Overmolded yoke assembly

• US 7,140,969 B2
• Filed: 08/22/2003
• Issued: 11/28/2006
• Est. Priority Date: 08/22/2003
• Status: Active Grant

• Current Assignee: American AXLE & Manufacturing Incorporated (American AXLE & Manufacturing Holdings Incorporated)
• Original Assignee: American AXLE & Manufacturing Incorporated (American AXLE & Manufacturing Holdings Incorporated)
• Inventors: Prucher, Bryan Paul
• Primary Examiner(s): THOMPSON, KENNETH L
• Application Number:
  US10/646,237
• Publication Number:
  US 20050043103A1
• Time in Patent Office: 1,194 Days
• Field of Search: 464/134, 464/902, 464/903, 464/905, 403/58, 403/57, 403/74
• US Class Current: 464/134
• CPC Class Codes: F16D 3/387 Fork construction; Mounting of fork on shaft; Adapting shaft for mounting of fork
• CPC Class Codes: F16D 3/41 with ball or roller bearings
• CPC Class Codes: Y10S 464/902 Particular material
• CPC Class Codes: Y10S 464/903 Nonmetal
• CPC Class Codes: Y10T 403/32041 Universal

Abstract

A universal joint having a first yoke including a body portion and an overmold portion. The body portion includes a base and a pair of arms that extend from the base. A trunnion assembly is coupled to the first yoke and extends between the arms. A second yoke is coupled to the trunnion assembly.

Claims

1. A universal joint comprising:

a first yoke including a body portion and an overmold portion, the body portion including a base and a pair of first arms that extend from the base;

a trunnion assembly coupled to the first yoke and extending between the first arms; and

a second yoke having a pair of second arms, the second yoke being coupled to the trunnion assembly such that the trunnion assembly extends between the second arms;

wherein the pair of first arms each include an opening formed therethrough that are aligned with one another and the overmold portion at least partially surrounds the portion of the first arms that define the openings; and

wherein the overmold portion at least partially fills a groove formed in a portion of the trunnion assembly to thereby secure the portion of the trunnion assembly to the overmold portion.

2. The universal joint of claim 1, wherein the base and the pair of first arms of the first yoke are unitarily formed.

3. The universal joint of claim 2, wherein the base and the pair of first arms of the first yoke are unitarily formed.

4. The universal joint of claim 1, wherein the overmold portion is formed of a material selected from a group of materials consisting of plastics and metals.

5. The universal joint of claim 4, wherein the overmold portion is formed of nylon.

6. A yoke assembly for coupling a first driveline component to a second driveline component, the yoke assembly comprising:

a first yoke having a first body portion and a first overmold portion molded thereto, the first yoke being adapted for coupling to the first driveline component;

a second yoke having a second body portion and a second overmold portion molded thereto, the second yoke being adapted for coupling to the second driveline component; and

a trunnion assembly coupled to the first and second yokes;

wherein at least one of the first and second overmold portions is directly coupled to the trunnion assembly

wherein the first body portion includes a pair of first arms, the first arms defining a pair of aligned first openings that are configured to receive a first portion of the trunnion assembly

wherein each of the first openings is round

wherein the second body portion includes a pair of second arms, the second arms defining a pair of aligned second openings that are configured to receive a second portion of the trunnion assembly

wherein each of the second openings is round

wherein the trunnion assembly includes four bearings, each of the bearings being disposed in an associated one of the first and second openings

wherein the first overmold portion fixes a first pair of the bearings to the first arms and the second overmold portion fixes a second pair of the bearings to the second arms

wherein the first pair of bearings is partially encapsulated by a plurality of tabs formed from the first overmold portion.

7. A yoke assembly for coupling a first driveline component to a second driveline component, the yoke assembly comprising:

a first yoke having a first body portion and a first overmold portion molded thereto, the first yoke being adapted for coupling to the first driveline component;

a second yoke having a second body portion and a second overmold portion molded thereto, the second yoke being adapted for coupling to the second driveline component; and

a trunnion assembly coupled to the first and second yokes;

wherein at least one of the first and second overmold portions is directly coupled to the trunnion assembly

wherein the first body portion includes a pair of first arms, the first arms defining a pair of aligned first openings that are configured to receive a first portion of the trunnion assembly

wherein each of the first openings is round

wherein the second body portion includes a pair of second arms, the second arms defining a pair of aligned second openings that are configured to receive a second portion of the trunnion assembly

wherein each of the second openings is round

wherein the trunnion assembly includes four bearings, each of the bearings being disposed in an associated one of the first and second openings

wherein the first overmold portion fixes a first pair of the bearings to the first arms and the second overmold portion fixes a second pair of the bearings to the second arms

wherein a groove is formed in each of the first bearings, and wherein the first overmold portion at least partially fills each of the grooves.