Gkn Driveline North America, Inc.

James Lyon

Donald W Dine

Michael James Miller

Ramon Kuczera

Brian Michael Valovick

Robert Genway-Haden

Danny Lee Booker

David G Sasseen

Mark Nicholls

A multiple-tube propeller shaft assembly includes a first tube with a plurality of splines defining a splined portion, a second tube with a plurality of splines defining a splined portion, and a third tube with a plurality of splines defining a splined portion. In an embodiment, one end of the third tube is telescopically received within the first tube in a slip tube spline connection, while the other end is received within the second tube in a locked tube spline connection. In another embodiment, the first tube is telescopically received in one end of the third tube in a slip tube spline connection, while the second tube is received in the other end of the third tube in a locked tube spline connection. The propeller shaft assembly can be tuned to absorb crash energy between 0 and 50 kN.

Multiple-tube propeller shaft assembly

A telescoping propeller shaft includes an elongated hollow cylindrical body having a splined interior surface, the splines defining a minor diameter (x) and a major diameter (y), and a correspondingly splined shaft mating in register with the cylindrical body along an engagement length (L). Major (c) and minor (b) diameters of the splined shaft are less than the respective major (y) and minor (x) diameters of the interior splines of the cylindrical body such that the two shafts can freely telescope at least along the engagement length (L) and a free plunge region (D). In response to a sufficient inward axial load, the cylindrical body is adapted to telescope over the splined shaft through an interference region (D) comprising an interference mechanism for energy dissipation.

Propshaft with crash-worthiness

A propeller shaft assembly comprises a connect shaft portion, a plungable constant velocity joint, and a hollow shaft portion with a cavity. An energy absorbing material is disposed within at least a portion of the cavity. The material absorbs energy when the constant velocity joint plunges into the hollow shaft portion when a predetermined force is exerted upon the constant velocity joint. The energy absorbing material may comprise a foam material, such as, an organic foam, a cellular foam, a synthetic foam, a metal foam, and the like. In addition to absorbing energy, the foam material minimizes the transmission of high frequency vibration of the propeller shaft assembly.

Propeller shaft assembly with energy absorbing material

A propeller shaft assembly includes an inner member having an outer surface with a plurality of splines defining a splined portion, and an outer member having an inner surface with a plurality of splines defining a splined portion. The splined portion of the inner member is capable of being slidably engaged with the splined portion of the outer member to form a splined connection therebetween. One of the inner and outer members includes a tunable energy absorption feature that controls an amount of interference between the inner and outer members. For example, the tunable energy absorption feature can be in the form of a friction ramp on one member that frictionally engages an angled leading ramp on the other member, a raised portion on one or more splines, or splines having different length that can progressively absorb energy during axial deformation of the propeller shaft assembly.

Propeller shaft assembly with tunable energy absorption feature

A constant velocity joint has an outer part, an inner part, a plurality of balls, and a cage having windows for retaining the balls in the ball tracks of the outer and inner parts. The cage retains the balls in a plane. Corresponding pairs of outer and inner ball tracks guide the balls. Corresponding pairs of outer and inner ball tracks that are axially straight alternate with corresponding pairs of outer and inner ball tracks forming angles of intersection with respect to an axis. The outer part and the inner part operate in a normal axial range, there being at least one energy absorption surfaces located in the outer extended axial range or the inner extended axial range of either part. The energy absorption surface interferes with at least one of the balls when the joint is operated beyond the normal axial range.

Cross groove hybrid plunging constant velocity joint for a propshaft tuned for energy absorption

A constant velocity joint has an outer part, an inner part, a plurality of torque transmitting balls, and a cage having windows for retaining the balls in the ball tracks of the outer and inner parts. The balls are retained in a plane by the cage and guided by corresponding pairs of outer and inner ball tracks. The outer and inner ball tracks form angles of intersection with respect to an axis where the angles are identical in size but set in opposite directions to one another. The outer part and the inner part operate in a normal axial range, there being at least one energy absorption surfaces located in the outer extended axial range or the inner extended axial range. The energy absorption surface interferes with at least one of the torque transmitting balls when the joint is operated beyond said normal axial range.

Plunging constant velocity joint for a propshaft tuned for energy absorption

A constant velocity joint has an outer part, an inner part, a plurality of torque transmitting balls, and a cage having windows for retaining the balls in the ball tracks of the outer and inner parts. The balls are retained in a constant velocity plane by the cage and guided by corresponding pairs of outer and inner ball tracks. The cage has an outer spherical face guided in contact by an inner bore of the outer part and inner concave face rotatably guided in contact by the convex face of the inner part. The outer part having a normal axial range, an extended axial range, and at least one energy absorption surfaces located in the extended axial range. Wherein the energy absorption surface interferes with at least one of the torque transmitting balls when the joint is operated beyond said normal axial range.

A constant velocity joint with an outer part having innerly a normal range, an extended range, and a plurality of outer bores circumferentially spaced between a plurality of longitudinally extending tracks, Each track having a bottom spaced between two oppositely disposed sidetracks. An inner part is disposed within said outer joint part, having a plurality of sides circumferentially spaced between a plurality of trunions, each trunion having a top and an inner race. Also, a plurality of rollers each having an inner bore are mounted on said inner race of each trunion, whereby angular and axial displacement occur between the inner joint and the outer joint. Wherein at least one energy absorption surfaces is located in the extended range on the outer part. The energy absorption surface interferes with at least one of the rollers when the joint is operated beyond said normal range.

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Northampton, United Kingdom

James Lyon