between the main body portion and the second connection portion and the weak portion is formed in the inclined portion. However, the configuration may be such that the inclined portion is provided between the main body portion and the first connection portion and the weak portion is formed in the inclined portion.