Composite vehicle driveshaft assembly with bonded end yoke and method for producing same

1. A composite vehicle driveshaft assembly comprising:

a composite tube, the composite tube being formed from wound filaments and a resin material and having inner and outer peripheral surfaces and inner and outer axial ends; and

a yoke defining a longitudinal axis and including an outer coupler having a crown, a pair of arms that are transversely spaced from each other and extend axially outwardly from the crown, and an inner sleeve that extends axially inwardly away from the crown and that is concentrically received in one of the input and output ends of the tube, the sleeve having an outer peripheral surface that faces the inner peripheral surface of the tube with a cavity formed therebetween in the shape of an unsegmented right circular hollow cylinder, wherein the yoke includes:

an adhesive injection passage being formed in the yoke, and wherein the adhesive injection passage extends at an acute angle along a straight-line path that is inclined away from the longitudinal axis of the yoke from an inlet that is formed in an outer axial surface of the crown of the yoke between a pair of arms to an outlet that is formed in the outer peripheral surface of the sleeve and that opens into the cavity.

2. The composite driveshaft assembly of claim 1 , wherein the cavity is sealed at inner and outer axial ends thereof by structures extending between the outer peripheral surface of the sleeve and the inner peripheral surface of the tube.

3. The composite driveshaft assembly of claim 2 , wherein the structures comprise lands formed on the outer peripheral surface of the sleeve.

4. The composite driveshaft assembly of claim 1 , wherein the acute angle is between 5 degrees and 20 degrees.

5. The composite driveshaft assembly of claim 1 , wherein the injection passage is circular in transverse cross section and the outlet opening is elliptical in shape.

6. The composite driveshaft assembly of claim 1 , wherein the pair of arms are configured for connection to a driveline joint.

7. The composite driveshaft assembly of claim 1 , wherein the filaments of the composite tube are formed from at least one of fiberglass and a carbon fiber.

8. The composite driveshaft assembly of claim 1 , wherein the composite tube has an inner diameter of 65 mm to 125 mm, a thickness of 31.75 mm to 39.37 mm, and a length of 254 mm to 1780 mm.

9. A yoke configured for use with a composite driveshaft assembly, the composite driveshaft assembly including the yoke and a composite tube, the composite tube being formed from wound filaments and a resin material and having inner and outer peripheral surfaces and inner and outer axial ends, the yoke comprising:

an outer coupler and an inner sleeve that is configured to be concentrically received in one of the input and output ends of the tube, wherein

the outer coupler includes crown with an outer axial surface and a first arm and a second arm that are transversely spaced from each other and extend axially outwardly from the crown;

the sleeve extends axially inwardly away from the crown and has an outer peripheral surface that is configured to face the inner peripheral surface of the tube with a cavity formed therebetween, wherein

an adhesive injection passage is formed in the yoke, and wherein

the adhesive injection passage extends at an acute angle from an adhesive injection inlet that is formed in the outer axial surface of the crown of the yoke between the first and second arms to an adhesive injection outlet that is formed in the outer peripheral surface of the sleeve and that opens into the cavity,

the adhesive injection passage extends at the acute angle along a straight-line path that is inclined away from the longitudinal axis of the yoke and that extends from the injection passage inlet to the injection passage outlet;

a bleed passage is formed in the yoke, and wherein

the bleed passage extends at an acute angle from a bleed passage inlet that is formed in the outer peripheral surface of the sleeve and that opens from the cavity to a bleed passage outlet that is formed in the outer axial surface of the crown of the yoke between the first and second arms,

the bleed passage extends at the acute angle along a straight-line path that is inclined away the longitudinal axis of the yoke and that extends from the bleed passage outlet to the bleed passage inlet.

10. The yoke of claim 9 , wherein the cavity is sealed at inner and outer axial ends thereof by structures on the yoke configured to extend between the outer peripheral surface of the sleeve and the inner peripheral surface of the tube.

11. The yoke of claim 10 , wherein the structures comprise lands formed on the outer peripheral surface of the sleeve.

12. The yoke of claim 9 , wherein the acute angle is between 5 degrees and 20 degrees.

13. The yoke of claim 9 , wherein the injection passage is circular in transverse cross section and the outlet opening is elliptical in shape.

14. The yoke of claim 9 , wherein the first and second arms are configured for connection to a driveline joint.

15. A composite vehicle driveshaft assembly comprising:

a composite tube, the composite tube being formed from wound filaments and a resin material and having inner and outer peripheral surfaces and an a pair of axial ends that define an input end and an output end;

a yoke defining a longitudinal axis and including:

an outer coupler having a crown with an outer axial surface;

a pair of arms that are transversely spaced from each other and extend axially outwardly from the crown;

an inner sleeve that extends axially inwardly away from the crown and that is concentrically received in one of the input and output ends of the tube, the sleeve having:

an outer peripheral surface with a pair of lands that extend radially outward from the outer peripheral surface of the sleeve, wherein the pair of lands includes an inner land and an outer land with the inner land positioned further from the crown of the outer coupler than the outer land;

an injection passage having:

an injection passage inlet formed in the outer axial surface of the crown of the outer coupler between the pair of arms;

an injection passage outlet having an elliptical perimeter shape formed in the outer peripheral surface of the sleeve;

wherein the injection passage extends at an acute angle along a continuous straight-line path between the injection passage inlet and the injection passage outlet;

a bleed passage having:

a bleed passage inlet having an elliptical perimeter shape formed in the outer peripheral surface of the sleeve;

a bleed passage outlet formed in the outer axial surface of the crown of the outer coupler between the pair of arms;

wherein the bleed passage extends at an acute angle along a continuous straight-line path between the bleed passage inlet and the bleed passage outlet;

a cavity configured to receive a volume of adhesive during an adhesive injection procedure, wherein the cavity is in the form of an unsegmented right circular hollow cylinder that is bordered at:

respective inner and outer ends thereof by the inner land and the outer land of the sleeve;

an outer surface thereof by the inner peripheral surface of the composite tube; and

an inner surface thereof by the outer peripheral surface of the sleeve;

receives the volume of adhesive through the injection passage outlet at a first side of the cavity; and

releases a volume of air through the bleed passage inlet at a second side of the cavity that is opposite the first side of the cavity.