A process for forming a flexible composite driveshaft includes providing a mandrel having a rigid region and a compressible region, applying fiber tape to the mandrel using automated fiber placement with in-situ laser curing in the rigid region and without in-situ laser curing the compressible region, and compressing the fiber tape and compressible material in the compressible region to form diaphragms that extend radially outward to a diameter that is at least twice the size of a diameter of the composite driveshaft in the rigid region.

An injection molded shaft includes a shaft body having a first connecting part formed integrally with the first torque applied part, a second connecting part formed integrally with the second torque applied part, a core part extending from the first connecting part to the second connecting part along the longitudinal center axis, the core part having a crisscross cross section orthogonal to the axial direction, and a framework part disposed in a portion partitioned by the first connecting part, the second connecting part, and the core part. The framework part is a diagonal brace extending diagonally across the first connecting part, the second connecting part, and the core part. A through-hole extends through the first torque applied part along the longitudinal center axis from an axial end face of the first torque applied part to the first connecting part of the shaft body, and the first torque applied part, the second torque applied part, and the shaft body are integrally formed of a resin material to have a unitary one-piece construction.

In a shaft body, a first end in an axial direction of a core part having a crisscross cross section orthogonal to the axial direction is connected to a helical gear via a first connecting part, and the second end in the axial direction of the core part is connected to a worm via a second connecting part. A plurality of first framework parts are formed at regular intervals along a direction of a shaft core in the core part between the first connecting part and the second connecting part. A second framework part extends across the first connecting part, the first framework part, and the core part like a diagonal brace. A third framework part extends across a pair of the first framework parts adjacent to each other and the core part like a diagonal brace. A fourth framework part extends across the second connecting part, the first framework part, and the core part like a diagonal brace.

A method of forming a component having grooves formed into an outer surface of a component includes the steps of applying at least one mold to an outer surface of a component preform. The mold is forced into contact with the outer surface to form a detent into the outer surface.

A drive shaft is for selectively connecting a drive input to an output. The drive shaft has a tubular portion, a first diaphragm member, and a second diaphragm member displaced axially along the shaft from the first diaphragm member. The first and second diaphragm members each are formed with two axial ends. At least one undulation extends radially of the ends. The tubular portion connects the first and second diaphragm members. The first and second diaphragm members and the tubular portion are formed of fiber-reinforced polymer matrix composites. The first and second diaphragm members are connected to first and second axial ends of the tubular portion through a mechanical connection at joints. A method of forming a drive shaft is also disclosed.

In a shaft body, a first end in an axial direction of a core part having a crisscross cross section orthogonal to the axial direction is connected to a helical gear via a first connecting part, and the second end in the axial direction of the core part is connected to a worm via a second connecting part. A plurality of first framework parts are formed at regular intervals along a direction of a shaft core in the core part between the first connecting part and the second connecting part. A second framework part extends across the first connecting part, the first framework part, and the core part like a diagonal brace. A third framework part extends across a pair of the first framework parts adjacent to each other and the core part like a diagonal brace. A fourth framework part extends across the second connecting part, the first framework part, and the core part like a diagonal brace.

In a shaft body, a first end in an axial direction of a core part having a crisscross cross section orthogonal to the axial direction is connected to a helical gear via a first connecting part, and the second end in the axial direction of the core part is connected to a worm via a second connecting part. A plurality of first framework parts are formed at regular intervals along a direction of a shaft core in the core part between the first connecting part and the second connecting part. A second framework part extends across the first connecting part, the first framework part, and the core part like a diagonal brace. A third framework part extends across a pair of the first framework parts adjacent to each other and the core part like a diagonal brace. A fourth framework part extends across the second connecting part, the first framework part, and the core part like a diagonal brace.

A flexible coupling for transmitting torque between parts of a transmission shaft system comprises a tubular section of continuous-fibre-reinforced composite material which has been modified to form a living hinge section with reduced bending stiffness to allow flexion of the tubular section. The tubular section may be modified through the provision of a pattern of formations within the living hinge section. The formations may be in the form of apertures and/or recesses in the continuous-fibre-reinforced composite material to create a plurality of living hinges in the material between, in particular slots and/or grooves.

In a shaft body, a first end in an axial direction of a core part having a crisscross cross section orthogonal to the axial direction is connected to a helical gear via a first connecting part, and the second end in the axial direction of the core part is connected to a worm via a second connecting part. A plurality of first framework parts are formed at regular intervals along a direction of a shaft core in the core part between the first connecting part and the second connecting part. A second framework part extends across the first connecting part, the first framework part, and the core part like a diagonal brace. A third framework part extends across a pair of the first framework parts adjacent to each other and the core part like a diagonal brace. A fourth framework part extends across the second connecting part, the first framework part, and the core part like a diagonal brace.

A disc coupling includes a spacer and discs coupled to opposite ends of the spacer. Each of the discs includes an annular body defining a plurality of circumferentially spaced fastener holes and a plurality of links with each link extending between a pair of the fastener holes. The disc further includes a washer defining a bore aligned with one of the fastener holes. The washer includes one face facing the body and another face facing away from the body and a plurality of surfaces extending between the faces. The surfaces include radially outer and inner surfaces and side surfaces extending between the radially inner and outer surfaces and defining vertices at intersections with the radially inner and outer surfaces.