Patent ID: 7950151

Claim:
A method of constructing an integral coupling system containing a sun gear, the method comprising: providing an integral sun gear comprising a sun gear component and a connection shaft; machining a first straight flat inner edge on a first diaphragm to use as a datum point; fixturing the first straight flat inner edge; machining a tapered outer edge on the first diaphragm; and welding the first diaphragm to the integral sun gear wherein the first straight flat inner edge is perpendicular to a central axis of the connection shaft, wherein the first diaphragm comprises an outer radius Ra with a corresponding outer radius thickness ta, an inner radius Rb with a corresponding inner radius thickness tb, an outer ring radius ro, an inner ring radius ri, and a shaft fillet radius Rs, and wherein the first diaphragm has the following design criteria: Rb/Ra<0.6 2<tb/ta<3.5 ri>2*ta ro>2*ri Rs>2*tb.